JPS59129788A - Novel method of continuously zinc plating and annealing continuously moving low carbon content iron wire at high speed - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for galvanizing a wire such as a steel wire in order to obtain a corrosion-resistant wire with a silvery luster.
Continuously galvanize the low carbon steel wire, the plated steel wire can be annealed without destroying the corrosion-resistant coating or rust-colored luster, resulting in a softer galvanized iron wire with excellent corrosion resistance. The present invention relates to a manufacturing method for obtaining.

In the past, numerous attempts have been made to draw galvanized steel wire and other elongated steel materials to smaller diameters, and many references to such attempts are also found in Century REIT. It has been recognized that. However, the process seen in the prior art [7] is very hard, has low formability,
The production method has been limited to galvanized wires of the type that have silicone and brittle properties. The process may cause part or all of the zinc coating to disappear during post-drawing annealing, thereby reducing or destroying corrosion resistance, and/or oxidizing the I+a lead coating surface, thereby creating an attractive, shiny appearance. Most of the silver luster is destroyed.

U.S. Pat. No. 3,730,758 describes a wide band m (steel
5trip) with a metal, such as zinc, to make a galvanized steel strip, e.g. vacuum evaporation or electroplating to provide a side chain coating, followed by hot-dipping to make a galvanized steel strip. A process for performing a subsequent coating is disclosed. Section 4 states that the initial Franch coating may be an aluminum coating since adding aluminum to the galvanizing bath usually reduces the formation of zinc alloys at the surface interface of the strip. There is. However, after galvanizing, a wire drawing or forming step is provided, so that the galvanizing step results in a slow speed of the wire and a faster speed in the annealing step, or Relieving the stress by annealing is not disclosed, nor is a means of annealing the galvanized strip without impairing the bright, silvery luster of the zinc coating.

US patent! 3313,83? i 1,133,628
and 1,818,131? Each of the steel wires is precoated with zinc by electrolytic means or precoated with zinc flue dust;
A method of subsequently hot-dip galvanizing is disclosed. However, these patents do not disclose a method for drawing galvanized wire or a method for annealing it after drawing. It states that if such a process were used, the zinc would be oxidized and partially vaporized during annealing, resulting in a wire with poor corrosion resistance and a rough, unsightly surface.

U.S. Patent 101,284. , 2,288,073.
Nos. 2,288,782 and 21,482,978 each disclose a method of galvanizing wire and then drawing it to elongate it and reduce its thickness.

However, both patents disclose that subsequent annealing is performed to eliminate the tension generated by wire drawing, reduce the stiffness of the drawn galvanized wire, and increase formability. It has not been. If post-drawing annealing is performed, the wire will be strongly oxidized and unsightly.
It is said that it will have a rough, dark finish.

U.S. Pat. No. 2,378,458 discloses precoated copper.
ating.

A method is disclosed that prevents the formation of zinc-iron alloys based on pre-coating and galvanizing and makes the lead coating more ductile and easier to work with. However, after drawing the galvanized wire, it is annealed to remove the stress (tension) generated during drawing, resulting in a beautiful, silver-finished wire. There is nothing to disclose about.

US Pat.
This disclosure discloses that the surface is coated with a paint containing 7 parts of zinc and 7 parts of zinc to prevent the surface from deteriorating when the temperature is raised to the subsequent hot rolling temperature. The coated steel forms an alloy with the steel billet under heat and pressure. To add flexibility to the alloy, post-work and replacement of the steel billet alloy is required. After hot rolling, the fillets and two fins may be washed and alloyed with zinc. After this complex operation to form a suitable alloy on the steel billet surface, a second metal, e.g. aluminum or zinc, is applied to the surface.
Other methods of bonding in the form of lips or continuous solidification or using aluminum and zinc powder can also be used. Despite the complicated method described above, this product still tends to peel off the coating from the steel billet and requires special wiping to prevent peeling.

U.S. Patent 213,015. 2,268,817. 2
No. 1', 353,095 and No. 2,472,393 describe various methods of utilizing copper cladding, but post-drawing annealing is also performed to remove the tension of wire drawing. There is no disclosure, no teaching, no suggestion that a shiny, silvery finish is applied after annealing.

Galvanizing (Hot-Dip'), 3rd edition, written by Hyphen Nohebrick, published by E.F.F. Spon, 1850.
by He1hzBablik, 3rd Edit
ion, published by E, and
F.

N-5pan, Ltd., 1950) describes a method of adding aluminum to a hot-dip galvanizing bath.
Discussed extensively. For the purpose of maintaining the shine of the zinc coating, it is appropriate to include 0.02% in the bath. The use of higher concentrations of 0.2-0.3% orter17 causes structural changes in the coating by retarding the reaction between the homogeneous iron matrix and the molten zinc. If it is immersed for 1 hour at a low temperature, no reaction will occur (p. 208).

If the aluminum content j41 is made higher, it will melt, 4I! It becomes more difficult to react the lead with the solid, requiring higher temperatures and longer immersion times to proceed (p.
209), pre-plating in hot-dip zinc (without aluminum) yields a thin iron-zinc alloy which, when produced, contains ll1 (0.4%).
A lead bath facilitates the reaction, but when the concentration of aluminum is increased to a higher concentration, 1) the reaction does not occur even if 1j is reversed (p, 213). In a % lead bath containing 5% aluminum, no reaction occurs even at 440° C. (824° F.) pre-melt coating (p, 214). 0.24% aluminum (without pre-coating) has a very strong reaction inhibition, so 440°C! (824°F), 1 hour bath immersion resulted in no reaction (p, 221; Amer
icanSociety for Metals, 18
Published in 1964, Metal Hand-books (
Metal Handbook), 2nd heel, Heat Treating.

Cleaning and Finishing (see also Heat Treatment, Washing and Finishing, P. 500)
.

According to Toki Public, a reaction must occur between the iron substrate and the zinc coating in order to obtain good adhesion. If the reaction is inhibited by the presence of aluminum, no iron-zinc alloy will form and adhesion will be inhibited (p. 306-307).

A small amount of aluminum (0.01%) is l.ross (dros).
The addition of aluminum to the galvanizing bath is rarely practiced, but almost completely prevents the formation of 7.s) (P, 377). If added, 0.1-0.3% is added, but in the absence of an iron-zinc alloy layer, the zinc coating is extremely flexible, but +1f thinner, which is usually undesirable (p, 482). ! l! When lead-plated wire is annealed, the wire turns dark gray or vS green, some vaporizes, and oxidation results in a rough surface, and the iron-zinc reaction continues during annealing. , increases brittleness and adhesion (p, 4E13),
Also, the addition of aluminum substantially increases the fluidity of the bath, making it more difficult to obtain uniform, thick coatings (p. 265.2).
88; J. H. Camp et al., 1Jnit-ed.
5tate, s 5teel, published in 1981, T
he making.

Shaping and Treating of 5
steel (manufacturing, processing and processing of steel), 6th edition,
See also p. 942).

These trees, i.e. /Hebric, Metallic, or Camping A, have a melting point lower than that of relatively imitation aluminum, i.e. zinc (e.g. about 420°C), and There is no teaching of the advantage of using sufficient heat to produce a eutectic alloy in a galvanizing bath whose melting point is not lower than that of a eutectic alloy of zinc and aluminum containing 5% aluminum. Or there is nothing to be confused about. These plates are then galvanized.

Galvanized wire is drawn and annealed, and these treatments virtually eliminate the zinc coating, harden it, lose its corrosion resistance, and cause it to lose its shine due to oxidation.
Or, there is no disclosure that the coated surface does not become rough. These books teach not to use too much aluminum. The iron-zinc alloying reaction, which is required in small quantities to improve adhesion, has the opposite effect; increasing the aluminum acid content increases the fluidity of the zinc bath, which is undesirable and can drip off the coated steel wire. This is because the coating becomes very thin. These books do not teach a sequential process of galvanizing, wire drawing and annealing.

Rheinhold Publishing Corp.
Job+ published in 1946 by oration
The Galvanizing by rR, Daesen
Handbook (Zinc plating handbook: l pp, 1
7-106.1!370 September Proceedings
s of the Galvanized Co+nm
1t-tee (newsletter of the Galvanizing Committee) and published by Armco 5teel Corp.
Paul E.

5chnedler the text A11oye
d Zinc Coatings (alloyed zinc layer 7
1) p, 2; 1972 12) 1 The I ra
Sn+i of nand 5teel In5titut
th et al chopsticks Fe -ZnA11ay For
Mation During Galvanneali
ng (%Formation of Fe-Zn alloy during lead plating) pp
, 897, 899; and Bablik, 5up
ra, page, 462, 463 are respectively "gal"
``vannealing'' process, which promotes the zinc-zinc alloying reaction and thereby improves the adhesion of the coating to the iron substrate.
- Immediately after exiting the molten zinc bath, the zinc-coated iron is heated, for example, from 850°F to 1200°F.
or in a high temperature atmosphere of 1450°F. this gal ma
The surface zinc layer of the heat-treated wire is oxidized, resulting in an unattractive gray color, the coating is torn, making it rough, and the iron-bite alloy layer grows, making it more brittle, making it unsuitable for wire drawing. It disappears.

Low aluminum addition paper of 0.08-0.25% does not produce a brittle alloy layer, making it easier to work with iron.
1) Develops lead alloys and is recommended by Daesen and Sm1th et al.

In the book by Sm1th et al., p. 5H, it is stated that at aluminum levels higher than 0.15%, there is a large interruption during the entire alloying reaction. Daesen's book p.
60, the sacrificial protection given to iron by zinc is often associated with high aluminum content (0,15%)
A thicker coating is required than that which is uniformly coated in the bath, and it is best to keep the aluminum gold at about 0.05%, low enough to maintain practical flowability. It is being In Snyder's book, Al
According to 5I terminology, r ga, l vannea l
The term J is usually used for light weight [alloy coated with industrial coatings]. In both of these books, [it is not recommended to add relatively large amounts of aluminum as indicated in L to the lead bath, and it is not recommended to carry out galvanizing, wire drawing, and annealing continuously. does not disclose, teach or suggest.

This invention relates to a method for continuously high speed hot dip plating and annealing of continuously moving ferrous wire to impart a high degree of corrosion resistance with a bright silvery luster and further ductility. In a preferred form, after washing the wire, the continuous iron wire is placed in a zinc electrolytic bath to apply a coating of zinc to the surface of the wire, and then a coating of zinc and aluminum is applied around the wire. Therefore, it passes through a hot-dip plating bath. The bath temperature of the molten menki bath is about 734°F to about 786°F.
maintained between.

In addition, the bath composition of the hot-dip plating bath includes zinc as the main component and aluminum as the other component, and a single piece of aluminum contains aluminum in the bath.
and aluminum 7 (eutectical
5 w based on the total amount of zinc and aluminum alloy in the bath;
It shall not be lower than the melting point of a eutectic alloy of zinc and aluminilla containing t% aluminum.

Up until now, molten coating baths have been operated at higher bath temperatures, so that the zinc coating that was already applied to the wire was washed away.1. molten zinc and relatively large amounts,
For example, an aluminum coating of 5% solidifies r'r
: + flows out from the wire relatively quickly and 1.1) 1-
According to reviews, only very thin coatings of little value can be C) applied.

The present invention was completed based on the following discovery. 10, by plating and hardening a sufficiently thick plating coating of zinc and about 4 to about 6% aluminum on the ferrous wire, this plating gives the wire a protective and silvery color. Not only does it give a high gloss, but it can also be drawn into a thinner cross section or OT, and even after annealing, it does not lose its luster or lose its luster or corrosion resistance. In a preferred embodiment of the invention, the wire is first electroplated with zinc, which is subsequently applied to the wire.
%~8% Aluminum - Strengthens the adhesion of coatings on shipboards. This preferred embodiment is extremely advantageous when thick wires of about 0.028 inch or greater are plated, and also exhibits stronger adhesion when thin wires are plated. . It is well known that the alloy bond formed by the R-diff lead plating process is extremely slow and the iron-zinc reaction is sometimes inhibited by C aluminum.

Zinc coatings plated by electrolysis will hardly melt when the dirty wire is immersed in a hot-dip plating bath. This is because the hot-dip plating temperature is kept below the melting point of zinc. The bath temperature of the hot-dip plating bath is the melting point of zinc, that is, about 41111.13°C (78
7°F) and below the melting point of an aluminum-zinc bath (e.g., about 719.6 for a 5% l~Zn bath)
By maintaining the temperature substantially higher than 0°F, a relatively thick coating can be obtained.

and many are based on the use of low melting bath temperatures of eutectic alloys of zinc and about 5% aluminum.

This low melting point is 4[well lower than the melting point of lead. As a result, aluminum-11 (lower than the melting point of zinc)
It allows the application of lead eutectic alloys, and the wire is not easily removed since the lead coating is already coated on the wire.

First, it is possible to omit the deplating of zinc prior to A-Znn conjugate alloy hot-dip plating, in which case,
After cleaning, the wire is directly passed through a molten A, Q, -Znn conjugate bath. Other methods include, for example, diameters of about o,
It is particularly useful for fine lines, 02a inches and smaller.

A thin line like this is compared to a dog line, iron-τII? Depending on the lead alloying temperature, 4<temperature l-,'tL L, easy.

In this method, the wire is immersed in a bath of molten iron-zinc jI-crystalline alloy in a bath of molten iron-zinc jI-crystalline alloy.
Swirl.

In order to promote the iron-III leadable alloying reaction, the bath temperature may have to be set higher than the range specified in the preferred embodiment, e.g., above about 1040°F. unknown. Additionally, the residence time in the hot dip bath can be increased to promote a certain amount of iron-zinc alloying reaction. The degree of iron-zinc alloying reaction is limited to the extent that there is a suitable bonding force between the zinc coating and the wire to maintain the coating against the wire, and the coating becomes too hard, making wire drawing difficult. It must not be so large as to make the wire surface rough and unattractive.

In this invention, the wire speed and annealing speed after drawing can be adjusted to 25QQ, for example, without encountering other harmful problems.
It is possible to significantly increase the fpm. The speed of the wire exiting the wire drawing machine can be more than five times the speed entering the wire drawing machine. This invention has the advantage of producing a speed difference by plating before the wire drawing machine and annealing after the wire drawing machine.

Slower speeds are required during plating due to the time-temperature relationship during hot-dip plating, due constraints due to the electrical resistance of the wire in the electrolytic process, and mechanical constraints of the equipment. Also, since the plating rate is slow, a reasonable amount of time can be taken for the limited iron-zinc alloying reaction in the other methods mentioned above. The iron-lead alloying reaction in the molten bath is dependent on bath temperature and time. The preferred embodiment method requires an appropriate amount of time to increase the thickness of the aluminum-zinc alloy coating to the desired extent. In the double edge method, consideration must be given to speed from mechanical and dynamic aspects of the plating system. In this case, using too high a speed will cause the wire to twist and/or put too much tension.

Thus, after the wire has been coated with an aluminum-zinc alloy coating, with or without pre-coating with electrolytic zinc, the wire is drawn to a very fine cross-section.

Then, the drawn continuously moving low carbon content iron wire (
low carbon ferrouswire) is annealed for a short time (pro
cess-annealed). The annealing time should be sufficient to release the stress applied to the wire during the wire drawing stage, and should not be too long. If the length is too long, the aluminum component in the coating will no longer have the effect of inhibiting the iron-zinc alloying reaction that would normally occur, and oxidation will occur. After this, the annealed wire is cooled and packed in the desired manner.

If the coolant is a lubricant, the wire should be polished during cooling or after cooling in the usual way.
gdie). Polishing dies are molds made to reduce dimensions by 10% or less;
Makes the coating surface smooth and shines more evenly.

Prior to applying the zinc precoat or aluminum-zinc coating to the wire, the wire is thoroughly cleaned using any suitable method used in the plating industry. for example,
A convenient cleaning device is a non-contact electrolytic cleaning machine.
It contains 8-16% (by volume) sulfuric acid and has a liquid temperature of about 14
Stay below 0'F. When a wire is passed by an electrode, the wire alternately becomes a cathode and an anode.゛Due to the gas decomposition action, hydrogen and resistant elements are released on the wire surface.

This foaming action removes dirt and oxides from the wire. Other suitable wire cleaning devices may be used.

Thereafter, the wire enters an electrolytic galvanizing apparatus, and a coating of zinc is applied to the wire. The transfer of the wire from the cleaning equipment to the electrolytic plating equipment is done quickly enough to avoid oxidation of the wire surface. 4. As long as the appropriate electrolytic bending lead plating machine or equipment is used.
There is no limit to the amount, and the zinc coating is illustratively applied to the surface of the wire at a thickness of 3-7 microns. That is, I+
11 By applying the lead coating, the radius of the wire eventually becomes 3
~7 microns, and the diameter increases by twice this value.

The bath temperature of the electroplating bath in the electroplating equipment is 30 to 7
It can be varied between 0°C. A flow density on the order of 1000 amperes per square foot can be used depending on the speed and diameter of the wire. Residence time in the electrolytic bath varies depending on many factors such as bath temperature, wire diameter, desired coating thickness, current density, concentration of zinc ions in the bath and other factors, and their relationships are well-known in this field. well known. As an example, approximately 70 feet I.
0.0 to obtain a suitable thickness of zinc coating when the electroplating bath was run at a speed of 325 fpm
A residence time of 13-15 seconds is suitable for a 274'' diameter wire.

For example, after applying a 3-7 micron thick zinc coating to the wire, the wire is run through a water washer to wash off any remaining electrolyte and then wiped with an airwipe to remove excess water. The wire is then immediately exposed to molten aluminum-zinc (eu-tectic alloy).
pass through a hot-dip plating bath containing (lay). The amount of aluminum in the bath is sufficient to bring the melting point of the eutectic alloy or below the melting point of zinc. The eutectic alloy preferably has about 4-6%
of aluminum, more preferably about 5z of aluminum.

The melt bath may be of any suitable construction, and various types of equipment are available and/or disclosed in the art. The temperature of the molten bath ranges from about 734"F to about 78"F to ensure a suitable thickness coating of aluminum-zinc on the wire.
Must be maintained between 86F. Approximately 4 to 6%
The melting point of a mixture of aluminum and zinc is 730, which is the melting point of a 4-6% aluminum-zinc mixture.
'F (388°C) to about 719.8'F (382°C), which is the melting point of the 5z aluminum-zinc mixture. These temperatures are the melting point of sufficiently pure zinc, about 787
Well below °F (419,8°C). ? 1.9
, 6'F, preferably 734'F or less, is suitable to maintain the hot-dip bath in a molten state, and bath temperatures below about 786F will remove the zinc already coated on the wire. can be completely dissolved or avoided. Of course, a temperature well below the melting point of zinc and still above the melting point of the aluminum-zinc eutectic mixture in the bath is preferred. For example, the film thickness of the eutectic aluminum-zinc alloy coated in the hot-dip plating bath is about 3 to about 7 microns,
Preferably it is about 3-5 microns.

The residence time of the wire in the hot dipping bath depends on many factors, including the diameter of the wire being coated.

Thicker wires usually require more time in coating to initiate the reaction between the zinc and iron that provides adequate adhesion. However, in the case of pre-coating, where electrolytic zinc is applied to the wire, such considerations are secondary. - In a hot-dip eutectic alloy plating bath, the total residence time of the wire without precoating is longer than that with precoating. Uncoated wire cannot be plated at much faster speeds than 300 fpm, while line speeds of pre-coated wire can reach as high as 500 fpm. To obtain sufficient adhesion, the uncoated wire was coated with zinc r
For example, 18 gauge requires much higher temperatures than typical 1i Germans; for example, 18 gauge requires about 1040"F for about 1 second to achieve sufficient bonding strength with the eutectic alloy. When exiting the molten aluminum-zinc bath, the wire is sizing die or suitable wiping to smooth the surface of the aluminum-zinc coating and make the diameter of all the coated wires uniform. Passing through a die. The wire that reaches the wire drawing machine now has a soft outer coating of plating that acts as a lubricant and thus facilitates wire drawing. The preferred method is to remove the iron- The pure electrolytic galvanized coating in the preferred embodiment is superior to the one-step process of hot-dipping alone, since it contains little or no hard alloys of zinc. Zinc coatings are softer than zinc coatings, have lubricating properties, are resistant to flaking, and significantly extend the life of the stick. This prevents the wire from being damaged during wire drawing.

After leaving the hot-dip plating bath, the coated wire immediately passes through a water cooling bath maintained at ambient temperature, which quickly reduces the temperature of the coated wire, thereby reducing oxidation of the coated surface. And defense 11-. Following water cooling, it is wiped dry with wire t±air.

Then, the wire passes through a suitable type of wire drawing machine,
In it the cross section decreases. The reduction ratio of cross-sectional area can be varied up to 95%, preferably the X reduction ratio is 65-90
%. This reduction rate, %It, is calculated by subtracting the final cross-sectional area of the wire after drawing from the final cross-sectional area of the wire before drawing, dividing this difference by the initial cross-sectional area, and multiplying by 100. The operation takes place at ambient temperature, but the temperature of the wire increases due to mechanical action. Depending on the reduction rate of the wire, the wire drawing operation dramatically increases the wire speed. For example, when 0.075" wire is drawn to 0.0274", the speed increases from about 330 to about 340 feet per minute before drawing to about 2500 feet per minute after drawing.

The pre-drawing operations, i.e. cleaning, electroplating, hot dipping, and water cooling, range from about 200 feet per minute or less to about 5507 feet per minute. All operations after wire drawing, carried out at speeds ranging up to
From 500 feet or less.

This is done over a speed range up to about 2500 feet or more. The input speed to the ordinary wire drawing machine, that is, the plating speed, is within the range of 550 fpm or less, and the output speed of the wire drawing machine, that is, the annealing 1.7 speed, is 2500 fp1.
11 or less or 250 Ofpm or more. During wire drawing, considerable stress is applied to the middle part of the wire.
This makes the wire relatively more brittle and less ductile.

To provide a more useful product, the wire is then annealed in a manner that does not substantially reduce or destroy the aluminum-zinc coating. Further, this annealing is carried out under conditions that do not cause the coating to become more brittle or the adhesion to the wire to be weaker due to the iron-lead-aluminum alloying reaction occurring all at once. Also, the process is carried out in a state where the surface to be placed is not oxidized or has any adverse effects. When the pre-electroplating coverage method is used, sufficient aluminum in the 4-coat will penetrate the underlying zinc and inhibit alloy formation. Therefore, the annealing operation must be carried out quickly under stress-relieving conditions. ■One, the 11-effect of aluminum in the coating is almost completely eliminated, and the coating becomes excessively brittle due to the iron-CIF lead alloy effect, or the appearance becomes black and rough due to oxidation, and corrosion resistance decreases. must be carried out quickly and under unfavorable conditions.

Although any suitable annealing means meeting the above conditions may be used, inducton annealing has been found to be extremely useful and efficient for achieving the desired results. In a particularly useful arrangement, the coated wire is heated to a temperature of 1200-1500°F and passed vertically through an induction coil for residence times ranging from less than 0.29 seconds to more than 0.48 seconds. The arrangement is such that it leads downward. The vertical arrangement of the wires helps prevent the coating from twisting under gravity and creating a teardrop-like cross-sectional shape, and maintains a circular cross-sectional shape.

Additionally, it is extremely important to avoid stressing the wire while keeping it heated during annealing to avoid thinning or other deformation of the wire.

This is the top and bottom of the induction coil]; the bottom capstan (c
The solution is to install apstan). Before entering the induction coil, the wire is guided around the toe gear stan several times to avoid any upstream forces. After leaving the induction coil, the wire is wrapped several times around the lower capstor 7 to prevent it from being affected by downstream stresses as it passes through the induction coil.

After leaving the induction coil, the annealed wire immediately passes through an oil bath to reduce the temperature to avoid oxidation. The lower capstan may be placed in an oil bath. The temperature of the oil bath should be maintained at ambient temperature for effective quenching.

Typical wire tension reduction is approximately 125,000 ps
It will be about 75,000 psi from i. Additionally, if desired, add a polishing agent to the oil bath.
Or sononishing.

aie); thereby, 1
ILE lead-plated and annealed wire is attenuated to the desired final dimensions, smoothed, evenly distributed around the wire, improved surface appearance, and (=
Remove most of the oil that is on it. After this, the wire is wound around a deadblock or other suitable device for coiling the wire, from which it exits and falls into the carrier stem, or into a spooler. ) around the reel.

After annealing, instead of passing the wire directly through an oil bath, it can also be passed through a water cooler, after which the wire is wiped with air and passed through a lubricated die after exiting the cooling tank. A lubricated die finishes or polishes the coated wire to ensure a uniform and smooth coating around the wire. The wire is then placed on a winder or other suitable winding machine or packed. When using finishing dies, the percentage reduction is typically less than 10%.

The method of the present invention can be used with a fairly wide range of sizes of wire, from 34 gauge (0.0104" diameter) or thinner to 9 gauge (0.1483" diameter) or thicker. The gauge system referred to here
system) is a “Steel Wire Gauge” that is widely accepted in the U.S. industry.
The method of the present invention is a particularly preferred method for galvanizing, drawing, and annealing fine wire, i.e., 17 gauge (0,0540" diameter) or thinner wire. . This is due to the large economic benefits achieved by the present invention and the inefficiency of conventional production of galvanized wire in batches. The diameter of 9-gauge wire is slightly larger than 14 times the diameter of 34-gauge wire, so 34-gauge wire (3,463 ft, /lb,) weighs less per pound than 9-gauge wire (1?,'03 ft, /lb,). 200 times longer. 17 gauge wire (128,4f
t, /1b,) is about one-third the diameter of the 9 gauge, but the length is more than seven times longer.In this invention, each process of discharging, cleaning, and galvanizing is easy to manage. These processes are well controlled because they are carried out at relatively slow speeds, while the final product is produced at high speeds due to recycling. This release [! Eleven methods include cleaning, galvanizing, fine wire and annealing compacts in one continuous operation.
ct). In the conventional method, a carrier coat is used for cleaning and wire drawing in the first section? #Overturn.

The second operation is wire drawing, which is carried out in a separate department. The third operation also carries out the annealing and galvanizing in a separate section continuously. The present invention reduces the conventional three separate operations to one continuous operation. The invention is economically advantageous. That is, 1. Even a small company can carry out wire drawing because the equipment is compact. These small companies do not have to benefit from increased production scale in the same way that larger companies do. Investment can be saved.

2. Scrap is reduced because the process is not divided into three parts as in the past.

3. Space-saving modules (uni, )) can be divided and placed in the locations where they are used, saving transportation costs and labor costs.

Wire users can go to the wire drawing machine. The need for scale-up has been dramatically reduced.

4. The people who work there will be energized and their labor efficiency will increase because they have predecessors in all the areas of cleaning, galvanizing, wire drawing, and annealing wire manufacturing. Furthermore, it takes less time to produce one finished wire.
) +1.0274" diameter wire can be completely finished into galvanized and annealed 0.0100" diameter wire in one continuous process, 1.6 times faster than conventional wires. . (2) Although the wire is drawn into a 0.128″ diameter wire or a 0.0605″ diameter wire,
On the same base, it is about 2.4 times faster than the conventional method.

Compared to zinc, the corrosion resistance of the 51A-Zn coating is enhanced by the method of the present invention, both at ambient and elevated temperatures. Approximately 5$ A sentence - Zn coated surface is corrosion resistant in industrial and salt water atmospheres.

At the same time, it is extremely effective in high temperature corrosion resistance.

In an industrial environment under salt water, the relative corrosion currents of zinc and 5% A-Zn were 4.3 mi II iamp, respectively.
s/Cm' and 1.8 milliamps/cm'. The environment is 0.1N H2SO4+ 3.5X
NaCl solution Tea Tsuta, Kono-Environment-do, 5% 1-Z
The corrosion resistance of n is approximately 2.4 times that of zinc. 3.5%N
a Corrosion current of pure zinc in a 0-liter solution is 1.
At 243 ma/crrf, 5% A-Znte is Q,
38Q ma/crn'te was there. In this saline environment, 5'% A I-Zn was 3.27 times more corrosion resistant than pure zinc. The corrosion current of pure zinc in 0.1NH2S04 solution is 4. B ma/cm'te,
On the other hand, 5% AM-Znte had 3.1 ma/cnff.

Under this resistant atmosphere, blue AM-Zn is 1
．． It was 48 times more corrosion resistant.

Furthermore, the present invention provides good corrosion resistance at high temperatures.

Complete destruction of zinc was observed at the annealing temperature. However, 5% 1j-Zn had short-term durability at temperatures near 1400°F.

Example This will be explained below using the drawings (FIG. 1).

payoff (pay-off) from ml 10,
Wire 12 moves at a speed of approximately 493 feet per minute to wire drawing machine 14. The wire is drawn from 0.052″ to 0.0223″ in the wire drawing fi14, so
The wire wire becomes looser and the speed of wire movement increases. The total cross-sectional area of the wire is reduced by 82%. The drawn wire 12 passes through the wire drawing machine 14 at a speed of about 2300
feet per minute until it is turned into a coil by the winder 16.
While maintaining this speed and then falling in a coiled manner onto the handle 7 of the carrier 18, the wire passes through an acidic bath 22 several times in the non-contact electrolytic cleaner 20, leaving the bath 22 non-conducting. Form rollers 26 and 24 are arranged around which the wire 12 passes alternately in order to provide sufficient passage for sufficient cleaning of the wire. The wire 12 thus becomes alternately negative and positive. When the wire passes by the anode, the wire becomes polarized. The wire passes by the cathode, the wire becomes anodic, and the wire leaves the bath in anodic mode.

The purifying action of hydrogen and oxygen generated at the cathode ray running around the roller 26 and the anode ray running around the roller 24 removes dirt stuck to the cathode ray around the roller 26 and metal stuck to the anode ray around the roller 24. It is well known that it has an eliminating effect.

Bath 22 preferably contains about 8% (by volume) sulfuric acid and operates at a bath temperature of 140'F and a pH below 2.

After cleaning, wire 12 enters electrolytic plating apparatus 28.

That is, ZnSO4 electrolyte 32' along the contactor 30
The contactor 30 then passes along the first non-conductive roll 34, then along the second non-conductive roll 36, and then returns to the contactor 30. A zinc anode 38 is placed in a zinc sulfate electrolyte 32, constantly replenishing the bath with zinc ions, and the wire becomes a cathode by virtue of the negative charge imparted to it by the contactor 30. Wire 12 continues this trajectory,
The surface of the wire is electrolytically plated with zinc from 3 to about 7 microns, such as from about 3 to about 5 microns, for a safe number of passes, such that the radius of the wire is from about 3 to about 7 microns, such as from about 3 to about 5 microns. It increases by about 5 microns.

The preferred electrolyte is 80-120 grams of zinc metal in the form of sulfuric acid, zinc and 11 liters of water per 11 liters of water.
Contains about 150 to about 165 grams of H2SO4 per r. The bath operates at temperatures ranging from 86″F to +58°F. Current densities are greater than I000 amps/ft, 2 and range from approximately 1200 amps/ft, 2. Plating times of 8-9 seconds result in electrolysis on the wire surface. The obtained zinc is about 5 microns thick.

That is, the radius of the wire increases by approximately 5 microns.

After leaving the contactor 30, the wire 12 is rinsed with water and dried with air.

After passing through the electrolytic plating device 28, the wire 2 passes through a hot-dip plating bath 40 of hot-dip zinc containing about 5% aluminum based on the total amount of aluminum and zinc;
Receives surface coating of 5% A-Zn.

The residence time of wire 12 in bath 40 ranges from a little more than 1 second to less than 1 second, and bath 40 is maintained at a temperature range of about 734F to 786F. wire! 2 is a sizing tie (s) 42 or a suitable wiper (wi
pe), exits the bath 40, and is coated with 5% A -Q, -Zn iF' on the surface of the wire depending on the size of the wire 42.
The thickness is increased by applying an overcoat from 12 to about 4 microns thick. 5% Aluminum 111 (lead) coated on the electrolytic coating and its cumulative thickness of about 5 to about 7 microns This cumulative thickness, τ
The width of the decomposition substrate layer and the coating layer ↓- is thicker and thinner than the range of the ridges described in , and within that range, the relationship between the passing time of the electrolytic bath 28 and the current density, Hot-dip plating bath 40
By controlling the temperature of the bath 40, the residence time in the bath 40, and the diameter of the sizing pin 42 or wiper hole, it can be tailored to suit the particular requirements of the operator.

Following hot dip bath 40, the wire passes through a water cooling bath 44 maintained at room temperature to quickly solidify the aluminum-zinc coating and prevent oxidation caused by high temperatures. After leaving the water cooling bath 44, the wire is wiped clean with air.

The wire drawing machine 14 draws the wire 12 to a thickness of approximately 5 mm below the desired final wire thickness. Thin it to ~10% thicker size. The wire is
Exiting the wire drawing machine 14, the wire is turned at an angle in two directions about 15 feet on each side from the floor, and the capstan (capst
an) Turn around the cab tongue 46, wrapped appropriately to prevent excessive tension in the wire between 4B and the cab tongue 48 below. wire 1
2 moves downward and within 1 second the induction coil 50
The temperature reached about 1400"F, and the temperature was scorched.
neal) process. At this temperature, the tensile strength is very low and the tension between capstans 46 and 48 is minimized by the multiple wraps around each capstan. The wire is connected to a cab tank 48 located in an oil bath 52 to prevent excessive tension from being transferred back to the portion of wire 12 between gear buttons 46 and 48.
The oil path 52 is maintained at ambient temperature and acts as a coolant to reduce the wire temperature to ambient temperature, and the glazing tie, also located within the oil bath 52, acts as a coolant to reduce the wire temperature to ambient temperature. (pollshingdie)
54 act as a tie lubricant. This die 54 not only trims the wire 12 to the final desired size, but also helps to smooth the coating around the wire and distribute it more evenly. Due to annealing, the coated surface may be somewhat rough, resulting in uneven application.

A water cooling bath with an air wiper is used instead of the oil cooling bath 52, and a water bath tank, winder 16 or spooler is used.
It is also possible to place a lubricated die between the spanners.

The loose wire is coiled by a winder 16 (or a spooler in the case of very thin wire), which is a commercially available equipment part, and is dropped by gravity through the handle of a carrier 18.

- The method and apparatus disclosed in 1) is also useful, with some modifications, when manufacturing brass plated wire. For brass plating, the electrolytic zinc bath described above is preceded by a copper plating bath to provide a copper coating to the wire prior to step (a) of the preferred method. Thus,
The copper clad wire is electrolytically plated with zinc and then subjected to the remaining steps of the preferred method as described above. (b) the wire is passed through a molten bath containing an aluminum-zinc eutectic alloy, then (C) drawn to a finer cross section, and then (d) annealed at temperatures up to 1400°F. receive. After annealing, the wire assumes a shiny brass appearance and (e) cools.

The benefit of this modification is to avoid unsightly oxidation, and to avoid special defensive atmospheres. Furthermore,
Since the zinc is not destroyed by the eutectic aluminum-zinc alloy, diffusion of copper and zinc occurs during annealing to produce a brass cladding.

The various methods described above, including the preferred method or other methods, may also be used to prepare a "black-skinned annealed wire" useful for a variety of applications.
black annealed wira) J. In this case, instead of plating baths, namely electrolytic zinc baths and molten aluminum-zinc co-alloys, to promote copper plating on the wire, if desired,
A bath of an aqueous solution of sulfuric copper which also contains, for example, up to 8% tin, based on the weight of copper, may be provided. The wire is coated with copper while passing through a copper sulfate bath, and it undergoes a wire drawing operation (
c) provides lubricity. Then, in step (C), after copper coating, the surface of the wire turns into a uniform and attractive black color, and the drawn wire is annealed in step (d).

The wire is cooled in a commercially available blackening solution of compounds such as those containing selenium and copper in the form of mild acids to enhance adhesion and improve color.

It is believed that the copper helps darken the gray color caused by the selenium and then adheres more easily to the steel, altering the metallurgical bond between the steel and the copper. Further wiping with lubricating oil or wax with black dye further improves corrosion resistance, color and adhesion. Acrylic water based oils or waxes create a glossy black surface. Alternatively, an oil that drives out water to form a dry film will also provide a satisfactory black surface. An air knife helps remove water and create a dry film.

The black surface produced by cooling is amorphous (amorphous).
phous), the oil or wax penetrates the metal substrate, fixing the black part and improving adhesion.

That is, the above-mentioned methods, including the preferred method or other methods, use as a cooling bath a mild intoxicant of copper or a commercially available blackening solution containing copper and selenium, followed by annealing in a dielectric coil; It can be used as a method for producing black-skinned annealed wire by thereby creating a desirable black color.

The substrate is coated with a 5% aluminum-zinc eutectic alloy to provide high corrosion resistance and then passed through an induction coil. If the wire is blackened by the above-mentioned method, a highly corrosion-resistant black-skin annealed wire will be produced since there is a highly corrosion-resistant base of 5% aluminum-zinc under the black skin.

The methods and apparatus described above can be further used and modified by adding other steps and manipulating the steps and adding the operations described above to obtain advantageous effects and useful products.

[Brief explanation of drawings]

FIG. 1 is an explanatory diagram diagrammatically showing each step in carrying out the method of the present invention. The illustrated parts are for illustrating the embodiments and are not intended to limit the invention. The various process parts can also be carried out using a variety of equipment, such as standard equipment well known in the wire handling and processing arts. 10 fights, fist dispensing coil, 12... iron wire (wire)
, 14... wire drawing machine, 16... winding machine, 18... carrier (winding frame), 20... cleaning tank (cleaner),
22... Washing bath, 24.26φ... Roller, 28...
・Electrolytic plating equipment, 30... Contactor, 32... Electrolyte, 34. 36... Non-conductive roll, 38, ψ, string lead anode, 40... Hot-dip plating bath 142... Gui , 44
...Water cooling tank, 46.48・Fist・Capstan, 50
...Induction coil, 52 Fighting Fist/Oil Bath, 54... Finishing Gui. Patent Applicant Xie F. Muzuken Ta-Liu Ho Ng Agent Patent Attorney Kata” - Masao Procedural Amendments February 228, 1982 1. Indication of the case 1982 Patent Application No. 2117 2. Name of the invention Continuous Novel Method for Continuous, High-speed Galvanizing and Annealing of Low Carbon Content Steel Wire Transferred to 3, Relationship to the Amended Person's Case Patent Applicant Address 6216 Hills Polo Road, Natschville, Tennessee 37215, United States of America Name James Duprew φ Hogg 4, Agent 240-01 6. Number of inventions increased by amendment None 7. Subject of amendment (1) The scope of claims on pages 1 to 4 of the specification will be corrected as shown in the attached sheet. . (2) "Molten iron-zinc eutectic alloy" in the fifth line from the bottom of page 18 of the specification is corrected to "molten aluminum-zinc eutectic alloy j. (3) On the second line from the bottom of page 23, "4-6%" is corrected to "4 and 6%." (4) "The coated surface is not oxidized" on page 28, line 8.
"The coated surface is not substantially oxidized." (5) On page 33, lines 10 to 11, "Divide the module (unit) and place it in the places where it will be used" should be corrected as "Distribute and place the module in the places where it will be used." (8) Same as above. Page 41, lines 15-16, ``Furthermore, since it is not destroyed,'' was changed to ``Furthermore, since zinc does not convert into zinc oxide or iron-zinc alloy, if it is not protected by the eutectic aluminum-zinc alloy.'' It doesn't change, though,'' he corrected. ) - Attachment [2, Claim 1, In order to obtain a steel wire with a silver luster, high corrosion resistance, and more ductility, a continuously moving iron wire with a low carbon content is continuously moved at high speed. Galvanized and annealed. A method having the following features (a), (b), (c), (d) and (e). (a) After cleaning, the continuously moving iron wire is passed through a side chain electroplating bath to apply galvanization around the iron wire. (b) the galvanized iron wire is maintained at a temperature of from about 734° F. to about 786° F. to apply a coating therearound comprising zinc and aluminum; Passing a bath of molten aluminum-zinc eutectic alloy having a melting point lower than that of zinc and containing sufficient aluminum to form an aluminum-zinc alloy with a melting point within the range of about 7340F to about 78136F. (C) Draw the coated continuously moving iron wire to a smaller cross section. (d) The drawn and continuously moving coated iron wire is added to the iron by wire drawing at a temperature of less than about 786° F. (approximately 786° F.). stop for a short period of time sufficient to remove the tension caused by
(e) subsequently cooling the annealed iron wire; 2. The method of claim 1, wherein the content of aluminum in the molten aluminum-zinc alloy bath is about 5% by weight based on the total weight of aluminum and zinc in the bath. 3. The method of claim 1, wherein the content of aluminum in the molten aluminum-zinc alloy bath is from about 4 to about 6% by weight based on the total weight of aluminum and zinc in the bath. 4. The moving speed is approximately 2 in steps (a) and (b).
00 to about 55 Ofpm, and after drawing in step (C), about 1500 to about 250 Ofpm. 5. The method of claim 4, wherein the thickness of the coating plated on the iron wire in the electroplating bath and the zinc-aluminum bath is about 5 to 8 microns. 8. The method of claim 2, wherein the coated and drawn iron wire is annealed for about 1 second. 7. The method according to claim 2, wherein the annealing is performed by induction heating. 8. Claim 7, wherein the iron wire is drawn while moving substantially vertically downward at a speed of about 1500 to about 2500 fpm.
9. The method according to claim 2, wherein the cooling is carried out in an oil bath. 10. The method of claim 9, wherein the annealed iron wire is passed through a polishing die in an oil bath. 11. The method of claim 2, wherein the coated iron wire is cooled in a water bath after passing through a molten bath of zinc and aluminum. 12. Claim 2 in which the iron wire to be tested is cooled with a coolant or nitrogen gas spray after passing through the molten bath.
The method described in section. 13. In order to obtain iron wire with silver luster, high corrosion resistance and more ductility, a continuously moving iron wire with low carbon content is galvanized and annealed continuously and at high speed. ), (b), (c) and (d). (a) A continuously moving iron wire is heated at approximately 104° after cleaning in order to apply zinc and aluminum coating around the iron wire.
passing through a molten bath maintained at a temperature above F and containing the principal component zinc and sufficient aluminum to form an aluminum-zinc alloy having a melting point lower than that of zinc. (b) Drawing a coated continuously moving # wire. The cross-sectional area should be smaller. (c) The coated iron wire, which is drawn and moved successively, is made of Zn-A texture-U about 788″FL on about 14
At temperatures below 00°F, the aluminum wire is heated for a short period of time sufficient to remove the tension applied to the steel wire by wire drawing. and (d) thereafter cooling the annealed iron wire."

Claims (1)

[Claims] 1. In order to obtain a steel wire with silver luster, high corrosion resistance, and more ductility, a continuously moving iron wire with a low carbon content is continuously galvanized and baked at high speed. to soften,
A method having the following features (a), (b), (c), (d) and (e). (a) After cleaning, passing the continuously moving iron wire through a zinc electroplating bath to apply galvanization around the iron wire. (b) Place the side chain plated iron wire around it.
Approximately 734° due to coating containing lead and aluminum
It is maintained at a temperature of about 78 degrees Fahrenheit, and has a melting point lower than the melting point of zinc, and has a melting point of about 734 degrees Fahrenheit.
and sufficient aluminum to form an aluminum-zinc alloy having a melting point within the range of about 786 degrees Fahrenheit. (C) Draw the coated continuously moving iron wire to a smaller cross section. (d) continuously sintering a drawn, continuously moving, coated iron wire at a temperature above about +400° F. for a short time sufficient to remove the tension imparted to the iron wire by drawing; annealing; and (e) thereafter cooling the annealed iron wire. 2 molten aluminilla L, -aluminum in lead alloy bath 1
, the total type of aluminum and lead in the early soaking bath of
The method according to claim 1, a, wherein the amount is about 5 times ψ% with respect to X. 3. The method according to claim 1, wherein the content of aluminum in the molten aluminum-zinc alloy bath is about 4 to about 6 weight ψ% based on the total form φ of aluminum and zinc in the bath. 4. The moving speed of the iron wire is approximately 2 in steps (a) and (b).
3. The method of claim 2, wherein the wire has a wire drawing speed of about 1,500 to about 2,500 fpm after being drawn in step (C). 5. 5. The method of claim 4, wherein the thickness of the coating plated on the iron wire in the electroplating bath and the zinc-aluminum bath is about 5 to 8 microns. 6. The B'J method according to claim 2, wherein the coated and drawn iron wire is annealed for about 1 second. 7. The method according to claim 2, wherein the annealing is performed by induction heating. 8. The method of claim 7, wherein the iron wire is drawn while moving substantially vertically downward at a speed of about 1500 to about 2500 fPIIl. 9. The method according to claim 2, wherein the cooling is carried out in an oil bath. 10. The method of claim 9, wherein the annealed iron wire is passed through a polysing die in an oil bath. 11. The method of claim 2, wherein the coated iron wire is cooled in a water bath after passing through a molten bath of zinc and aluminum. 12. The method according to claim 2, wherein the coated iron wire is cooled with a coolant or nitrogen scum spray after passing through the Pa melt bath. 13. In order to obtain a steel wire with silver luster, high corrosion resistance and more ductility, a continuously moving iron wire with a low carbon content is galvanized and annealed continuously and at high speed. A method having the characteristics of (a), (b), (c) and (d). (a) A continuously moving iron wire is heated at approximately 104° after cleaning in order to apply zinc and aluminum coating around the iron wire.
passing through a molten bath maintained at a temperature greater than or equal to F and containing the -L component zinc and a sufficient amount of aluminum to form an aluminum-111 lead alloy having a melting point lower than that of zinc; . (b) Drawing a coated continuously moving iron wire to a smaller cross-sectional area. (C) Drawn, continuously moving, covered iron wire is turned into four-layered iron wire by wire drawing at a temperature below about 1400°F.
＝JContinuously short enough to remove the applied tension
and (d) thereafter cold-concave the annealed iron wire.