JP2009114512A - Resin-coated steel sheet and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a resin-coated steel sheet having an excellent surface appearance, and a method for manufacturing the same. <P>SOLUTION: The hot dip Zn-Al-based alloy-plated steel sheet constituting the resin-coated steel sheet has a hot dip Zn-Al-based alloy plating layer containing 1.0 to 10 mass% Al, 0.2 to 1.0 mass% Mg, 0.005 to 0.1 mass% Ni, and consisting of the balance Zn and inevitable impurities on at least one surface of the steel sheet. In the manufacturing method, the cooling rate down to 250°C of the steel sheet pulled up from a hot dip Zn-Al-based alloy plating bath is held at 1 to 15°C/second when the steel sheet is pulled up from the plating bath and is cooled. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a resin-coated steel sheet excellent in surface appearance and used in the fields of architecture, civil engineering, home appliances and the like and a method for producing the same.

  Conventionally, a hot-dip Zn—Al-based alloy-plated steel sheet has been widely used in the fields of automobiles, architecture, civil engineering, home appliances and the like as so-called pre-coated steel sheets whose surfaces are coated. As the hot-dip Zn-Al alloy-plated steel sheet for coating base, a hot-dip Zn-plated steel sheet (hereinafter referred to as GI) whose Al content in the plating layer is 0.2% by mass or less, 5% by mass of galfan (hereinafter referred to as GF) and galvanium steel sheet (hereinafter referred to as GL) having the same Al content of about 55% by mass are used, but especially in the fields of construction and civil engineering, the cost is lower than that of GL. GF is often used for reasons such as better corrosion resistance than GI.

However, GF generally has the following problems.
(I) Plating appearance Turtle-shaped spangles are formed, but the spangles have different forms depending on plating conditions (for example, annealing before plating, bath components), cooling conditions after plating (for example, cooling rate), etc. For this reason, even when it is used after painting, the turtle shell pattern may float on the painted surface and impair the appearance after painting. For this reason, in recent years, there has been an increasing demand for GF having a beautiful plating layer having a metallic luster without spangles even for a coating base.
(Ii) Blackening resistance Even if the GF is left for a short time after plating, depending on the corrosive environment, a so-called blackening phenomenon occurs in which the plating surface locally changes to black-gray. There is relatively little problem when coating is performed by chemical conversion treatment immediately after plating, but in reality, it is often packed in a coiled state after plating, and after a certain period of time, it is often subjected to chemical conversion treatment and painting, during which time blackening occurs. Will occur. In this case, a chemical conversion treatment failure occurs thereafter, and as a result, the adhesion, workability, corrosion resistance, and the like of the coated film after coating are lowered, and the commercial value may be significantly impaired.

Conventionally, for example, the following proposals have been made for the purpose of improving the plating appearance and blackening resistance of a hot-dip Zn-Al alloy-plated steel sheet having a GF composition.
Patent Document 1 adds Mg: more than 2% by mass to 10% by mass in a Zn—Al based alloy plating layer of Al: 0.5-20% by mass for the purpose of improving blackening resistance and chemical conversion treatment. In addition, it is shown that the surface length ratio of the Zn—Al—Mg eutectic + Zn single phase on the plating surface is 50% or more, and in order to improve the chemical conversion treatment property, Pb, Sn, It has been shown to add one or more of Ni and the like.

In Patent Document 2, for the purpose of improving blackening resistance, Pb: 0.01% by mass or less, Sn: 0.005 for a Zn—Al-based alloy plating layer of Al: 4.0-7.0% by mass. It is shown that Ni: 0.005 to 3.0% by mass and Cu: 0.005 to 3.0% by mass are added, and skin pass treatment is performed after plating, followed by chromate treatment. .
Further, although not intended to improve blackening resistance, Patent Document 3 discloses that in order to improve workability, Al: 0.1 to 40% by mass of a Zn—Al based alloy plating layer, Mg: 0.1 to 10% by mass and addition of Mg-based intermetallic compound phase of predetermined size is shown to be a dispersed structure, and for improving sliding resistance, as necessary It has been shown that one or more of Ni, Ti, Sb and the like are added.

JP 2001-329354 A JP-A-4-297562 JP 2001-64759 A

However, according to a study by the present inventors, it has been found that the above-described conventional technique has the following problems.
Even if the plated steel sheet of Patent Document 1 can improve the blackening resistance to some extent, the plating appearance is likely to deteriorate due to a decrease in color tone or dross adhesion, and cracks are likely to occur in the plating layer, so that the workability also deteriorates. Cheap. Further, when the amount of Mg increases, the blackening resistance is also inferior.
The chromate-treated plated steel sheet of Patent Document 2 is not sufficiently effective in improving blackening resistance, and spangles similar to those of normal GF are formed, so that appearance defects as plated steel sheets and coated steel sheets are likely to occur.
The plated steel sheet of Patent Document 3 causes any problems such as deterioration of blackening resistance, deterioration of color tone, poor plating appearance due to dross adhesion, and poor appearance due to spangle formation.

Therefore, the object of the present invention is to solve the above-mentioned problems of the prior art, a beautiful plating appearance with metallic luster in which spangles are not formed or very fine spangles are formed, and melting having excellent blackening resistance. An object of the present invention is to provide a resin-coated steel sheet having excellent surface appearance and a method for producing the same, using a Zn-Al alloy-plated steel sheet as a base-plated steel sheet.
Another object of the present invention is to provide a production method capable of stably producing such a resin-coated steel sheet having an excellent surface appearance.

  In order to solve the above-mentioned problems, the present inventors have conducted extensive research on the optimum plating composition and structure of the hot-dip Zn-Al alloy-plated steel plate constituting the resin-coated steel plate and the plating process, The alloy plating composition is based on the general Al concentration of GF, and by containing appropriate amounts of Mg and Ni, it is a beautiful plating with a metallic luster that has no spangles or very fine spangles. It has been found that a hot-dip Zn—Al-based alloy-plated steel sheet having an appearance and excellent blackening resistance can be obtained. Furthermore, by controlling the cooling rate after plating to a specific range, it is possible to promote the concentration of Ni to the outermost layer of the plated layer by the synergistic effect of Mg and Ni, thereby obtaining better blackening resistance. I found out.

The present invention has been made on the basis of such knowledge and has the following gist.
[1] In a resin-coated steel sheet having a molten Zn—Al-based alloy plating layer on at least one surface of the steel sheet, and having a chemical conversion treatment layer and a resin layer in this order on top of the molten Zn—Al-based alloy plating layer,
The molten Zn—Al-based alloy plating layer contains Al: 1.0 to 10% by mass, Mg: 0.2 to 1.0% by mass, Ni: 0.005 to 0.1% by mass, and the balance A resin-coated steel sheet comprising Zn and inevitable impurities.
[2] The resin-coated steel sheet according to [1], wherein a primer layer is provided between the chemical conversion treatment layer and the resin layer.
[3] The resin-coated steel sheet according to [1] or [2], wherein Ni is concentrated in an outermost layer portion of the molten Zn—Al-based alloy plating layer.

[4] In the resin-coated steel sheet according to [1] to [3], the molten Zn—Al alloy plating layer is formed of a Zn—Al binary eutectic and an Al—Zn—Mg intermetallic ternary eutectic. A resin-coated steel sheet characterized by containing.
[5] The resin-coated steel sheet according to [4], wherein the Mg intermetallic compound is MgZn ₂ .
[6] In the resin-coated steel sheet according to [4] or [5] above, the molten Zn—Al-based alloy plating layer has a ternary eutectic of Al—Zn—Mg intermetallic compound in a cross section of the plating layer of 10 to 30% by area. A resin-coated steel sheet characterized by containing.
[7] The resin-coated steel sheet according to any one of [4] to [6], wherein an average major axis of a Zn—Al binary eutectic is 10 μm or less.

[8] After dipping the steel sheet in a molten Zn-Al alloy plating bath, the steel sheet is pulled out from the plating bath and cooled to form a molten Zn-Al alloy plating layer on the steel sheet surface, and the molten Zn-Al alloy plating is performed. In the method for producing a resin-coated steel sheet, after chemical conversion treatment of the steel sheet, applying a resin coating,
The cooling rate of the steel sheet pulled up from the plating bath to 250 ° C. is 1 to 15 ° C./second,
The molten Zn—Al-based alloy plating layer contains Al: 1.0 to 10% by mass, Mg: 0.2 to 1.0% by mass, Ni: 0.005 to 0.1% by mass, and the balance A method for producing a resin-coated steel sheet comprising Zn and inevitable impurities.

[9] After dipping the steel sheet in a molten Zn-Al alloy plating bath, the steel sheet is pulled up from the plating bath and cooled to form a molten Zn-Al alloy plating layer on the steel sheet surface, and the molten Zn-Al alloy plating is performed. In the method for producing a resin-coated steel sheet, after the chemical conversion treatment of the steel sheet, the primer treatment, and further applying the resin coating,
The cooling rate of the steel sheet pulled up from the plating bath to 250 ° C. is 1 to 15 ° C./second,
The molten Zn—Al-based alloy plating layer contains Al: 1.0 to 10% by mass, Mg: 0.2 to 1.0% by mass, Ni: 0.005 to 0.1% by mass, and the balance A method for producing a resin-coated steel sheet comprising Zn and inevitable impurities.

The resin-coated steel sheet of the present invention has a metallic luster in which the molten Zn-Al alloy-plated steel sheet constituting the steel sheet does not have spangles or has very fine spangles while maintaining excellent workability unique to GF. Because it has a beautiful plating appearance and excellent blackening resistance, it has an excellent surface appearance.
In addition, according to the production method of the present invention, as the base plated steel sheet, a beautiful plated appearance having a metallic luster in which spangles are not formed or very fine spangles are formed, and molten Zn- having particularly excellent blackening resistance Since an Al-based alloy-plated steel sheet is obtained, a resin-coated steel sheet having an excellent surface appearance can be produced.

The resin-coated steel sheet of the present invention has a molten Zn-Al alloy plating layer on at least one surface of the steel sheet, and has a chemical conversion treatment layer and a resin layer in this order on top of the molten Zn-Al alloy plating layer. A resin-coated steel plate, wherein the molten Zn-Al alloy plating layer is Al: 1.0 to 10% by mass, Mg: 0.2 to 1.0% by mass, Ni: 0.005 to 0.1% by mass %, With the balance being Zn and inevitable impurities.
In the molten Zn-Al alloy-plated steel sheet (hereinafter referred to as “the present invention-plated steel sheet” for convenience) constituting the resin-coated steel sheet of the present invention, Mg added to the molten Zn—A1 alloy-plated layer is mainly spangled. Aiming to obtain a beautiful metallic appearance with no metallic or very fine spangles, and to improve the blackening resistance of Ni added to the plating layer. However, in order to improve the blackening resistance by adding Ni, it is preferable that Ni is concentrated in the outermost layer portion of the plating layer by coexistence of an appropriate amount of Mg, and the cooling rate after plating is in an appropriate range. By controlling to, Ni concentration in the outermost layer portion of the plating layer can be caused more appropriately.

Hereinafter, the reason for limitation of the component composition of the hot-dip Zn—Al-based alloy plating layer (hereinafter simply referred to as “plating layer”) of the plated steel sheet of the present invention will be described.
When the Al content in the plating layer is less than 1.0% by mass, an Fe—Zn alloy layer is formed thick at the plating layer-substrate interface, and the workability deteriorates. On the other hand, if the Al content exceeds 10% by mass, a eutectic structure of Zn and Al cannot be obtained, and the Al-rich layer increases and the sacrificial anticorrosive action decreases, so that the corrosion resistance of the end face portion is inferior. Moreover, when it is going to obtain the plating layer in which Al exceeds 10 mass%, the top dross which has Al as a main component will generate | occur | produce easily in a plating bath, and the problem that a plating external appearance is impaired also arises. For these reasons, the Al content in the plating layer is 1.0 to 10% by mass, preferably 3 to 7% by mass.

One of the objects of the present invention is to eliminate the spangle peculiar to the hot dip Zn-Al alloy plating of GF composition (zero spangle) or to form a very fine spangle and to have a metallic luster without unplating. In order to obtain a good plating appearance, the present inventors conducted the following experiment in order to investigate the relationship between the plating composition and the plating appearance.
Mg and Ni were added individually to a hot-dip Zn-Al alloy plating bath containing Al (4 to 5% by mass) of GF composition, and a steel plate was hot-dip Zn-Al alloy plated in these plating baths. The plated appearance (particularly spangle size, degree of dross adhesion, color tone, gloss) of the plated steel sheet was visually observed. As a result, the plating layer to which Ni was added showed no change in the plating appearance within the experimental range of the present inventors, and showed a plating appearance almost equivalent to that of normal GF, but the plating layer to which Mg was added was The spangle size, color tone, gloss, etc. changed depending on the added amount.

Mg is added to a molten Zn-Al alloy plating bath containing Al: 4 to 5 mass% and Ni: 0.03 mass%, and a steel plate is formed using the molten Zn-Al alloy plating bath. The relationship between the Mg content in the plating layer and the plating appearance (spangle size, degree of dross adhesion, color tone) was examined. The result is shown in FIG. According to this, when the Mg content is 0.1% by mass or more, the spangle starts to become finer, and when it is 0.2% by mass or more, the spangle almost disappears and the color tone shows a white taste with a metallic luster. Further, when the Mg content is less than 0.2% by mass, the blackening resistance is also lowered. As will be described later, if Mg coexisting with Ni in the plating layer is less than 0.2% by mass, the concentration of Ni in the outermost layer portion of the plating layer is eliminated, resulting in a decrease in blackening resistance. It is estimated that. On the other hand, when the Mg content exceeds 1.0% by mass, the color tone changes from grayish white to gray and the dross adhesion increases. Moreover, when Mg content exceeds 1.0 mass%, it will become easy to produce a crack in a plating layer and the problem that workability falls also arises. Moreover, when there is too much Mg, blackening-proof property is also inferior.
Therefore, the Mg content in the plating layer has a lower limit of 0.2% by mass in order to obtain a beautiful plating appearance and excellent blackening resistance, preventing dross adhesion and color tone deterioration, and further preventing deterioration of workability. Therefore, the upper limit is set to 1.0% by mass.

  In the plating composition, it has been described that Mg mainly contributes to the improvement of the plating appearance and Ni mainly contributes to the improvement of the blackening resistance. As a result of the examination by the present inventors, Ni improves the blackening resistance. It was found that coexistence with Mg is indispensable for exerting the effect. That is, it has been found that Mg has an effect of forming a beautiful plating appearance and indirectly promotes the effect of improving the blackening resistance by Ni by coexisting with Ni. This was clarified by analyzing the plating layer in the depth direction by glow discharge luminescent surface analysis (GDS) for the plated steel sheets having different blackening resistance. An example of the analysis result is shown below.

Regarding the hot-dip Zn-Al alloy-plated steel sheet having the following three types of GF compositions (1) to (3) (all are cooled to 250 ° C. after plating at 5 ° C./second), the depth from the plating layer surface The concentrated form of each element of Al, Zn, Mg, and Ni was investigated in the vertical direction.
(1) Plated steel sheet containing only Mg in the plating layer and poor in blackening resistance (2) Plated steel sheet containing only Ni in the plating layer and inferior blackening resistance (3 ) Plated steel sheet containing Mg and Ni in the plating layer and excellent in blackening resistance Since blackening is considered to be a problem of the plating surface, the samples (plated steel sheets) of (1) to (3) above From the outermost surface, a depth of about 200 nm (2000 mm) was intensively analyzed. The result is shown in FIG. In the analysis of the plating component elements, a GDS analyzer was used to discharge for 30 seconds in the depth direction at an anode diameter of 4 mmφ and a current of 20 mA for analysis.

According to FIG. 2, the concentration peak of each plating component element is observed in the vicinity of the plating surface in any of the above samples (1) to (3), but the concentration form of each element is slightly different in each sample. I understand that.
First, in the plating layer of sample (1) containing only Mg, which has poor blackening resistance, an Mg concentration peak is observed at almost the same position as Zn in the outermost layer (outermost surface), and the concentration of Al is increased. The enrichment peak is on the inner side (substrate side) of the Zn and Mg concentration peaks.
Moreover, the concentration peak of the plating layer of the sample (2) containing only Ni having poor blackening resistance is Al, followed by Zn at the outermost layer portion, and the Ni concentration peak is the Al concentration peak. On the inside (base side).

On the other hand, the plating layer of the sample (3) containing Mg and Ni, which has excellent blackening resistance, has a Ni concentration peak in the same outermost layer as Zn, and each concentration peak of Mg and Al is Ni. It is inside the concentration peak (base side).
Although not shown in FIG. 2, the same amount of Mg and Ni as in the sample (3) coexist in the plating layer, and the plating obtained at a cooling rate of up to 250 ° C. after plating was 30 ° C./second. A steel plate that did not show a significant effect on blackening resistance was analyzed in the same manner, but it was found that the concentration of Ni in the outermost layer portion of the plating layer was less than that of the sample (3).

From the above analysis results, Ni is concentrated in the outermost layer portion of the plating layer excellent in blackening resistance, and it is necessary for the Ni concentration in the outermost layer portion to coexist with Mg. understood. It has also been found that the cooling rate after plating affects the Ni concentration.
In addition, from the analysis result by the fluorescent X-ray mentioned above, it is estimated that Ni concentration of a plating layer outermost layer part exists in the depth of about 30 nm (300 kg) from the plating outermost surface.

  In general, in terms of standard energy for oxide generation, Al and Mg are elements that have a stronger oxidization action than Zn, and conversely, Ni is an element that has a low oxidization action. Blackening is due to oxygen deficiency by diffusing (moving and concentrating) the plating component element with strong oxidization action to the outermost surface of the plating layer, and taking some oxygen from the zinc oxide generated on the outermost surface of the plating layer. If it occurs due to the conversion to zinc oxide, the plating layer of sample (1) with inferior blackening resistance shows that Mg concentrated in the outermost layer deprives oxygen of zinc oxide, and also has inferior blackening resistance. Since the plating layer of sample (2) was concentrated with Al on the surface layer side than Ni, Al, which is also highly oxidizable, took oxygen from zinc oxide and converted it into oxygen-deficient zinc oxide. Can be considered.

In contrast, the outermost layer portion of the plating layer of the sample (3) excellent in blackening resistance is enriched with Ni, which is weakly oxidizable, and this is the outermost layer portion of Mg and Al that coexists as a barrier layer. It is considered that the diffusion (migration / concentration) to the surface is suppressed and the blackening resistance is improved.
That is, in order to improve blackening resistance, it is necessary that Ni is concentrated in the outermost layer portion of the plating layer, so that it plays a role as a barrier layer. This is thought to be caused by the coexistence of However, the mechanism by which Ni moves and concentrates in the outermost layer portion of the plating layer by coexisting with Mg is not always clear at present.

When the Ni content in the plating layer is less than 0.005% by mass, the effect of improving blackening resistance cannot be obtained. This is considered to be because even if Mg coexists, the concentration of Ni on the outermost layer portion of the plating layer is small. Moreover, even if Ni is 0.005 mass% or more, if Mg is less than 0.2 mass%, the effect of improving blackening resistance cannot be obtained. This is presumably because Ni is not concentrated on the outermost layer.
In addition, when the Ni content exceeds 0.1% by mass, although there is an effect of improving blackening resistance, Al—Mg-based dross containing Ni is generated in the plating bath, and the plating appearance due to dross adhesion is impaired. It is not preferable.
For the above reasons, in the present invention, the Ni content in the plating layer is set to 0.005 to 0.1% by mass, and the Mg content is set to 0.2 to 1.0% by mass as described above. .
As described above, by containing appropriate amounts of Mg and Ni in the plating layer of GF composition, there is no spangle or very fine spangle, beautiful plating appearance with metallic luster, and excellent blackening resistance It is possible to obtain a hot-dip Zn—Al-based alloy-plated steel sheet.

  FIG. 3 shows a cross-sectional SEM photograph of the plating layer (Al: 4.4 mass%, Mg: 0.6 mass%, Ni: 0.03 mass%, remaining Zn) of the plated steel sheet of the present invention. According to the SEM photograph, fine grayish black precipitates are interspersed between primary crystal Zn (white part), and grayish white stripe-like precipitates are observed along with the grayish black precipitates. It was done. About this plating layer, while performing X-ray diffraction from the surface, elemental analysis was performed by EDX from the cross section and the surface. FIG. 4 shows the results of X-ray diffraction, and FIG. 5 shows the results of EDX analysis of the cross section of the plating layer (EDX element mapping and EDX spectrum, mapping data type: net count, magnification: 3000 times, acceleration voltage: 5.0 kV). FIG. 6 shows the results of EDX analysis of the plating layer surface (EDX element mapping and EDX spectrum, mapping data type: net count, magnification: 3000 times, acceleration voltage: 10.0 kV).

From these results, MgZn ₂ was identified as an intermetallic compound in the plating layer of the plated steel sheet of the present invention. Further, the fine grayish black precipitates were estimated to be Zn—Al binary eutectic mainly composed of Al, and scattered throughout the plating layer. The grayish white stripe pattern is mainly composed of MgZn ₂ identified as an intermetallic compound, and is presumed to be a ternary eutectic of Zn and Al (hereinafter referred to as Zn-Al-MgZn ₂ ternary eutectic). It was done. In particular, the ternary eutectic spreads in the form of a network near the surface of the plating layer, and fine Zn-Al binary eutectics are scattered in the network.

Next, as a comparison, the cross section and the surface of a plating layer of general GF (Al: 4.3 mass%, remaining Zn) were subjected to EDX analysis. The results of EDX analysis of the plating layer cross section (EDX element mapping and EDX spectrum, mapping data type: net count, magnification: 3000 times, acceleration voltage: 5.0 kV) are shown in FIG. EDX elemental mapping and EDX spectrum, mapping data type: net count, magnification: 3000 times, acceleration voltage: 10.0 kV) are shown in FIG. The GF plating layer is composed of a binary eutectic of white primary Zn and gray-black Zn-Al, and this binary eutectic is continuously present near the plating layer surface and the plating layer-substrate interface. It is significantly larger than the Zn—Al binary eutectic of the plated steel sheet of the present invention.
Although data is omitted, since the Zn-Al binary eutectic was present in the center of the turtle shell pattern, the Zn-Al binary eutectic is the nucleus for the formation of the turtle shell pattern. It was thought that.

Therefore, the grain size, eutectic rate, etc. of the Zn—Al binary eutectic and the Zn—Al—MgZn ₂ ternary eutectic in the plated layer of the plated steel sheet of the present invention were investigated in detail. As a result, in the plated steel sheet of the present invention, the eutectic rate of the ternary eutectic of Zn—Al—MgZn ₂ is 10 to 30% by area ratio in the cross section of the plating layer. It was found that a beautiful plating appearance with no surface was obtained. The details of this mechanism are not necessarily clear, but if estimated from the above analysis results, if the GF turtle shell pattern is cored by a Zn-Al binary eutectic, the large continuous Zn in general GF -Since the binary eutectic of Al is formed, the number of nuclei is reduced, and a turtle shell pattern is formed and grows. However, in the plated layer of the present invention to which Mg is added, the ternary eutectic of Al-Zn-MgZn ₂ is formed. Forms a mesh when solidified, breaks the Zn-Al binary eutectic that becomes the core of the tortoise shell pattern and refines it to increase the number of nuclei, resulting in a beautiful plating appearance without the tortoise shell pattern Is considered to be obtained.

The eutectic ratio of Zn—Al—MgZn ₂ ternary eutectic (the area ratio of the ternary eutectic in the cross section of the plating layer; the same applies hereinafter) is less than 10 area% because Mg in the plating layer is 0 This is a case of less than 2% by mass, and the formation of Zn—Al—MgZn ₂ ternary eutectic is small, so that the Zn—Al binary eutectic is not sufficiently refined and spangles are formed. On the other hand, the eutectic rate of the ternary eutectic of Zn—Al—MgZn ₂ exceeds 30 area% when Mg in the plating layer exceeds 1.0 mass%, and the plating appearance is beautiful. However, the increase in MgZn ₂ increases the hardness of the plating layer, and a large crack is likely to occur during bending, resulting in a decrease in workability.

The particle size of the Zn—Al binary eutectic is affected by the eutectic rate of the Zn—Al—MgZn ₂ ternary eutectic, and the eutectic rate of this ternary eutectic is 10 to 30% by area. If it is a range, an average major axis will be 10 micrometers or less. The average major axis of the Zn—Al binary eutectic exceeds 10 μm when Mg in the plating layer is less than 0.2% by mass, and the Zn—Al binary eutectic is not refined. A sufficient and fine turtle shell pattern starts to form, and a beautiful plating appearance with metallic luster cannot be obtained.
Here, the eutectic rate of the ternary eutectic of Zn—Al—MgZn ₂ and the particle size (average major axis) of the binary eutectic of Zn—Al are measured as follows. Eight or more objects are randomly selected from a cross-sectional SEM photograph (for example, a magnification of 3000 times) of the plating layer, and the area of the entire plating layer is first determined for each object. Next, for each object, the area of the ternary eutectic of Zn—Al—MgZn ₂ is obtained, the area ratio of the entire plating layer is calculated, and the average value thereof is taken as the eutectic rate. For the same cross-sectional SEM photograph object, the maximum length (see FIG. 9) of each Zn—Al binary eutectic is measured as the major axis, and the average value is taken as the average major axis.

The resin-coated steel sheet of the present invention has a chemical conversion treatment layer as an upper layer of the molten Zn—Al-based alloy plating layer (at least one plating layer in the case of having a plating layer on both sides), and further has a resin layer as an upper layer. Have Moreover, you may provide a primer layer between a chemical conversion treatment layer and a resin layer as needed.
What is necessary is just to apply what is employ | adopted for the normal precoat steel plate as a chemical conversion treatment layer, a primer layer, and a resin layer.
For the formation of the chemical conversion treatment layer, a chromate treatment with a treatment liquid mainly composed of normal chromic acid, dichromic acid or a salt thereof may be applied, or a titanium-based or zirconium-based material containing no chromium. You may apply the chromium free process by a process liquid.

The primer layer is made of, for example, one or more organic resins such as epoxy resin, polyester resin, modified polyester resin, and modified epoxy resin, and one or more rust preventive pigments (for example, zinc chromate, strontium chromate, barium chromate, etc.). ), A primer mixed with a curing agent (one or more of melamine, isocyanate resin, etc.) can be applied. In addition, it is also possible to add a color pigment or extender pigment to the primer to form a highly workable coating film.
The resin layer is formed by applying and baking an appropriate amount of a top coating material such as a commonly known polyester-based paint, fluororesin-based paint, acrylic resin-based paint, vinyl chloride-based paint, or silicone resin-based paint. Can do. The film thickness of the resin layer and the coating method (spray coating, roll coating, brush coating, etc.) may be the same as those of a normal precoated steel plate.
Also, the baking (drying) conditions for forming the chemical conversion treatment layer, the primer layer, and the resin layer are maintained at a maximum reached plate temperature (PMT) of 50 to 280 ° C. for 1 to 100 seconds. It ’s fine.

Next, the manufacturing method of the resin-coated steel sheet of the present invention will be described.
In the present invention, the steel plate used as the base steel plate of the plated steel plate may be appropriately selected from known steel plates depending on the application, and is not particularly limited. For example, a low carbon aluminum killed steel plate or an extremely low carbon steel plate is used. It is preferable from the viewpoint of plating work.
In the method for producing a plated steel sheet of the present invention, first, a steel sheet (underlying steel sheet) is immersed in a molten Zn-Al alloy plating bath and subjected to thermal immersion (melting) plating, and then pulled up from the plating bath and cooled. A molten Zn—Al alloy plating layer is formed on the surface. This plating layer contains Al: 1.0 to 10% by mass, Mg: 0.2 to 1.0% by mass, Ni: 0.005 to 0.1% by mass, and the balance from Zn and inevitable impurities. Become. Therefore, it is preferable to adjust the bath composition of the molten Zn—Al-based alloy plating bath to be substantially the same as the alloy plating layer composition.
Further, as described above, it is preferable that Ni is concentrated in the outermost layer portion of the molten Zn—Al-based alloy plating layer.
Next, the molten Zn—Al alloy-plated steel sheet obtained as described above is subjected to a chemical conversion treatment and then coated with a resin. If necessary, after chemical conversion treatment, primer treatment is performed, and a resin coating is applied thereon. The details of the chemical conversion treatment layer, primer layer, and resin layer to be formed are as described above.

The inventors of the present invention, in particular, as a result of earnestly examining the content of Mg and Ni in the molten Zn-Al alloy plating layer, the cooling rate after plating, and the concentration behavior of the plating component elements on the outermost layer of the plating layer, As described above, coexistence of Mg and Ni is indispensable for improvement of blackening, that is, Ni concentration on the outermost layer portion of the plating layer, but this Ni concentration requires up to 250 ° C. after plating. It has been found that the cooling rate has a great influence.
It is known that metals such as Al, Mg, and Ni in the molten Zn-Al alloy plating layer gradually diffuse toward the outermost surface of the plating layer during solidification and normal temperature after plating. In particular, it has been found that the concentration of Mg and Ni on the outermost surface of the plating layer, which has been noted in the experiments by the present inventors, is greatly influenced by the cooling rate up to 250 ° C. after plating. On the other hand, the cooling rate in the temperature range below 250 ° C. hardly affected the concentration of Mg and Ni.

Specifically, by controlling the cooling rate of the plated steel sheet pulled up from the molten Zn—Al alloy plating bath to 250 ° C. to 1 to 15 ° C./second, preferably 2 to 10 ° C./second, It has been found that Ni concentration on the surface layer can be more effectively promoted. When the cooling rate of the plated steel sheet pulled up from the plating bath to 250 ° C. is less than 1 ° C./second, although Ni is sufficiently concentrated in the outermost layer of the plated layer, an alloy layer grows in the plated layer, and a turtle shell pattern As a result, the appearance deteriorates and the workability deteriorates. On the other hand, if the cooling rate exceeds 15 ° C./second, the Mg content in the plating layer is in the range of 0.2 to 1.0 mass% and the Ni content is in the range of 0.005 to 0.1 mass%. Further, the concentration of Ni in the outermost layer portion of the plating layer is reduced, and the blackening resistance is not significantly affected. Further, when the cooling rate to 250 ° C. exceeds 15 ° C./second, the eutectic ratio of Zn—Al—MgZn ₂ ternary eutectic in the plating layer may be less than 10%, and the fine turtle shell pattern May form. Therefore, the cooling rate of the plated steel sheet pulled up from the molten Zn—Al-based alloy plating bath to 250 ° C. is preferably 1 to 15 ° C./second, more preferably 2 to 10 ° C./second.
The plating bath temperature is preferably in the range of 390 to 500 ° C. If the plating bath temperature is less than 390 ° C., the viscosity of the plating bath increases and the plating surface tends to be uneven, while if it exceeds 500 ° C., dross in the plating bath tends to increase.

In a continuous hot-dip Zn—Al-based alloy plating facility, an unannealed Al-killed steel plate having a plate thickness of 0.5 mm and a plate width of 1500 mm was hot-plated to produce a hot-dip Zn—Al alloy-plated steel plate. About the obtained plated steel sheet, the result of evaluating the plating appearance and blackening resistance was determined by using the plating composition of each plated steel sheet (average composition, Zn—Al binary eutectic grain size, Zn—Al—MgZn ₂ ternary). Table 1 shows the eutectic eutectic ratio), the presence / absence of Ni concentration at the outermost layer of the plating layer, and the plating treatment conditions (plating bath temperature, bath immersion time, cooling rate to 250 ° C. after plating). .
Here, the eutectic ratio of Zn—Al—MgZn ₂ ternary eutectic (area ratio of the ternary eutectic in the cross section of the plating layer) and the particle diameter (average major axis) of Zn—Al binary eutectic are as follows: Measured by the method described above.
The presence / absence / degree of Ni concentration in the outermost layer portion of the plating layer was evaluated according to the following criteria by the GDS analysis described above.
○: Ni concentration peak is almost the same position as Zn concentration peak Δ: Ni concentration peak is slightly inside of Zn concentration peak (base side)
X: Ni concentration peak is inside of Al and Mg concentration peak (base side)

The plating appearance and blackening resistance were evaluated by the following evaluation methods.
(1) Plating appearance (1-1) Adherence of foreign matter (dross) Visually count the number of foreign matter (dross) adhering to the surface of a predetermined area (70 mm x 100 mm) of a molten Zn-Al alloy-plated steel sheet, based on the following criteria Five grades were evaluated. An evaluation of 4 or more was evaluated as “good”.
Evaluation 5: No foreign matter attached Evaluation 4: One foreign matter attached Evaluation 3: Two to three foreign matters attached Evaluation 2: Four to six foreign matters attached Evaluation 1: Seven or more foreign matters attached

(1-2) Spangle size The surface spangle form of a molten Zn-Al alloy-plated steel sheet was photographed with a stereo microscope (magnification 10 times), the number of spangle nuclei within a predetermined area (70 mm x 100 mm) was counted, and based on the following formula Then, the spangle equivalent circle diameter (spangle size) was obtained and evaluated in accordance with the following criteria. When the evaluation is 4 or more, the spangle is remarkably fine in visual observation, so that the surface appearance is “good”.
[Measurement area] / [Number of spangle nuclei] = π (d / 2) ²
D: Spangle circle equivalent diameter (spangle size)
π: Circumference ratio Evaluation 5: No spangle Evaluation 4: Spangle size is 0.2 mm or less Evaluation 3: Spangle size is more than 0.2 mm, 1.0 mm or less Evaluation 2: Spangle size is more than 1.0 mm, 2.0 mm or less Evaluation 1: Spangle size is over 2.0mm

(1-3) Color tone / gloss While visually observing the color tone of the molten Zn—Al alloy-plated steel sheet, the gloss (60 ° specular gloss) was measured with a gloss meter, and evaluated according to the following criteria. An evaluation of 4 or more was evaluated as “good”.
Color tone Glossiness rating 5: White taste 100-200
Evaluation 4: Grayish white taste 201-250
Evaluation 3: Gray taste 251 to 300
Evaluation 2: Silvery white taste 301-350
Evaluation 1: Silver mirror color 351 or more

(2) Blackening resistance Test specimens (50 mm x 70 mm) were taken from a molten Zn-Al alloy-plated steel sheet, and the specimens were laminated together in a humid atmosphere (relative humidity: 95% or more, temperature: 49 ° C). After performing a test for 10 days (blackening test), the L value (lightness) of the surface of the test piece was measured with a color difference meter according to the provisions of JIS-Z-8722, and the L value before and after the blackening test. (ΔL: L value before the test−L value after the test) was determined, and blackening resistance was evaluated in five stages according to the following criteria. A rating of 3 or higher was effective, and a rating of 4 or higher was evaluated as “good”.
Evaluation 5: ΔL = 0
Evaluation 4: ΔL = 1 to 3
Evaluation 3: ΔL = 4-8
Evaluation 2: ΔL = 9-12
Evaluation 1: ΔL = 13 or more

Next, the molten Zn-Al alloy-plated steel sheet obtained as described above is subjected to chemical conversion treatment, and after primer coating as necessary, overcoating (resin) coating is performed to obtain a resin-coated steel sheet. The resin coated steel sheet was manufactured and evaluated for coating appearance, coating film adhesion, bending workability (1T bending), and the like.
When manufacturing a resin-coated steel sheet, it is relatively rare to perform chemical conversion treatment after plating. Therefore, apart from those that have undergone chemical conversion treatment, primer coating, and top coating (resin) coating immediately after plating, dozens of samples cut out after plating are stacked and packaged until the chemical conversion treatment is performed. About what was left to stand in a coil place for 60 days, after investigating the generation | occurrence | production conditions, such as blackening of the plating surface, chemical conversion treatment, primer coating, and top coating (resin) coating were performed.

For the chemical conversion treatment, “ZM3360H” (trade name, manufactured by Nihon Parkerizing Co., Ltd.) was used for chromate treatment, and “CT-E320” (trade name, manufactured by Nihon Parkerizing Co., Ltd.) was used for chromium-free treatment. . In the chromate treatment, after the treatment liquid was applied by spraying, baking was carried out at a maximum plate temperature (PMT) of 60 ° C. for 3 seconds. The adhesion amount was 18 mg / m ^{2 in} terms of Cr per side. In the chromium-free treatment, after the treatment liquid was applied with a roll coater, baking was performed by holding at a maximum plate temperature (PMT) of 80 ° C. for 3 seconds. The adhesion amount was 800 mg / m ² (0.8 μm) per side.
As a primer, “JT250” (trade name, manufactured by Nippon Fine Coatings Co., Ltd.), which is an epoxy paint, was used. In the primer coating, the coating was applied by a roll coater and then baked by holding at a maximum plate temperature (PMT) of 200 ° C. for 20 seconds.
As the top coating material, “KP1500” (trade name, manufactured by Kansai Paint Co., Ltd.) was used as the polyester system, and “Precolor NO 8800” (trade name, manufactured by BASF Japan Co., Ltd.) was used as the fluororesin system. In the application of the polyester-based top coating material, the coating material was applied by a roll coater and then baked by holding at a maximum plate temperature (PMT) 210 ° C. for 30 seconds. In addition, in the application of the fluororesin-based top coating, the coating was applied by a roll coater and then baked by holding at a maximum plate temperature (PMT) of 240 ° C. for 60 seconds.

Table 2 shows the appearance after coating of each product, coating film adhesion, bending workability, and blackening resistance of samples left for 60 days before chemical conversion treatment, along with each type of chemical conversion treatment layer, primer layer, and topcoat (resin) layer. And in Table 3.
For blackening resistance, the L value (lightness) of the test piece surface was measured with a color difference meter in accordance with JIS-Z-8722 for a test piece left for 60 days before chemical conversion treatment, and the L value before and after being left as it was. (ΔL: L value before being left-L value after being left) was determined, and was evaluated in five stages in the same manner as in the above “(2) Blackening resistance”.
Further, the appearance after coating, coating film adhesion and bending workability were evaluated by the following evaluation methods.
(3) Appearance after painting The surface of the resin-coated steel sheet was visually observed and evaluated according to the following criteria.
Evaluation 3: Spangle pattern is not transparent Evaluation 2: Spangle pattern is slightly transparent Evaluation 1: Spangle pattern is transparent

(4) Adhesiveness of coating film 100 grids (mesh) were engraved on the surface of the test piece of the resin-coated steel sheet, and adhesive tape was attached and peeled.
Evaluation 5: No peeling Evaluation 4: Peeling number 1 to 5 Evaluation 3: Peeling number 6 to 15 Evaluation 2: Peeling number 16 to 35 Evaluation 1: Peeling number 36 or more (5) Bending workability After the test piece is bent 1T with the resin coating on the outside (a bending process of 180 ° with one plate having the same thickness as the test piece), the adhesive tape is attached and peeled off, and the state of the coating film is observed. The following criteria were used for the 5-level evaluation.
Evaluation 5: Almost no cracking / no peeling Evaluation 4: Little cracking / no peeling Evaluation 3: Many cracks occurred / Peeling occurred in part (area ratio 10% or less) Evaluation 2: Area of peeling Rate 11-50%
Evaluation 1: Area ratio of peeling 51% or more

The graph which shows the relationship between Mg content in a plating layer, and a plating external appearance about the hot-dip Zn-Al type alloy plating steel plate which has a plating layer of GF composition containing an appropriate amount of Ni A hot-dip Zn-Al alloy-plated steel sheet having a GF composition, a plated steel sheet containing only Mg in the plating layer, a plated steel sheet containing only Ni in the plating layer, and Mg and Ni in the plating layer The graph which shows the component analysis result of the plating layer depth direction about the plated steel sheet Cross-sectional SEM photograph of the plated layer of the hot-dip Zn-Al alloy-plated steel sheet constituting the resin-coated steel sheet of the present invention Drawing which shows the X-ray-diffraction result of the plating layer of the hot-dip Zn-Al system alloy plating steel plate which constitutes the resin coat steel plate of the present invention Drawing which shows the EDX analysis result of the plating layer cross section of the hot-dip Zn-Al system alloy plating steel plate which constitutes the resin coat steel plate of the present invention Drawing which shows the EDX analysis result of the plating layer surface of the hot-dip Zn-Al system alloy plating steel plate which constitutes the resin coat steel plate of the present invention Drawing showing EDX analysis result of cross section of plating layer of general GF Drawing showing the results of EDX analysis of the surface of a general GF plating layer Explanatory drawing which shows the definition of the long diameter of the binary eutectic of Zn-Al

Claims (9)

In a resin-coated steel sheet having a molten Zn-Al-based alloy plating layer on at least one surface of the steel sheet, and having a chemical conversion treatment layer and a resin layer in this order on the upper layer of the molten Zn-Al-based alloy plating layer,
The molten Zn—Al-based alloy plating layer contains Al: 1.0 to 10% by mass, Mg: 0.2 to 1.0% by mass, Ni: 0.005 to 0.1% by mass, and the balance A resin-coated steel sheet comprising Zn and inevitable impurities.   The resin-coated steel sheet according to claim 1, further comprising a primer layer between the chemical conversion treatment layer and the resin layer.   The resin-coated steel sheet according to claim 1 or 2, wherein Ni is concentrated in the outermost layer portion of the molten Zn-Al alloy plating layer.   The molten Zn-Al alloy plating layer contains a binary eutectic of Zn-Al and a ternary eutectic of an Al-Zn-Mg intermetallic compound. Resin-coated steel sheet. The resin-coated steel sheet according to claim 4, wherein the Mg intermetallic compound is MgZn ₂ .   6. The resin coating according to claim 4, wherein the molten Zn—Al-based alloy plating layer contains a ternary eutectic of Al—Zn—Mg intermetallic compound in an amount of 10 to 30 area% in the cross section of the plating layer. steel sheet.   The resin-coated steel sheet according to any one of claims 4 to 6, wherein an average major axis of the binary eutectic of Zn-Al is 10 µm or less. After immersing the steel sheet in a molten Zn-Al alloy plating bath, the steel sheet is pulled out from the plating bath and cooled to form a molten Zn-Al alloy plating layer on the steel sheet surface, and the molten Zn-Al alloy plated steel sheet is formed. In the manufacturing method of the resin-coated steel sheet to which the resin coating is applied after the treatment,
The cooling rate of the steel sheet pulled up from the plating bath to 250 ° C. is 1 to 15 ° C./second,
The molten Zn—Al-based alloy plating layer contains Al: 1.0 to 10% by mass, Mg: 0.2 to 1.0% by mass, Ni: 0.005 to 0.1% by mass, and the balance A method for producing a resin-coated steel sheet comprising Zn and inevitable impurities. After immersing the steel sheet in a molten Zn-Al alloy plating bath, the steel sheet is pulled out from the plating bath and cooled to form a molten Zn-Al alloy plating layer on the steel sheet surface, and the molten Zn-Al alloy plated steel sheet is formed. In the method for producing a resin-coated steel sheet that is treated with a primer, and further coated with a resin,
The cooling rate of the steel sheet pulled up from the plating bath to 250 ° C. is 1 to 15 ° C./second,
The molten Zn—Al-based alloy plating layer contains Al: 1.0 to 10% by mass, Mg: 0.2 to 1.0% by mass, Ni: 0.005 to 0.1% by mass, and the balance A method for producing a resin-coated steel sheet comprising Zn and inevitable impurities.