EP2281912B1 - Continuous wire galvanizing method and corresponding galvanizing machine - Google Patents

Continuous wire galvanizing method and corresponding galvanizing machine Download PDF

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Publication number
EP2281912B1
EP2281912B1 EP10170263A EP10170263A EP2281912B1 EP 2281912 B1 EP2281912 B1 EP 2281912B1 EP 10170263 A EP10170263 A EP 10170263A EP 10170263 A EP10170263 A EP 10170263A EP 2281912 B1 EP2281912 B1 EP 2281912B1
Authority
EP
European Patent Office
Prior art keywords
wire
stage
station
galvanizing
cleaning
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Not-in-force
Application number
EP10170263A
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German (de)
English (en)
French (fr)
Other versions
EP2281912A1 (en
Inventor
Martí Guerrero Desirre
Javier Roig Serra
Pablo Pedrosa Diaz
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Automat Industrial SL
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Automat Industrial SL
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Publication date
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Publication of EP2281912A1 publication Critical patent/EP2281912A1/en
Application granted granted Critical
Publication of EP2281912B1 publication Critical patent/EP2281912B1/en
Not-in-force legal-status Critical Current
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    • C—CHEMISTRY; METALLURGY
    • 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
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C2/00—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor
    • C23C2/04—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor characterised by the coating material
    • C23C2/06—Zinc or cadmium or alloys based thereon
    • C—CHEMISTRY; METALLURGY
    • 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
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C2/00—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor
    • C23C2/34—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor characterised by the shape of the material to be treated
    • C23C2/36—Elongated material
    • C23C2/38—Wires; Tubes
    • C—CHEMISTRY; METALLURGY
    • 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
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C2/00—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor
    • C23C2/003—Apparatus
    • C23C2/0038—Apparatus characterised by the pre-treatment chambers located immediately upstream of the bath or occurring locally before the dipping process
    • C—CHEMISTRY; METALLURGY
    • 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
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C2/00—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor
    • C23C2/02—Pretreatment of the material to be coated, e.g. for coating on selected surface areas
    • C23C2/022—Pretreatment of the material to be coated, e.g. for coating on selected surface areas by heating
    • C23C2/0224—Two or more thermal pretreatments
    • C—CHEMISTRY; METALLURGY
    • 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
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C2/00—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor
    • C23C2/02—Pretreatment of the material to be coated, e.g. for coating on selected surface areas
    • C23C2/024—Pretreatment of the material to be coated, e.g. for coating on selected surface areas by cleaning or etching

Definitions

  • the invention relates to a continuous continuous wire galvanizing method for at least one wire that comprises the following stages: cleaning the surface of said wire, induction heating to a first temperature, cooling to a second temperature lower than said first temperature, galvanizing and final draining of said wire, with said heating, cooling and galvanizing stages being carried out individually and separately for each of said wires in an inert atmosphere.
  • the invention relates to a continuous wire galvanizing machine comprising a cleaning station, an induction oven for heating at least one wire to a first temperature, a cooling station for cooling said wire to a second temperature lower than said first temperature and a galvanizing station, with said induction oven, said cooling station and said galvanizing station being under an inert atmosphere and with said wire passing through the inside of a duct being guided under said inert atmosphere, and extending through said induction oven, said cooling station, into said galvanizing station.
  • the machine comprises in a series a cleaning station, a first induction heating chamber, a second cooling chamber downstream from the heating chamber and finally a third chamber downstream from the cooling chamber.
  • the three chambers are connected to each other and they are under an inert atmosphere to prevent the wire from oxidising during the processing, due to the high temperatures.
  • the wire is drawn through an alkaline bath of sodium hydroxide and sodium bicarbonate.
  • the cleaning station obliges the wire to remain there a certain time so that the following stages of the method can be carried out correctly. Therefore, this method suffers from the drawback that it cannot be applied to continuously galvanizing wires at high speed.
  • the residue from the alkaline bath are difficult to manage in ecological terms.
  • the long time the wire remains in the bath means large size facilities have to be available.
  • the fact that a machine requires a greater space has considerable effect on the final cost of the processed product, as it must be placed in larger facilities.
  • the aim of the invention is to provide a continuous wire galvanizing method of the type indicated at the beginning, which allows processing the wire at high speeds and which at the same time is more efficient and environmentally friendly than the known methods.
  • Another aim of the invention is to provide a machine for putting the method into practice, which also optimises the space necessary for carrying out the method.
  • the cleaning unit using the phosphoric acid and ultrasound allows cleaning the soap remains that have been deposited on the surface of the wire during the wire drawing process prior to the method described herein.
  • the phosphoric acid prepares the surface of the wire by means of chemical etching, which facilitates better zinc adherence to the surface of the wire.
  • Another advantage associated with the invention consists in that the energy consumed by the bath is less.
  • the solution only has to be heated between 45 oC and 55 oC, whereas the traditional alkaline bath must be heated to 90oC. Furthermore, due to the lower temperature, in the bath there are fewer losses of reactant through evaporation.
  • the alkaline cleaning produces aggressive residues. Therefore, another additional advantage of the method according to the invention, consists in the fact that the cleaning with phosphoric acid is much less aggressive, and its residues are much more environmentally friendly. Also for the operator, the phosphoric acid is more ergonomic, as it is not harmful or irritant. Furthermore, the neutralization of the phosphoric acid is simpler and its elimination costs by reduction are much less than in other options.
  • the wire vacuum drying by evaporation allows entering the heating stage without loosing speed, as the drying is specially fast.
  • a deficient drying leads to significant losses in the induction oven for heating, as part of the power applied to heat the wire is lost in evaporating the water that remains on the surface of the wire.
  • the drying of the wire is carried out at very low temperatures and the wire enters the heating stage in a dry state, which naturally leads to a reduction in energy costs. This is due to availing of all the energy of the induction oven applied to the wire, as losses do not occur through burning or evaporating other elements such as water, soaps, oils, emulsions, cutting fluid, etc.
  • said vacuum drying stage is carried out inside a drying device that comprises a chamber traversed by said wire, there being created in said chamber a negative vacuum pressure between 500 and 1000 mbar. In these ranges of depression the evaporation is produced at atmospheric temperature.
  • the method further comprises a pre-cleaning stage of said wire, prior to said cleaning stage, wherein the surface of said wire is scraped and cleaned by means of a cleaning substance when passing through a scraping device and in a specially preferable way said scraping device in said pre-cleaning stage is a drawing die.
  • a pre-cleaning stage of said wire prior to said cleaning stage, wherein the surface of said wire is scraped and cleaned by means of a cleaning substance when passing through a scraping device and in a specially preferable way said scraping device in said pre-cleaning stage is a drawing die.
  • the pre-cleaning allows preparing the extent of dirt that exists on the wire. This dirt comes from the sodium and calcium stearates that are used in the process for lubricating the wires during the wire drawing process.
  • the ideal degree of cleaning to be obtained via the pre-cleaning unit is 0.5 to 1 g/m 2 .
  • the method further comprises a first draining stage, at the exit of said cleaning stage, by projecting a gas or fluid blown by a nozzle onto the surface of said wire, with the excess liquid on said wire being returned to said first bath and with said method further comprising a rinsing stage after said draining stage and prior to said drying stage.
  • the wire passes through the nozzle, so that the surface can be drain in a uniform manner. The nozzle allows guaranteeing the state of the rinsing bath in perfect conditions as the transfer and consequently the contamination of the rinsing bath by phosphoric acid aggregate is avoided.
  • the method comprises a second draining stage by passing said wire through a draining device at the exit of said galvanizing stage for removing the excess coating deposited on the surface of said wire and a cooling stage of said coating by passing said wire through a vacuum chamber for cooling with a cooling liquid.
  • a draining device at the exit of said galvanizing stage for removing the excess coating deposited on the surface of said wire
  • a cooling stage of said coating by passing said wire through a vacuum chamber for cooling with a cooling liquid.
  • another objective of the invention consists in providing a machine that allows galvanizing wire continuously according to the proposed method.
  • This aim is achieved by means of a continuous wire galvanizing machine of the type indicated at the beginning, characterized in that said cleaning station comprises a first bath with a phosphoric acid aqueous solution and an ultrasound generating device for cleaning the surface of said wire and in that said machine further comprises a drying station with a drying device by evaporation downstream from said cleaning station.
  • the solution comprises phosphoric acid in a proportion less than 7.5% by weight and in a specially preferable way, in a proportion of 2% by weight.
  • the machine can process several wires at a time in parallel.
  • the machine also comprises a pre-cleaning stage that comprises a device for scraping the surface of said wire arranged upstream from said washing station.
  • the vacuum drying device by evaporation comprises a chamber traversed by said wire, with said drying device being suitable for creating a negative vacuum pressure between 500 to 1000 mbar.
  • the chamber consists of a tube that is traversed by the wire to be dried originating from the cleaning bath, in the inside of which a negative depression is created, by applying a liquid ring vacuum pump and some guides adjusted to the size of the wire to be processed. This causes the water to evaporate at room temperature within the drying chamber due to the negative pressure created inside it.
  • the machine comprises a first draining station between said cleaning station and said drying station which comprises a nozzle that is adaptable to projecting a gas or liquid onto the surface of said wire.
  • the machine comprises a second draining station at the exit of said galvanizing station, with said second draining station comprising at least one draining device for removing the excess coating deposited on the surface of said wire and a vacuum chamber for cooling with a cooling liquid.
  • the figures show the continuous wire galvanizing machine 1 according to the invention which for greater clarity is shown in two parts which in practice are assembled in series, but which in the figures have been joined together by a dotted line. Furthermore, in the figures, also in the interest of simplicity, one single wire 3 to be processed is shown, although preferably machine 1 is also suitable for processing several wires 3 in parallel simultaneously. It is worth mentioning that from the delivery station 2 to the bath in which they are galvanized, each wire is led and guided independently and separately.
  • wire 3 to be processed is extracted from a coil 30 and led to a pre-cleaning station 4.
  • wire 3 passes through a scraping device 24.
  • Scraping device 24 consists of a drawing die carrier for each individual wire, wherein the drawing die has the diameter of wire 3 to be processed originating from a previous wire drawing stage, which together with the action of a cleaning product, causes most of the soaps, that have been deposited during the previous wire drawing process, to be removed.
  • the surface of wire 3 has sodium and calcium stearates from lubrication which must be removed in order to guarantee a correct galvanization.
  • the purpose of the pre-cleaning station 4 is to scrape the surface of wire 3 in order to obtain a reduction in the stearates of the order of 0.5 to 1 g/m 2 . Thanks to this pre-cleaning stage, the subsequent cleaning can be carried out at a greater speed.
  • wire 3 passes via an unwinding reel 32 to the cleaning station 6 wherein a cleaning stage is carried out.
  • wire 3 is dipped in a first bath 26 containing a phosphoric acid aqueous solution at 2% by weight.
  • Cleaning station 6 comprises an ultrasound generating device 34 that subjects wire 3 to an ultrasound treatment during its passage through first bath 26 which intensifies the cleaning.
  • the cleaning stage allows removing the stearates that have not been removed in the pre-cleaning stage, and on the other handy it slightly etches the surface of wire 3 so as to improve the adherence of the zinc in a subsequent galvanizing stage.
  • This cleaning stage 6 allows passing wire 3 at high speed as in the embodiment shown it only needs a residency time of 2 seconds in first bath 26. Also, the phosphoric acid solution only needs to be heated to between 45o and 55°, thereby improving energy consumption with respect to traditional alkaline baths and reducing reactant losses through evaporation. Finally it is worth highlighting that the phosphoric acid is not harmful, or irritant, and that its removal is easier and more economical.
  • wire 3 passes through a draining stage in a draining station 8 via a nozzle 36, that projects a gas onto the surface of wire 3.
  • Nozzle 36 can be either a subsonic nozzle, or a supersonic one. This removes the liquid coming from first bath 26 from the surface of wire 3.
  • wire 3 After passing through draining station 8, wire 3 passes through a rinsing stage in a rinsing station 10 wherein wire 3 passes through a second bath 38 of water. This rinsing allows removing any residue of phosphoric acid that may be on the surface of wire 3, in spite of the previous draining by means of nozzle 36.
  • drying device 28 consists in passing wire 3 through a tubular shaped vacuum chamber. Thanks to the effect of the vacuum, the liquid evaporates at room temperature. Thus drying energy is saved and furthermore wire 3 enters the following heating stage completely dry. The correct drying allows processing wire 3 at high speeds, since the total absence of humidity allows that the induction oven does not consume additional power to evaporate the rinsing water or to burn lubrication products from previous stages or from the drawing.
  • wire 3 undergoes an annealing or austenitizing treatment at a first temperature of approximately 750oC in the case of annealing, or 1000oC for austenitizing.
  • the purpose of this treatment is to reduce any internal tension in the wire which may have been produced during the drawing stage prior to the method described herein.
  • wire 3 passes through a gradual cooling stage inside the same tubular passage independent of induction oven 14 to a second temperature close to the temperature of the zinc in liquid state, in other words, approximately 460oC.
  • This stage is also carried out in an inert atmosphere to prevent the possible oxidisation caused by the temperature.
  • wire 3 From the cooling stage, wire 3 enters directly, still in an inert atmosphere, into the galvanizing stage.
  • wire 3 is dipped in a third bath 40 containing zinc, guided under a wire guiding device known in the art as a sinker 42.
  • machine 1 according to the invention is provided for processing multiple wires 3 simultaneously.
  • machine 1 comprises an individual sinker 42 for each wire 3 processed, with each of said sinkers 42 being movable between a dipped position wherein it is suitable for guiding said wire 3 dipped in said third bath 40 and a withdrawn position wherein said sinker 42 is above the surface of said third bath 40.
  • each of the sinkers 42 can rise or descend independently, so that the operator can thread wire 3 horizontally and then lower sinker 42. This considerably improves safety when using machine 1, as in the case of integral fixed sinkers for all the processed wires, which are common in the art, the worker is obliged to thread the wire by dipping it into the zinc bath and passing it under sinker 42.
  • Individual and movable sinkers 42 are also advantageous for periods when there is no production. During these periods, sinker 42 rises and wire 3 remains above the bath. Thanks to this, wire 3 does not deteriorate by remaining submerged although it does not pass through machine 1.
  • wire 3 comes out of third bath 40 containing liquid zinc it passes through a polycrystalline drawing die 50 for draining, into a chamber 46 or vertical tube that has a vacuum, inundated by a cooling liquid, such as water, which reduces the excess liquid or semi-liquid zinc layer according to the diameter of its interior calibre.
  • a cooling liquid such as water
  • the polycrystalline drawing die 50 is in contact with cold water which acts as a cooling element for the drawing die 50 and at the same time solidifies the liquid or semi-liquid zinc. This prevents damaging the galvanized layer before entering pulleys 48 and subsequent guidings, on the way towards the final take-up stage. Also with this, high processing speeds can be reached without losing galvanizing quality or concentricity with respect to wire 3.
  • other draining devices can be used such as pads, gas jet nozzles also known as jet wipes or electromagnetic draining systems.
  • cooling height is drastically reduced, which allows building a more compact machine, but mainly allows hugely increasing the processing speed of wire 3, as with conventional cooling systems it would not be possible to work at such a high speed, in view of the height of the cooling jets that would be necessary.
  • wire 3 now coated can pass through an optional waxing stage, and it is led to a winding device 44 where galvanized wire 3 is shaped in a roll.
  • machine 1 succeeds in processing wire 3 at a speed of 450 m/min, which speed is much higher than in the state of the art machines which usually process the wire at speeds of about 120 to 180 m/min

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  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Coating With Molten Metal (AREA)
EP10170263A 2009-08-06 2010-07-21 Continuous wire galvanizing method and corresponding galvanizing machine Not-in-force EP2281912B1 (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
ES200930568A ES2338204B1 (es) 2009-08-06 2009-08-06 Procedimiento de galvanizado de alambre en continuo y maquina de galvanizado correspondiente.

Publications (2)

Publication Number Publication Date
EP2281912A1 EP2281912A1 (en) 2011-02-09
EP2281912B1 true EP2281912B1 (en) 2012-05-09

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Application Number Title Priority Date Filing Date
EP10170263A Not-in-force EP2281912B1 (en) 2009-08-06 2010-07-21 Continuous wire galvanizing method and corresponding galvanizing machine

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EP (1) EP2281912B1 (es)
AT (1) ATE557110T1 (es)
ES (1) ES2338204B1 (es)

Families Citing this family (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2014020188A1 (es) 2012-07-31 2014-02-06 Automat Industrial S.L. Procedimiento de limpieza de alambre en continuo y maquina de procesado de alambre en continuo que comprende dicho procedimiento
GB2507309A (en) 2012-10-25 2014-04-30 Fontaine Holdings Nv Continuous single dip galvanisation process
ES2939302T3 (es) * 2018-11-14 2023-04-20 Druids Process Tech S L Método para enfriar un alambre y la correspondiente instalación de procesamiento de alambre
CN112226713A (zh) * 2020-09-07 2021-01-15 潘涛 一种金属板材镀锌装置及其加工方法

Family Cites Families (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3370992A (en) * 1963-10-14 1968-02-27 Diamond Shamrock Corp Pretreatment of a metal surface for conversion coating
US6861159B2 (en) * 1992-03-27 2005-03-01 The Louis Berkman Company Corrosion-resistant coated copper and method for making the same
US6491770B1 (en) 2000-05-31 2002-12-10 James M. Knott, Sr. Strand galvanizing line
EP1209245A1 (en) * 2000-11-23 2002-05-29 Galvapower Group N.V. Flux and its use in hot dip galvanization process
CN2692164Y (zh) * 2003-07-10 2005-04-13 北京金星超声波设备技术有限公司 钢丝表面化学清洗清洁化生产设备
EP2035594A4 (en) * 2006-06-09 2010-12-08 Teck Cominco Metals Ltd HIGH ALUMINUM ALLOY FOR GENERAL GALVANIZATION

Also Published As

Publication number Publication date
EP2281912A1 (en) 2011-02-09
ATE557110T1 (de) 2012-05-15
ES2338204A1 (es) 2010-05-04
ES2338204B1 (es) 2011-06-08

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