JP2018162476A - Corrosion-proof material, corrosion resistant member using the same, and cast iron pipe - Google Patents
Corrosion-proof material, corrosion resistant member using the same, and cast iron pipe Download PDFInfo
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本発明は、鉄製または鋼製の基材の表面に対して適用される防食材料と、その防食材料で形成されている防食層を有する耐食部材およびそのうちの鋳鉄管に関する。 The present invention relates to an anticorrosion material applied to the surface of a base material made of iron or steel, an anticorrosion member having an anticorrosion layer formed of the anticorrosion material, and a cast iron pipe thereof.
鉄製または鋼製（以下、合わせて「鉄系」ともいう。）の基材の外面に金属溶射によって形成された防食層を有する鉄系の耐食部材は、従来から様々な分野で使用されており、特に高い耐食性が要求される用途、例えば地中に埋設される上下水道管等の鉄系金属管によく用いられている。このような耐食部材は、防食層を構成する金属溶射層が、亜鉛とアルミニウムの合金や、亜鉛とアルミニウムをそれぞれ単独で同時に溶射して亜鉛層とアルミニウム層を混成した擬合金で形成されていることが多く、その金属溶射層が腐食性環境中で犠牲陽極となって生み出す腐食生成物が保護層として働くことにより、素地である鉄系基材の腐食を抑えるようになっている。 Iron-based corrosion-resistant members having a corrosion-proof layer formed by metal spraying on the outer surface of a base made of iron or steel (hereinafter also referred to as “iron-based”) have been used in various fields. Particularly, it is often used for applications requiring high corrosion resistance, for example, iron-based metal pipes such as water and sewage pipes buried in the ground. In such a corrosion-resistant member, the metal spray layer constituting the anti-corrosion layer is formed of an alloy of zinc and aluminum, or a pseudo-alloy in which zinc and aluminum are simultaneously sprayed independently and mixed with the zinc layer and the aluminum layer. In many cases, the corrosion product produced by the metal sprayed layer serving as a sacrificial anode in a corrosive environment acts as a protective layer, thereby suppressing corrosion of the iron-based base material.
一方、近年では、上記のような金属溶射層からなる防食層を有する耐食部材において、さらなる耐食性の向上による長寿命化が求められるようになってきている。このような要求に対し、例えば特許文献１では、鉄系の外面溶射管において、溶射によって管外面に形成される防食層を、亜鉛層とケイ素含有アルミニウム合金層とを混成した擬合金層とすることにより、従来の亜鉛とアルミニウムの擬合金層で防食層を形成する場合に比べて、擬合金層が生成する腐食生成物が緻密化して強固な保護層を形成するようになり、管の耐食性が向上して耐食寿命を延長することができるとしている。 On the other hand, in recent years, in the corrosion resistant member having the anticorrosion layer composed of the metal sprayed layer as described above, it has been required to extend the life by further improving the corrosion resistance. In response to such a request, for example, in Patent Document 1, in an iron-based outer surface sprayed tube, the anticorrosion layer formed on the outer surface of the tube by spraying is a pseudo alloy layer in which a zinc layer and a silicon-containing aluminum alloy layer are mixed. Therefore, compared with the conventional case where the anticorrosion layer is formed with a zinc-aluminum pseudoalloy layer, the corrosion product produced by the pseudoalloy layer becomes dense and forms a strong protective layer, and the corrosion resistance of the pipe It is said that the corrosion resistance life can be extended.
しかしながら、今後も、鉄系の耐食部材については、需要の増大とともに耐食性向上の要求が高まっていくと考えられる。 However, for iron-based corrosion resistant members, it is considered that the demand for improving corrosion resistance will increase as demand increases.
そこで、本発明は、表面に亜鉛とアルミニウムを主成分とする擬合金層（以下、「Ｚｎ−Ａｌ系擬合金層」と称する。）を有する防食層が形成されている鉄系の耐食部材の耐食性を一層向上させることを課題とする。 Therefore, the present invention provides an iron-based corrosion-resistant member having a corrosion-resistant layer having a pseudo-alloy layer (hereinafter referred to as “Zn—Al-based pseudo-alloy layer”) mainly composed of zinc and aluminum on the surface. It is an object to further improve the corrosion resistance.
上記の課題を解決するために、本発明者らはＺｎ−Ａｌ系擬合金層について研究を重ねた結果、その擬合金を形成するアルミニウムにケイ素だけでなくマンガンも適量添加すると、その擬合金層を有する防食層が形成されている鉄系の耐食部材の耐食性が向上することを見出した。 In order to solve the above problems, the present inventors have conducted research on a Zn-Al-based pseudoalloy layer. As a result, when an appropriate amount of not only silicon but also manganese is added to aluminum forming the pseudoalloy, the pseudoalloy layer is obtained. It has been found that the corrosion resistance of the iron-based corrosion-resistant member in which the anticorrosion layer having the above is improved.
ここで、ケイ素に加えてマンガンをアルミニウムに添加する理由は、アルミニウムの孔食電位を貴側にシフトさせるためである。アルミニウムの孔食電位を貴側にシフトさせることにより、アルミニウム自体の自己腐食が抑制されるので、その擬合金層を有する耐食部材の耐食性を向上させることができると考えられる。 Here, the reason why manganese is added to aluminum in addition to silicon is to shift the pitting corrosion potential of aluminum to the noble side. By shifting the pitting corrosion potential of aluminum to the noble side, self-corrosion of aluminum itself is suppressed, so that it is considered that the corrosion resistance of the corrosion-resistant member having the pseudo alloy layer can be improved.
そして、上記の知見に基づき、本発明の防食材料は、鉄製または鋼製の基材の表面に対して適用され、前記基材の表面を覆う擬合金層と、前記擬合金層を覆う封孔処理層と、前記封孔処理層を覆う合成樹脂層とを有し、前記擬合金層は、亜鉛層と、ケイ素およびマンガンを含有するアルミニウム合金層とが混成されているものである構成としたのである。この構成によれば、鉄系基材の表面に対して適用した場合に、従来の亜鉛とケイ素含有アルミニウム合金を用いて形成したＺｎ−Ａｌ系擬合金層を有するものに比べて、擬合金層の犠牲陽極作用以外のアルミニウムの自己腐食が進みにくく、優れた防食性能を得ることができる。 And based on said knowledge, the anticorrosion material of this invention is applied with respect to the surface of the base material made from iron or steel, the pseudo alloy layer which covers the surface of the said base material, and the sealing which covers the said pseudo alloy layer And a synthetic resin layer covering the sealing treatment layer, and the pseudo-alloy layer has a structure in which a zinc layer and an aluminum alloy layer containing silicon and manganese are mixed. It is. According to this configuration, when applied to the surface of an iron-based substrate, a pseudo-alloy layer compared to a conventional Zn-Al-based pseudo-alloy layer formed using zinc and a silicon-containing aluminum alloy The self-corrosion of aluminum other than the sacrificial anodic action is difficult to proceed, and excellent anticorrosion performance can be obtained.
ここで、擬合金層におけるケイ素の含有量は１．２〜１．７ｍａｓｓ％とすることが好ましい。ケイ素の含有量が１．２ｍａｓｓ％未満では耐食性向上の効果が小さく、１．７ｍａｓｓ％を超えると、擬合金層を形成する溶射の際に用いるアルミニウム合金線の加工が困難になるからである。また、マンガンの含有量は０．１８〜０．３４ｍａｓｓ％とすることが好ましい。マンガンの含有量が０．１８ｍａｓｓ％未満では耐食性向上の効果が小さく、０．３４ｍａｓｓ％を超えると靱性や伸びを低下させるからである。 Here, the silicon content in the pseudoalloy layer is preferably 1.2 to 1.7 mass%. This is because if the silicon content is less than 1.2 mass%, the effect of improving the corrosion resistance is small, and if it exceeds 1.7 mass%, it becomes difficult to process the aluminum alloy wire used for thermal spraying to form the pseudoalloy layer. Moreover, it is preferable that content of manganese shall be 0.18-0.34 mass%. This is because if the manganese content is less than 0.18 mass%, the effect of improving the corrosion resistance is small, and if it exceeds 0.34 mass%, the toughness and elongation are reduced.
そして、本発明の鉄系の耐食部材は、上記構成の防食材料で形成されている防食層を表面に有しているものであるから、従来よりも高い耐食性を得ることができ、そのうちでも鋳鉄管の場合は特に有効に本発明を適用できる。 And since the iron-based corrosion-resistant member of the present invention has a corrosion-proof layer formed on the surface of the above-structured corrosion-proof material, it can obtain higher corrosion resistance than conventional ones, and cast iron among them. In the case of a pipe, the present invention can be applied particularly effectively.
本発明は、上述したように、鉄系基材の表面に対して適用される防食材料を、鉄系基材の表面を覆う擬合金層と、擬合金層を覆う封孔処理層と、封孔処理層を覆う合成樹脂層とを有し、その擬合金層が亜鉛層とケイ素およびマンガンを含有するアルミニウム合金層とからなるものとすることにより、その擬合金層のアルミニウムの自己腐食が進みにくいようにしたので、防食材料の防食性能を従来のＺｎ−Ａｌ系擬合金層を有するものよりも向上させることができ、この防食材料を防食層とする鋳鉄管等の鉄系の耐食部材の耐食性を向上させることができる。 As described above, the present invention provides an anticorrosion material applied to the surface of an iron-based substrate, a pseudo-alloy layer covering the surface of the iron-based substrate, a sealing treatment layer covering the pseudo-alloy layer, A synthetic resin layer covering the pore-treated layer, and the pseudoalloy layer is composed of a zinc layer and an aluminum alloy layer containing silicon and manganese, so that self-corrosion of aluminum in the pseudoalloy layer proceeds. Since the anticorrosion performance of the anticorrosion material can be improved as compared with the conventional one having a Zn-Al system pseudo-alloy layer, the anticorrosion material such as a cast iron pipe having the anticorrosion material as an anticorrosion layer can be used. Corrosion resistance can be improved.
したがって、本発明の耐食部材では、従来のものと同等の耐食寿命を得るために必要な亜鉛およびアルミニウムの量が少なくなり、従来よりもコストが抑えられる効果を期待することもできる。 Therefore, in the corrosion-resistant member of the present invention, the amount of zinc and aluminum necessary for obtaining a corrosion-resistant life equivalent to that of the conventional one is reduced, and it can be expected that the cost can be suppressed as compared with the conventional one.
本発明の実施形態の防食材料は、鉄系の基材の表面を覆う擬合金層と、擬合金層を覆う封孔処理層と、封孔処理層を覆う合成樹脂層とを有し、その擬合金層が亜鉛層とアルミニウム合金に適量のケイ素およびマンガンを添加したアルミニウム合金層とからなるものである。この実施形態の防食材料の防食性能、およびその防食材料で形成されている防食層を表面に有している実施形態の鋳鉄管等の鉄系耐食部材の耐食性を確認するために、以下に述べる第１および第２の耐食試験を行った。 The anticorrosive material of the embodiment of the present invention has a pseudoalloy layer covering the surface of the iron-based substrate, a sealing treatment layer covering the pseudoalloy layer, and a synthetic resin layer covering the sealing treatment layer, The pseudoalloy layer is composed of a zinc layer and an aluminum alloy layer obtained by adding appropriate amounts of silicon and manganese to an aluminum alloy. In order to confirm the anticorrosion performance of the anticorrosion material of this embodiment and the corrosion resistance of the iron-based anticorrosion member such as a cast iron pipe of the embodiment having the anticorrosion layer formed on the surface thereof, the following is described. First and second corrosion resistance tests were performed.
第１の耐食試験では、まず、呼び径１００ｍｍのダクタイル鋳鉄管の外面に、亜鉛の線材とケイ素およびマンガンを添加したアルミニウム合金の線材とを同時にアーク溶射して２８０ｇ／ｍ２の擬合金層を形成し、次に、その擬合金層に封孔処理を施して１００ｇ／ｍ２の封孔処理層を形成し、さらに、合成樹脂塗装を施して膜厚８０μｍの合成樹脂層（塗膜）を形成した後、１５０ｍｍ×９０ｍｍの大きさに切り出して瓦状試験片（実施例１）を作製した。 In the first corrosion resistance test, first, a 280 g / m 2 pseudo-alloy layer was formed by simultaneously arc spraying a zinc wire and an aluminum alloy wire added with silicon and manganese on the outer surface of a ductile cast iron pipe having a nominal diameter of 100 mm. Next, the pseudo alloy layer is subjected to a sealing treatment to form a sealing treatment layer of 100 g / m 2 , and further, a synthetic resin coating is applied to form a synthetic resin layer (coating film) having a thickness of 80 μm. After forming, it cut out to the size of 150 mm x 90 mm, and produced the tile-shaped test piece (Example 1).
この実施例１の擬合金層を形成する溶射の際に用いたアルミニウム合金線の素材は、純アルミニウム系のＡ１０７０材（不純物としての鉄０．２５ｍａｓｓ％以下、マグネシウム０．０３ｍａｓｓ％以下、亜鉛０．０４ｍａｓｓ％以下を含む）に５ｍａｓｓ％のケイ素と０．８ｍａｓｓ％のマンガンを添加したものである。これにより、実施例１の擬合金層におけるケイ素の含有量は１．４ｍａｓｓ％、マンガンの含有量は０．２２ｍａｓｓ％となっている。また、合成樹脂塗装には、日本水道協会規格ＪＷＷＡ Ｋ １３９「水道用ダクタイル鋳鉄管合成樹脂塗料」に適合する塗料を用いた。 The material of the aluminum alloy wire used in the thermal spraying for forming the pseudoalloy layer of Example 1 was a pure aluminum-based A1070 material (iron 0.25 mass% or less as an impurity, magnesium 0.03 mass% or less, zinc 0 0.04 mass% or less) and 5 mass% silicon and 0.8 mass% manganese are added. Thereby, the silicon content in the pseudo-alloy layer of Example 1 is 1.4 mass%, and the manganese content is 0.22 mass%. In addition, for the synthetic resin coating, a paint conforming to the Japan Water Works Association standard JWWA K139 “ductile cast iron pipe synthetic resin paint for waterworks” was used.
また、比較例として、亜鉛の線材とＡ１０７０材に５ｍａｓｓ％のケイ素のみを添加したアルミニウム合金の線材を溶射して擬合金層を形成した試験片（比較例１）と、亜鉛の線材とＡ１０７０材に１２ｍａｓｓ％のケイ素のみを添加したアルミニウム合金の線材を溶射して擬合金層を形成した試験片（比較例２）を作製した。その作製方法は、実施例１の場合と同じで、ほぼ同量の擬合金層、封孔処理層、合成樹脂層が形成されるようにした。 Moreover, as a comparative example, a test piece (Comparative Example 1) in which a pseudo-alloy layer was formed by spraying an aluminum alloy wire in which only 5 mass% of silicon was added to a zinc wire and an A1070 material, a zinc wire and an A1070 material A test piece (Comparative Example 2) in which a pseudo alloy layer was formed by thermal spraying an aluminum alloy wire to which only 12 mass% of silicon was added was prepared. The manufacturing method was the same as in Example 1, and almost the same amount of pseudo alloy layer, sealing treatment layer, and synthetic resin layer were formed.
そして、各試験片の試験面以外を液状エポキシ樹脂塗料で塗装して乾燥させ、試験面の中央部に幅０．３ｍｍ、長さ５０ｍｍで鉄素地に達する深さのクロスカットを入れた後、各試験片に対し、ＪＩＳ Ｋ ５６００−７−９（２００６）のサイクル腐食試験方法のサイクルＡ（塩水噴霧２ｈｒ→乾燥４ｈｒ→湿潤２ｈｒのサイクルを繰り返す）に準拠して２７０日間の複合サイクル試験を行った。各試験片の試験後に測定した赤さびの面積率（試験片中央部の７０ｍｍ×７０ｍｍでの測定値）を表１に示す。 And after applying the liquid epoxy resin paint other than the test surface of each test piece and drying it, after putting a cross cut of the depth reaching the iron base with a width of 0.3 mm and a length of 50 mm in the center of the test surface, Each test piece is subjected to a combined cycle test for 270 days in accordance with cycle A of the cycle corrosion test method of JIS K 5600-7-9 (2006) (repeat cycle of salt spray 2 hr → dry 4 hr → wet 2 hr). went. Table 1 shows the area ratio of red rust (measured value at 70 mm × 70 mm in the center of the test piece) measured after the test of each test piece.
表１からわかるように、赤さびの面積率は、比較例１＞比較例２＞実施例１となっており、実施例１は大きさ１ｍｍ未満の軽微な赤さびしか発生しなかった。これにより、実施例１は、比較例１、２に比べて防食材料の防食性能が優れていること、および耐食部材として高い耐食性を有していることが確認された。 As can be seen from Table 1, the area ratio of red rust was Comparative Example 1> Comparative Example 2> Example 1. In Example 1, only a slight red rust having a size of less than 1 mm was generated. Thereby, it was confirmed that Example 1 is superior in anticorrosion performance of the anticorrosion material as compared with Comparative Examples 1 and 2 and has high corrosion resistance as a corrosion-resistant member.
第２の耐食試験では、実施形態の防食材料の擬合金層におけるマンガン含有量の影響を確認するため、第１の耐食試験と同様の方法で、マンガン添加量の異なるアルミニウム合金の線材を溶射材として用いて３種類の試験片（実施例２、実施例３、実施例４）を作製した。実施例２は、Ａ１０７０材に５ｍａｓｓ％のケイ素と０．７０ｍａｓｓ％のマンガンを添加したアルミニウム合金の線材を用い、実施例３、４は、それぞれ実施例２のアルミニウム合金のマンガン添加量のみを１．０４ｍａｓｓ％、１．２５ｍａｓｓ％に増量したものを用いた。これにより、実施例２、３、４の擬合金層におけるマンガンの含有量は、それぞれ０．１８ｍａｓｓ％、０．２８ｍａｓｓ％、０．３４ｍａｓｓ％となっている。 In the second corrosion test, in order to confirm the influence of the manganese content in the pseudo-alloy layer of the anticorrosion material of the embodiment, an aluminum alloy wire having a different manganese addition amount was sprayed in the same manner as in the first corrosion test. Three types of test pieces (Example 2, Example 3, and Example 4) were produced. Example 2 uses an aluminum alloy wire in which 5 mass% silicon and 0.70 mass% manganese are added to the A1070 material, and Examples 3 and 4 each only add the manganese addition amount of the aluminum alloy of Example 2. 0.04 mass% and 1.25 mass% were used. Thereby, the manganese content in the pseudo alloy layers of Examples 2, 3, and 4 is 0.18 mass%, 0.28 mass%, and 0.34 mass%, respectively.
上記のアルミニウム合金のマンガン添加量のほかで、各試験片の作製方法が第１の耐食試験の場合と異なるのは、擬合金層を２００ｇ／ｍ２とし、封孔処理層を５０ｇ／ｍ２としている点のみである。 In addition to the amount of manganese added to the aluminum alloy, the method for preparing each test piece differs from that in the first corrosion resistance test in that the pseudoalloy layer is 200 g / m 2 and the sealing treatment layer is 50 g / m 2. It is only the point which is said.
そして、第１の耐食試験と同じく、各試験片の試験面以外を塗装して乾燥させ、試験面の中央部にクロスカットを入れた後、各試験片に対し、ＪＩＳ Ｋ ５６００−７−９（２００６）のサイクル腐食試験方法のサイクルＡに準拠して１２０日間の複合サイクル試験を行った。各試験片の試験後に試験面を観察した結果、いずれの実施例も合成樹脂層（塗膜）の膨れや剥がれおよび鉄素地からの赤さびの発生がなく良好な状態を維持しており、実施例１と同様、防食材料の防食性能が優れ、耐食部材として高い耐食性を有していることが確認された。 And like a 1st corrosion resistance test, after coating and drying except the test surface of each test piece, and putting a crosscut in the center part of a test surface, it is JIS K 5600-7-9 with respect to each test piece. A combined cycle test for 120 days was performed according to cycle A of the cycle corrosion test method of (2006). As a result of observing the test surface after the test of each test piece, all the examples are maintained in a good state with no swelling or peeling of the synthetic resin layer (coating film) and occurrence of red rust from the iron base. As in No. 1, it was confirmed that the anticorrosion performance of the anticorrosion material was excellent, and the anticorrosion material had high corrosion resistance.
Claims (4)
前記基材の表面を覆う擬合金層と、前記擬合金層を覆う封孔処理層と、前記封孔処理層を覆う合成樹脂層とを有し、
前記擬合金層は、亜鉛層と、ケイ素およびマンガンを含有するアルミニウム合金層とが混成されているものである防食材料。 Applied to the surface of an iron or steel substrate,
A pseudo-alloy layer covering the surface of the substrate, a sealing treatment layer covering the pseudo-alloy layer, and a synthetic resin layer covering the sealing treatment layer,
The pseudo alloy layer is an anticorrosive material in which a zinc layer and an aluminum alloy layer containing silicon and manganese are mixed.
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| Publication number | Priority date | Publication date | Assignee | Title |
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| JP2021162159A (en) * | 2020-03-31 | 2021-10-11 | Ｊｆｅスチール株式会社 | Pipe installation method and pipe installation structure |
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| JP6422521B2 (en) | 2018-11-14 |
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