CN115216607A - 一种热镀锌铁合金外板合金化斑迹缺陷的控制方法 - Google Patents

一种热镀锌铁合金外板合金化斑迹缺陷的控制方法 Download PDF

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CN115216607A
CN115216607A CN202210770889.6A CN202210770889A CN115216607A CN 115216607 A CN115216607 A CN 115216607A CN 202210770889 A CN202210770889 A CN 202210770889A CN 115216607 A CN115216607 A CN 115216607A
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杜小峰
陈园林
杨芃
杜蓉
丁涛
杨奕
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Wuhan Iron and Steel Co Ltd
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    • C—CHEMISTRY; METALLURGY
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    • C21D8/02—Modifying the physical properties by deformation combined with, or followed by, heat treatment during manufacturing of plates or strips
    • C21D8/0205—Modifying the physical properties by deformation combined with, or followed by, heat treatment during manufacturing of plates or strips of ferrous alloys
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    • C21D8/00—Modifying the physical properties by deformation combined with, or followed by, heat treatment
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    • C21D8/0278—Modifying the physical properties by deformation combined with, or followed by, heat treatment during manufacturing of plates or strips involving a particular surface treatment
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    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
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    • C23C2/00—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor
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Abstract

本发明涉及冷轧生产领域，尤其涉及一种热镀锌铁合金外板合金化斑迹缺陷的控制方法，本发明的热镀锌铁合金外板合金化斑迹缺陷的控制方法，包括步骤炼钢、热轧、冷轧酸轧和冷轧镀锌工序，冷轧镀锌工序的清洗段控制槽内电导率为30～40ms/cm，清洗后钢板表面残油、残铁≤2000ppm，退火段控制氧含量≤10ppm，氢含量控制在2％～6％，露点控制在‑40℃以下，镀锌段控制锌锅Al含量控制在0.125～0.130％，入锌锅板温为460～480℃，氮气加湿湿氮流量阀控制在3％以下，抽锌泵流量≤300RPM。采用本发明的热镀锌铁合金外板合金化斑迹缺陷的控制方法，合金化斑迹缺陷产生率从传统的5％降低至0.2％。

Description

一种热镀锌铁合金外板合金化斑迹缺陷的控制方法
技术领域
本发明涉及冷轧生产领域，尤其涉及一种热镀锌铁合金外板合金化斑迹缺陷的控制方法。
背景技术
热镀锌铁合金(GA)产品以优良的焊接性能、可涂装性能及高耐蚀性能，广泛地应用在汽车白车身上，相较热镀锌(GI)产品，GA产品表面质量控制难度更大，基板的微小缺陷，在锌铁合金化反应中会无限放大，形成合金化斑迹缺陷。
合金化斑迹是GA外板表面出现的特有缺陷，炼钢和热轧氧化铁皮、酸轧残留、基板氧化、锌液氧化膜带入等均可形成合金化斑迹。合金化斑迹通常认为是合金化程度不一致产生，在宏观上，合金化斑迹会在表面形成明暗不同区域，呈现出目视可见的点状、条状、片状及山峰状白色缺陷。因此，如何有效控制GA外板合金化斑迹产生，是GA汽车外板生产的一大难题。
目前，如申请号为“201010590226.3”的中国发明申请文件公开了一种彩涂家电板的生产方法，对彩涂家电板涂装基板进行表面预处理，采用3辊涂装，通过优化工艺参数，控制涂装工艺、固化工艺及冷却、干燥工艺过程，获得外观质量良好的彩涂家电板。距彩涂家电板1m目视观察，板面无擦划伤、脏物线、油污、露铁、钝化斑迹、孔洞、毛刺及气泡、漏涂缺陷。
又如专利申请号为“201410494729.9”的中国发明申请文件公开了一种用于电镀锌机组镀槽用高耐磨高浸润性沉没辊胶辊及其制造方法，以及申请号为“201710439381.7”的中国发明申请文件公开了一种具备用于进行闪镀铁或镀铁的可溶性电极的垂直型镀敷槽构造，两件申请文件均是为了抑制电镀锌表面山形或丝状斑迹缺陷、材料及前处理工程不良引起的污渍。
再如申请号为“201610676446.5”的中国发明申请文件公开了一种提高轧辊表面清洁度的加工装置及其加工方法，其能够减少轧辊在轧制过程中粉末的产生，从而降低因轧辊表面清洁度的下降导致的带钢表面斑迹缺陷产生，并且同时也减少了轧辊粗糙度的衰减，从而提高轧辊的耐磨性。申请号为“201711282110.1”中国发明申请文件公开了一种二次冷轧机组乳化液喷嘴喷射方向角的优化方法，主要为提高二次冷轧机组乳化液在带钢宽度方向流量分布均匀程度，减少乳化液横向分布不均导致的局部浪形与乳化液斑迹缺陷。申请号为“201711285391.6”中国发明申请文件公开了一种二次冷轧机组乳化液喷嘴的喷射角度优化设定方法，能提升二次冷轧机组带钢板形质量，减少带钢表面乳化液条状斑迹缺发生率。申请号为“201521105643.9”中国发明申请文件公开了一种离线式冷轧带钢吹扫装置，可将残液斑迹造成的产品缺陷下降了90％以上，提高了冷轧带钢的成品质量，降低了生产成本和产品的不合格率；申请号为“201720486792.7”中国实用新型申请文件涉及一种罩式退火炉内罩出炉防淋水装置，其避免了罩式退火炉内罩吊出时，内罩内的残留水淋到冷轧薄板带卷的端面，使冷轧薄板带卷产生锈蚀、斑迹等质量缺陷。
综上所述，目前的钢材表面质量控制主要针对冷轧工序控制斑迹缺陷，对于合金化斑迹的控制方法未见相关记载，而且上述文件记载的内容均是解决冷轧板表面乳化液、油污之类斑迹，此类斑迹附着在冷轧成品表面，与本专利所说的合金化斑迹机理完全不同。
发明内容
为了克服以上问题，本发明的目的是提供一种热镀锌铁合金外板合金化斑迹缺陷的控制方法，能够明显减少GA外板的合金化斑迹缺陷。
为实现上述目的，本发明所设计的一种热镀锌铁合金外板合金化斑迹缺陷的控制方法，步骤包括炼钢、热轧、冷轧酸轧和冷轧镀锌工序：
所述炼钢工序包括冶炼和连铸，冶炼按照GA外板要求成分炼钢，连铸要保证铸坯表面缺陷清理干净；
所述热轧工序中控制加热温度1160～1200℃、加热时间150～260min、粗轧温度1020～1060℃；
所述冷轧酸轧工序包括酸洗段、轧制段和反射率检查段，酸洗段按照酸洗评价标准，酸洗后的钢板表面山水画评级控制在1级以下，轧制段乳化液的吹扫过程中中部气嘴吹扫压力2.5～5.0bar，边部气嘴吹扫压力2.3～4.8bar，同时边部中部吹扫压力差为0.1～0.2bar，反射率检查段控制板坯表面的反射率要达到75％以上；
所述冷轧镀锌工序包括清洗段、退火段和镀锌段，清洗段控制槽内电导率为30～40ms/cm，清洗后钢板表面残油≤2000ppm、残铁≤2000ppm；退火段控制氧含量≤10ppm，氢含量控制在2％～6％，露点控制在-40℃以下；镀锌段控制锌锅Al含量控制在0.125～0.130％，入锌锅板温为460～480℃，炉鼻子尖露点≤-15℃，氧含量≤15ppm，氮气加湿湿氮流量阀控制在3％以下，抽锌泵流量≤300RPM。
作为优选方案，所述炼钢工序中板坯清理采用机清和手工清理相结合的方式，其中机清深度≥3mm，机清后手工清理板坯表面确保针孔、气泡、卷渣等表面缺陷完全清理干净。
作为优选方案，所述热轧工序中粗轧除鳞水要求全开，粗轧入口除磷机(RSB)除鳞速度≤1m/s，精轧除磷水≥3组。
作为优选方案，所述热轧工序中均热时间25～60min。
作为优选方案，所述冷轧酸轧工序中，酸洗段中酸温度为75～90℃，自由HCl酸浓度≥60g/l，酸洗速度100～180m/min。
作为优选方案，所述冷轧酸轧工序中，轧制段中轧制速度≤950m/min。
作为优选方案，所述冷轧镀锌工序中，清洗段中清洗槽温度保证在80～90℃，漂洗槽温度90～120℃，其中碱洗槽氢氧化钠浓度＞6g/l。
本发明的优点在于：与传统的热镀锌铁合金外板合金化斑迹缺陷的控制方法相比，本发明的热镀锌铁合金外板合金化斑迹缺陷的控制方法具有以下优点：
(1)本申请的热镀锌铁合金外板合金化斑迹缺陷的控制方法从降低炼钢过程中外板铸坯表面缺陷、降低热轧过程中外板的氧化程度的思路出发，优化炼钢过程中的清洗方式以及优化热轧过程中的加热温度和加热时间以及严格把控除磷水。
(2)本申请热镀锌铁合金外板合金化斑迹缺陷的控制方法从酸洗形成的山水画和乳化液的残留严重影响合金化斑迹缺陷的思路出发，在酸洗工序后严格控制酸洗过程中形成的山水画的等级以及控制边部和中部的吹扫压力差，要求山水画的评级必须达到1级以下和吹扫压力差达到0.1～0.2bar；另外，本申请另外增加了酸洗轧制后的发射率检测的步骤，要求反射率达到75％以上，进一步控制酸洗轧制后的表面质量。
(3)本申请热镀锌铁合金外板合金化斑迹缺陷的控制方法从严格控制冷轧镀锌工序参数的思路出发，优化冷轧镀锌工序参数，冷轧镀锌工序是GA外板合金化斑迹形成的关键步骤，相对于传统工艺本申请对冷轧镀锌工序参数进行调整和优化，对于清洗段的导电率和残油、残铁进行实时监测控制，对于退火段实时监测氧含量和露点，尤其是镀锌段，通过控制锌锅Al含量、入锌锅板温度影响后续合金化，同时控制尖露点、氧含量以及氮气加湿和抽锌泵流量抑制合金化斑迹缺陷出现。
(4)GA外板合金化斑迹的产生与前工序密切相关，本申请在炼钢、热轧、冷轧酸轧、冷轧镀锌全流程工序进行综合控制，采用本申请热镀锌铁合金外板合金化斑迹缺陷的控制方法，GA外板合金化斑迹得到明显控制，合金化斑迹缺陷产生率从传统的5％降低至0.2％，外板的表面质量得到了显著的提升。
具体实施方式
为更好地理解本发明，以下将结合具体实例对发明进行详细的说明。
实施例1～7
一种热镀锌铁合金外板合金化斑迹缺陷的控制方法，包括步骤：
(1)炼钢
按照GA外板成分炼钢，板坯清理采用机清+手工清理两种方式并存。其中机清深度要大于3mm，保证钢板表层针孔、气泡、卷渣等表面缺陷清理干净。同时GA外板必须保证手工清理并检验，以确定表面缺陷是否完全清理干净。这些表面缺陷在冷轧大压下量轧制后才会显现，并进而在锌铁合金反应时形成点状或条状斑迹。
(2)热轧采用低温轧制工艺，加热温度1160～1200℃，降低了加热温度，有助于减少钢板的氧化，加热时间150～260min，其中均热时间为25～60min，缩短了均热时间，避免均热时间过长氧化铁皮增多；
粗轧采用低温轧制，轧制温度1020～1060℃，降低了轧制温度，有助于减少钢板的氧化，粗轧除鳞水要求全开，粗轧入口除磷机(RSB)除鳞速度≤1m/s，精轧除磷水≥3组(除鳞箱2组+机架间除鳞1组)。
(3)冷轧酸轧
酸洗：酸温度控制目标温度75～90℃，自由HCl酸浓度控制目标≥60g/l，酸洗速度稳定在100～180m/min，以保证酸洗表面质量，按照酸洗评价标准，酸洗表面山水画评级要在1级以下，其中山水画是指氧化铁皮在酸轧表面残留，形成类似山水画缺陷形貌，此种形貌会在后续合金化过程中形成严重斑迹缺陷。
轧制：为保证板形，轧制速度要求≤950m/min，板形控制不好，可能在后续镀锌过程中造成短擦伤，形成条状斑迹缺陷；同时，轧制过程中会投入乳化液，因此对边部吹扫进行严格控制，其中中部气嘴吹扫压力2.5～5.0bar，边部气嘴吹扫压力2.3～4.8bar，同时边部中部吹扫压力差为0.1～0.2bar。如果吹扫压力差过大，会导致乳化液在钢板上残留，并在酸轧后形成锈斑，造成斑迹缺陷。
反射率检查：酸洗轧制后要求每5卷检查反射率，反射率要达到75％以上，同时表面不允许存在辊印、压印、乳化液等残留以及表面带水。其中辊印、压印等残留会在合金化过程中进一步放大，形成白色点状斑迹缺陷，而乳化液残留及表面带水会在钢板表面形成锈迹，锈迹在后续碱洗清洗不掉，会在表面形成带状或条状合金化斑迹。
(4)冷轧镀锌
清洗段：为保证清洗效果，清洗槽温度保证在80～90℃，漂洗槽温度90～120℃，其中碱洗槽氢氧化钠浓度＞6g/l，槽内电导率30～40ms/cm。当槽内浓度和电导率达不到时，必须补充新的碱液。同时，对残油、残铁进行实时监测控制，要求清洗后钢板表面残油≤2000ppm、残铁≤2000ppm。残油、残铁会阻碍铁向锌层扩散，从而造成局部合金化程度不一致，从而导致片状合金化斑迹产生。
退火段：实时监测氧含量，要求氧含量≤10ppm，氧含量过高，会导致钢板在高温段局部氧化，形成氧化膜，阻碍锌铁合金反应，从而导致合金化斑迹出现。同时氢含量控制在2％～6％，露点控制在-40℃以下，这样可以避免外面氧势过高，钢板内合金元素向外部扩散形成外氧化，从而影响锌铁合金反应。
镀锌段：锌锅Al含量控制在0.125～0.130％，锌锅Al含量过高会导致在锌锅局部形成抑制层，阻碍合金化反应，从而导致合金化不均；入锌锅板温要求在460～480℃，温度过低会导致锌液温度降低，存在锌液凝固风险，而温度过高会导致形成爆发组织，也会影响后续合金化反应，并形成对应斑迹缺陷；炉鼻子尖露点≤-15℃，氧含量≤15ppm，防止钢板在炉鼻子位置形成局部氧化；同时，氮气加湿控制对生产GA外板尤为重要，其中氮气加湿湿氮流量阀控制在3％以下，防止氮气加湿氧化钢板，并在后续形成氧化斑迹；另外，抽锌泵流量≤300RPM，当流量过大时，会将锌液表层氧化膜带到钢板上，形成明显合金化斑迹缺陷。
为了更加直观地表现实施例对比例，各工序的参数如表1～4所示：
表1炼钢工艺参数
Figure BDA0003724183090000061
Figure BDA0003724183090000071
表2热轧工艺参数
Figure BDA0003724183090000072
Figure BDA0003724183090000081
表3酸洗轧制工艺参数
Figure BDA0003724183090000082
Figure BDA0003724183090000091
表4-1镀锌工艺参数
Figure BDA0003724183090000092
Figure BDA0003724183090000101
表4-2镀锌工艺参数-附表
实施例 氮气加湿湿氮流量，％ 抽锌泵流量，RPM
实施例1 1.5 250
实施例2 2 280
实施例3 3 300
实施例4 2 290
实施例5 2 280
实施例6 2 285
实施例7 1.5 265
对比例1 2 260
对比例2 2.5 280
对比例3 2 300
对比例4 2 300
对比例5 4 400
对比例6 5 450
对比例7 4 450
对比例8 4 400
对比例9 5 400
表5GA外板力学性能
Figure BDA0003724183090000111
上表5中，合金化斑迹按照分级分为4级，0-3级，其中0级：代表无斑迹，可以放行；1级：斑迹轻微，极个别用户可以放行；2级：斑迹稍重，3级：斑迹严重。斑迹达到2级以上，严禁放行，并立即退料切换内板生产，并进行工艺排查。
同时，本申请实施例1～7的GA外板力学性能较传统工艺制备得到GA外板(对比例1～7)相比未有明显差异，总的来说，本申请热镀锌铁合金外板合金化斑迹缺陷的控制方法既在优化表面质量的同时保证了力学性能的稳定性。

Claims (7)

1.一种热镀锌铁合金外板合金化斑迹缺陷的控制方法，包括步骤炼钢、热轧、冷轧酸轧和冷轧镀锌工序，其特征在于：
所述炼钢工序包括冶炼和连铸，冶炼按照GA外板要求成分炼钢，连铸要保证铸坯表面缺陷清理干净；
所述热轧工序中控制加热温度1160～1200℃、加热时间150～260min、粗轧温度1020～1060℃；
所述冷轧酸轧工序包括酸洗段、轧制段和反射率检查段，酸洗段按照酸洗评价标准，酸洗后的钢板表面山水画评级控制在1级以下，轧制段乳化液的吹扫过程中中部气嘴吹扫压力2.5～5.0bar，边部气嘴吹扫压力2.3～4.8bar，同时边部中部吹扫压力差为0.1～0.2bar，反射率检查段控制板坯表面的反射率要达到75％以上；
所述冷轧镀锌工序包括清洗段、退火段和镀锌段，清洗段控制槽内电导率为30～40ms/cm，清洗后钢板表面残油≤2000ppm、残铁≤2000ppm；退火段控制氧含量≤10ppm，氢含量控制在2％～6％，露点控制在-40℃以下；镀锌段控制锌锅Al含量控制在0.125～0.130％，入锌锅板温为460～480℃，炉鼻子尖露点≤-15℃，氧含量≤15ppm，氮气加湿湿氮流量阀控制在3％以下，抽锌泵流量≤300RPM。
2.根据权利要求1所述的热镀锌铁合金外板合金化斑迹缺陷的控制方法，其特征在于，所述炼钢工序中板坯清理采用机清和手工清理相结合的方式，其中机清深度≥3mm，保证钢板表层针孔、气泡、卷渣等表面缺陷清理干净。
3.根据权利要求1所述的热镀锌铁合金外板合金化斑迹缺陷的控制方法，其特征在于，所述热轧工序中粗轧除鳞水要求全开，粗轧入口除磷机除鳞速度≤1m/s，精轧除磷水≥3组。
4.根据权利要求1所述的热镀锌铁合金外板合金化斑迹缺陷的控制方法，其特征在于，所述热轧工序中均热时间25～60min。
5.根据权利要求1所述的热镀锌铁合金外板合金化斑迹缺陷的控制方法，其特征在于，所述冷轧酸轧工序中，酸洗段中酸温度为75～90℃，自由HCl酸浓度≥60g/l，酸洗速度100～180m/min。
6.根据权利要求1所述的热镀锌铁合金外板合金化斑迹缺陷的控制方法，其特征在于，所述冷轧酸轧工序中，轧制段中轧制速度≤950m/min。
7.根据权利要求1所述的热镀锌铁合金外板合金化斑迹缺陷的控制方法，其特征在于，所述冷轧镀锌工序中，清洗段中清洗槽温度保证在80～90℃，漂洗槽温度90～120℃，其中碱洗槽氢氧化钠浓度＞6g/l。
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