TWI616557B - 金屬被覆鋼帶 - Google Patents

金屬被覆鋼帶 Download PDF

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Publication number
TWI616557B
TWI616557B TW102127464A TW102127464A TWI616557B TW I616557 B TWI616557 B TW I616557B TW 102127464 A TW102127464 A TW 102127464A TW 102127464 A TW102127464 A TW 102127464A TW I616557 B TWI616557 B TW I616557B
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TW
Taiwan
Prior art keywords
coating
alloy layer
alloy
molten
intermediate alloy
Prior art date
Application number
TW102127464A
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English (en)
Other versions
TW201413053A (zh
Inventor
劉奎彥
Original Assignee
布魯史寇普鋼鐵有限公司
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Family has litigation
First worldwide family litigation filed litigation Critical https://patents.darts-ip.com/?family=50026983&utm_source=google_patent&utm_medium=platform_link&utm_campaign=public_patent_search&patent=TWI616557(B) "Global patent litigation dataset” by Darts-ip is licensed under a Creative Commons Attribution 4.0 International License.
Priority claimed from AU2012903281A external-priority patent/AU2012903281A0/en
Application filed by 布魯史寇普鋼鐵有限公司 filed Critical 布魯史寇普鋼鐵有限公司
Publication of TW201413053A publication Critical patent/TW201413053A/zh
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C2/00—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor
    • C23C2/04—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor characterised by the coating material
    • C23C2/06—Zinc or cadmium or alloys based thereon
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/01—Layered products comprising a layer of metal all layers being exclusively metallic
    • B32B15/012—Layered products comprising a layer of metal all layers being exclusively metallic one layer being formed of an iron alloy or steel, another layer being formed of aluminium or an aluminium alloy
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C21/00—Alloys based on aluminium
    • C22C21/02—Alloys based on aluminium with silicon as the next major constituent
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C21/00—Alloys based on aluminium
    • C22C21/10—Alloys based on aluminium with zinc as the next major constituent
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C2/00—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor
    • C23C2/003—Apparatus
    • C23C2/0034—Details related to elements immersed in bath
    • C23C2/00342—Moving elements, e.g. pumps or mixers
    • C23C2/00344—Means for moving substrates, e.g. immersed rollers or immersed bearings
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C2/00—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor
    • C23C2/003—Apparatus
    • C23C2/0038—Apparatus characterised by the pre-treatment chambers located immediately upstream of the bath or occurring locally before the dipping process
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C2/00—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor
    • C23C2/003—Apparatus
    • C23C2/0038—Apparatus characterised by the pre-treatment chambers located immediately upstream of the bath or occurring locally before the dipping process
    • C23C2/004—Snouts
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C2/00—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor
    • C23C2/02—Pretreatment of the material to be coated, e.g. for coating on selected surface areas
    • C23C2/022—Pretreatment of the material to be coated, e.g. for coating on selected surface areas by heating
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C2/00—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor
    • C23C2/02—Pretreatment of the material to be coated, e.g. for coating on selected surface areas
    • C23C2/024—Pretreatment of the material to be coated, e.g. for coating on selected surface areas by cleaning or etching
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C2/00—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor
    • C23C2/04—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor characterised by the coating material
    • C23C2/12—Aluminium or alloys based thereon
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C2/00—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor
    • C23C2/14—Removing excess of molten coatings; Controlling or regulating the coating thickness
    • C23C2/16—Removing excess of molten coatings; Controlling or regulating the coating thickness using fluids under pressure, e.g. air knives
    • C23C2/18—Removing excess of molten coatings from elongated material
    • C23C2/20—Strips; Plates
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C2/00—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor
    • C23C2/26—After-treatment
    • C23C2/28—Thermal after-treatment, e.g. treatment in oil bath
    • C23C2/29—Cooling or quenching
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C2/00—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor
    • C23C2/34—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor characterised by the shape of the material to be treated
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    • C23C2/40—Plates; Strips
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
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    • C—CHEMISTRY; METALLURGY
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    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
    • C23C28/02—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings only including layers of metallic material
    • C23C28/021—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings only including layers of metallic material including at least one metal alloy layer
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
    • C23C28/02—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings only including layers of metallic material
    • C23C28/023—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings only including layers of metallic material only coatings of metal elements only
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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    • Y10T428/24975—No layer or component greater than 5 mils thick
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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    • Y10T428/26—Web or sheet containing structurally defined element or component, the element or component having a specified physical dimension
    • Y10T428/263—Coating layer not in excess of 5 mils thick or equivalent
    • Y10T428/264—Up to 3 mils
    • Y10T428/265—1 mil or less

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  • Chemical & Material Sciences (AREA)
  • Organic Chemistry (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Physics & Mathematics (AREA)
  • Oil, Petroleum & Natural Gas (AREA)
  • Thermal Sciences (AREA)
  • General Chemical & Material Sciences (AREA)
  • Coating With Molten Metal (AREA)
  • Laminated Bodies (AREA)

Abstract

一種金屬被覆鋼帶，其包括一鋼帶及一在該帶的至少一邊上之金屬被覆。該金屬被覆包括一Al-Zn-Mg-Si覆蓋合金層及一在該鋼帶與該覆蓋合金層間的中間合金層。該中間合金層具有下列組成物，以重量計，4.0-12.0%Zn、6.0-17.0%Si、20.0-40.0%Fe、0.02-0.50%Mg，及剩餘部分係Al及無法避免的雜質。

Description

金屬被覆鋼帶
本發明係關於一種具有抗腐蝕性金屬被覆的金屬帶，典型為鋼帶之製造，其中在該被覆合金中包含鋁-鋅-矽-鎂作為主要元素，然而其不必需為唯一元素，且以此為基礎，其於此之後指為”Al-Zn-Si-Mg合金”。
特別是，本發明係關於一種在一帶上形成金屬被覆的熱浸塗佈方法，其包括將一未經塗佈的帶浸入一熔融Al-Zn-Si-Mg合金槽中，及在該帶上形成該合金之被覆。
典型來說，該熔融Al-Zn-Si-Mg合金之組成物包含下列範圍的Al、Zn、Si及Mg元素，以重量%計：Zn：30至60%
Si：0.3至3%
Mg：0.3至10%
剩餘部分 Al及無法避免的雜質。
更典型來說，該熔融Al-Zn-Si-Mg合金之組成物包含下列範圍的Al、Zn、Si及Mg元素，以重量計%：Zn：35至50%
Si：1.0至3.0%
Mg：1.2至2.5%
剩餘部分 Al及無法避免的雜質。
該熔融Al-Zn-Si-Mg合金之組成物可包含其它元素，其存在於該熔融合金中如為蓄意性合金化添加物或如為無法避免的雜質。因此，於本文中的措辭”Al-Zn-Si-Mg合金”經了解涵蓋包括此其它元素作為蓄意性合金化添加物或作為無法避免的雜質之合金。以實施例說明之，該其它元素可包括Fe、Sr、Cr及V之任何一或多種。
依末端用途應用而定，該金屬被覆帶可例如以聚合塗料塗裝在該帶的一或二表面上。就這一點而言，該金屬被覆帶可自身出售如為末端產物，或可具有一塗佈至一或二表面的塗料被覆且出售如為經塗裝的末端產物。
本發明特別但非專門關於一種鋼帶，其具有一從上述熔融Al-Zn-Si-Mg合金組成物形成之金屬被覆，及亦選擇性以一塗料被覆且之後冷形成(例如，藉由輥形成)一末端用途產物，諸如建築產品(例如，成型壁(profiled wall)及屋頂薄板)。
發明背景
一種在澳洲(Australia)及別處廣泛使用於建築產品，特別是成型壁及屋頂薄板的耐腐蝕性金屬被覆槽組成物，係一種55%Al-Zn合金被覆組成物，其亦包含Si。該成型薄板通常藉由冷形成經塗裝的金屬合金被覆帶而製造。典型來說，該成型薄板係藉由輥形成該經塗裝的帶而製造。
已經在專利文獻中提出將Mg添加至此已知的55%Al-Zn-Si合金被覆組成物之組成物有數年，參見例如以 日本鋼股份(有限)公司(Nippon Steel Corporation)的名義之美國專利6,635,359，但是Al-Zn-Si-Mg被覆鋼帶於澳洲無法商業購得。
已經建立出當Mg係包含在55%Al-Zn-Si合金被覆組成物中時，Mg在產品性能上引起某些有益的效應，諸如改良切割邊緣保護。
本申請人已在關於在帶諸如鋼帶上的Al-Zn-Si-Mg合金被覆上進行大量研究及開拓。本發明係此研究及開拓的部分結果。
上述討論不採用作為在澳洲及別處的共同常識之承認。
發明概要
本發明係以本申請人在鋼帶上形成Al-Zn-Si-Mg合金被覆之研究及開拓進程期間之發現為基準，以便在Al-Zn-Si-Mg合金被覆覆蓋層與該鋼帶間有一具有經選擇的組成物及較佳地一經選擇的結晶結構之中間合金層，其可改良該被覆帶的腐蝕性能。該研究及開拓亦發現可改良該被覆帶之腐蝕性能的中間合金層之經選擇的組成物及較佳結晶結構係該使用於熱浸塗佈槽的Al-Zn-Si-Mg合金組成物之選擇之非必然結果，及一些因素諸如但不限於熔融Al-Zn-Si-Mg合金槽組成物及熱浸漬製程條件，典型為帶沈浸時間及被覆鍋溫係形成具有所需要的組成物及較佳的結晶結構之中間合金層的相關因素。
根據本發明有提供一種金屬被覆鋼帶，其包括一鋼帶及一在該帶的至少一邊上之金屬被覆，其中該金屬被覆包括一Al-Zn-Si-Mg覆蓋合金層及一在該鋼帶與該覆蓋合金層間之中間合金層，及其中該中間合金層具有4.0-12.0%Zn、6.0-17.0%Si、20.0-40.0%Fe、0.02-0.50%Mg，以重量計，及剩餘部分係Al及無法避免的雜質之組成物。
該中間合金層可形成作為在該熔融的Al-Zn-Mg-Si合金的組成物中之元素與鋼帶的金屬間相。
再者，該中間合金層及Al-Zn-Mg-Si覆蓋合金層可形成如為分別的層。
該中間合金層可包括，以重量計，5.0-10.0%Zn、7.0-14.0%Si(典型為6.5-14.0%Si)、25.0-37.0%Fe、0.03-0.25%Mg，剩餘部分係Al及無法避免的雜質。
該中間合金層可包括，以重量計，6.0-9.0%Zn、8.0-12.0%Si、28.0-35.0%Fe、0.05-0.15%Mg，剩餘部分係Al及無法避免的雜質。
該中間合金層可包括，以重量計，0.01-0.2%Ca。
該中間合金層可包括，以重量計，0.1-3.0%Cr。
該中間合金層可包括，以重量計，0.1-13.0%Mn。
該中間合金層可包括，以重量計，0.1-2.0%V。
該中間合金層可具有厚度0.1-5.0微米，如在通過該被覆的厚度之截面上測量。
該中間合金層可具有厚度0.3-2.0微米，如在通過該被覆的厚度之截面上測量。
該中間合金層可具有厚度0.5-1.0微米，如在通過該被覆的厚度之截面上測量。
該中間合金層可包括短直徑測量50-1000奈米的實質上柱狀結晶，如在通過該被覆的厚度之截面上測量。
該中間合金層可包括長直徑測量50-4000奈米的實質上等軸結晶，如在通過該被覆的厚度之截面上測量。
該中間合金層可包括柱狀結晶及等軸結晶之混合物。
該中間合金層可包括體心立方結晶。
該中間合金層的Al、Zn、Si及Fe濃度可滿足式Fe10Al32Si5Zn3。
該中間合金層的Al、Zn、Si及Fe濃度可滿足式Fe10Al34Si4Zn2。
該帶可係一種經鈍化的帶，例如使用含Cr或無Cr鈍化系統。
該帶可在該Al-Zn-Mg-Si合金被覆的曝露表面上包含一樹脂被覆。
用以形成該金屬被覆之熔融Al-Zn-Si-Mg合金可包含多於0.3%Mg，以重量計。
用以形成該金屬被覆之熔融Al-Zn-Si-Mg合金可包含多於1.0%Mg，以重量計。
用以形成該金屬被覆之熔融Al-Zn-Si-Mg合金可包含多於1.3%Mg，以重量計。
用以形成該金屬被覆之熔融Al-Zn-Si-Mg合金可 包含多於1.5%Mg，以重量計。
用以形成該金屬被覆之熔融Al-Zn-Si-Mg合金可包含少於3%Mg，以重量計。
用以形成該金屬被覆之熔融Al-Zn-Si-Mg合金可包含少於2.5%Mg，以重量計。
用以形成該金屬被覆之熔融Al-Zn-Si-Mg合金可包含多於1.2%Si，以重量計。
用以形成該金屬被覆之熔融Al-Zn-Si-Mg合金可包含少於2.5%Si，以重量計。
用以形成該金屬被覆之熔融Al-Zn-Si-Mg合金可包含下列範圍的Al、Zn、Si及Mg元素，以重量%計：Zn：30至60%
Si：0.3至3%
Mg：0.3至10%
剩餘部分 Al及無法避免的雜質。
特別是，用以形成該金屬被覆之熔融Al-Zn-Si-Mg合金可包括下列範圍的Al、Zn、Si及Mg元素，以重量%計：Zn：35至50%
Si：1.2至2.5%
Mg：1.0至3.0%
剩餘部分 Al及無法避免的雜質。
該鋼可係低碳鋼。
根據本發明亦有提供一種在鋼帶上形成一金屬 被覆以形成上述金屬被覆鋼帶之方法，該方法包括將鋼帶浸入一熔融的Al-Zn-Si-Mg合金槽中及在該鋼帶的曝露表面上形成該合金之金屬被覆，及該方法包括控制該熔融合金槽的組成物之任何一或多種、該熔融合金槽的溫度及該鋼帶在該熔融合金槽中的沈浸時間，以在該鋼帶與該Al-Zn-Mg-Si覆蓋合金層間形成該中間合金層。
該熔融Al-Zn-Si-Mg合金可具有上述組成物。例如，該熔融Al-Zn-Si-Mg合金可包含下列範圍之Al、Zn、Si及Mg元素，以重量%計：Zn：30至60%
Si：0.3至3%
Mg：0.3至10%
剩餘部分 Al及無法避免的雜質。
1‧‧‧去捲繞站
2‧‧‧焊接器
3‧‧‧累積器
4‧‧‧帶清潔部分
5‧‧‧爐組合
6‧‧‧被覆鍋
7‧‧‧冷卻部分
8‧‧‧輥部分
10‧‧‧捲繞站
本發明進一步藉由實施例與參照其伴隨的圖形來說明：圖1係一圖式圖形，其闡明根據本發明之方法來製造被覆Al-Zn-Si-Mg合金的鋼帶之連續生產線的一個具體實例；圖2係已知的Al-Zn-Si合金被覆鋼帶與根據本發明之Al-Zn-Si-Mg合金被覆鋼帶樣品之Q-Fog壽命(至5%表面紅鏽的時間，以小時計)圖表；圖3顯示出在已知的Al-Zn-Si合金被覆鋼帶與根據本發明之Al-Zn-Si-Mg合金被覆鋼帶樣品上之進一步實驗工作結果； 圖4顯示出在根據本發明之Al-Zn-Si-Mg合金被覆鋼帶樣品上的進一步實驗工作結果；圖5顯示出在根據本發明之Al-Zn-Si-Mg及Al-Zn-Si-Mg-Cr合金被覆鋼帶樣品上的進一步實驗工作結果；圖6為一圖表，其顯示出鍋溫在該中間合金層的組成物上，及依次，在被覆相同Al-Zn-Si-Mg合金的樣品之Q-Fog質量損失上的效應；圖7係一實驗結果的圖表，其顯示出在Al-Zn-Si-Mg合金的被覆槽組成物中之Mg及Si於根據本發明之金屬被覆帶樣品的中間合金層之質量上的效應；圖8係一根據本發明之金屬被覆帶及其它金屬被覆鋼帶樣品之中間合金層厚度對使用來在該樣品上形成被覆的被覆槽中之沈浸時間的圖表；及圖9係根據本發明之金屬被覆帶樣品的中間合金層厚度對在該樣品上之覆蓋合金層厚度的圖表。
參照在圖1中概略顯示出之用於被覆鋼帶的連續生產線，在使用時，於去捲繞站1處去捲繞冷軋低碳鋼帶捲，及藉由焊接器2端對端焊接該後續去捲繞的帶長度而形成一連續長度的帶。
然後，讓該帶連續通過累積器3、帶清潔部分4及爐組合5。該爐組合5包括預熱器、預熱還原爐及還原爐。
該帶係在該爐組合中藉由控制包括下列之製程 變數來熱處理：(i)在熔爐中的溫度曲線，(ii)在熔爐中的還原氣體濃度，(iii)通過熔爐的氣體流速，及(iv)在熔爐中的帶停留時間(即，線速度)。
在爐組合5中的製程變數係經控制，以便有從該帶的表面移除氧化鐵殘餘物及從該帶的表面移除殘餘油及鐵細粒。
然後，讓該經熱處理的帶經由輸出噴口向下進入及通過保持在被覆鍋6中之包含Al-Zn-Si-Mg合金的熔融槽，及被覆該熔融的Al-Zn-Si-Mg合金。該Al-Zn-Si-Mg合金在被覆鍋中係使用加熱電感應器(無顯示)或其它合適的加熱選擇來維持在所選擇的溫度下呈熔融。在該槽內，該帶繞著配置於槽中的導輥(無顯示)通過及向上地從該槽中取出。線速度係經選擇以提供一經選擇在該被覆槽中的帶沈浸時間。該帶的二表面當其通過該槽時，其係由熔融的Al-Zn-Si-Mg合金被覆。
在離開被覆槽6後，該帶垂直通過一氣體擦拭站(無顯示)，在此處其被覆表面係接受擦拭氣體噴射以控制該被覆的厚度。
然後，該被覆帶通過一冷卻部分7及接受強迫冷卻。
然後，讓該經冷卻的被覆帶通過一調整該被覆帶的表面狀況之輥部分8。
之後，在捲繞站10處捲繞該被覆帶。
如上述討論，本申請人已進行關於Al-Zn-Si-Mg 合金被覆鋼帶之大量研究及開拓，及發現形成一包含覆蓋合金層與中間合金層的金屬被覆可改良該金屬被覆帶之腐蝕性能，其中該中間合金層在該覆蓋合金層與該鋼帶間具有一經選擇的組成物及較佳地一經選擇之結晶結構。
該研究及開拓包括以下列熔融合金組成物進行熱浸塗鋼帶樣品的工作：(a)已知的Al-Zn-Si合金(於此之後指為”AZ”)；(b)根據本發明的Al-Zn-Si-Mg合金(於此之後指為”MAZ”)；及(c)根據本發明MAZ合金加0.1重量%Cr，其等具有下列熔融合金組成物，以重量%計：
‧AZ：55Al-43Zn-1.5Si-0.45Fe-附帶的雜質。
‧MAZ：53Al-43Zn-2Mg-1.5Si-0.45Fe-附帶的雜質。
‧MAZ+0.1重量%Cr-附帶的雜質。
該熔融合金係以125克/平方公尺及150克/平方公尺的雙面被覆質量被覆到鋼帶樣品之曝露表面上。一組樣品係在本申請人的Wollongong指揮部處之金屬被覆線(”MCL”)上製造，及另一組樣品係在本申請人於Wollongong的研究工廠處以熱浸漬方法模擬器(”HDPS”)製造。實驗工作主要在HDPS上進行。HDPS係由Iwatani International Corp(Europe)GmbH為本申請人的專利說明書之目的而製造的技術現況單元。該HDPS單元包括熔融金屬鍋爐、紅外線加熱爐、氣體擦拭噴嘴、淘渣(de-drossing)機制、氣體混合及露點管理功能、及電腦化自動控制系統。該HDPS單元能模擬在習知金屬被覆線上的典型熱浸漬循環。
測試被覆樣品的耐腐蝕性(Q-Fog循環腐蝕測試 性能)，且使用掃描式電子顯微鏡及其它分析設備讓樣品接受微結構分析。
圖2係下列樣品的Q-Fog壽命(至5%表面紅鏽的時間，以小時計)圖表：
‧MCL AZ150-在金屬被覆線上製造之具有150克/平方公尺雙面被覆質量的AZ合金被覆。
‧MCL MAZ125-在金屬被覆線上製造之具有125克/平方公尺雙面被覆質量的MAZ合金被覆。
‧HDPS MAZ125-在熱浸漬方法模擬器上製造之具有125克/平方公尺雙面被覆質量的MAZ合金被覆。
‧HDPS MAZ125+0.1%Cr-在熱浸漬方法模擬器上製造之具有125克/平方公尺雙面被覆質量的MAZ+0.1%Cr合金被覆。
已從圖2明瞭該MAZ合金被覆樣品具有明顯較長的Q-Fog壽命，因此明顯比AZ合金被覆樣品好的抗腐蝕性，其中該MAZ+0.1%Cr樣品具有全部樣品最好的性能。
圖2闡明由於將Mg添加至AZ來形成MAZ合金而在抗腐蝕性上的改良。圖2亦闡明將少量0.1%Cr添加至MAZ合金在抗腐蝕性上產生進一步明顯改良。
圖3進一步闡明當與AZ合金被覆比較時，Mg對改良MAZ合金被覆的抗腐蝕性之貢獻。顯示在圖3的結果係在下列樣品上的實驗工作之結果：
‧MCL AZ150-在金屬被覆線上製造之具有150克/平方公尺雙面被覆質量的AZ合金被覆。
‧MCL MAZ125-在金屬被覆線上製造之具有125克/平方公尺雙面被覆質量的MAZ合金被覆。
圖3的左手邊為通過二個樣品的厚度斷面之二個SEM背散射電子影像。圖3的右邊係樣品的Q-Fog壽命(至5%表面紅鏽的時間，以小時計)圖表。二個樣品係在相同金屬被覆線上製造。SEM影像顯示出該等樣品由於Mg存在於MAZ合金中而具有不同被覆微結構。SEM影像亦顯示出二個樣品的被覆包括一覆蓋合金層11及一在該鋼帶13(在圖形中指為”基底鋼”)與覆蓋層11間之中間合金層12(在此及其它圖形中指為”合金層”)。該中間合金層係一從在熔融合金槽中的元素與鋼帶所形成之金屬間層。該圖表顯示出該MAZ合金被覆樣品具有明顯較長的Q-Fog壽命，因此明顯比AZ合金被覆樣品好的抗腐蝕性，此可能歸因於Al/Zn/MgZn2共熔合金及Mg2Si相存在於MAZ合金被覆覆蓋的微結構中，雖然該中間層亦可已促成腐蝕性能差異。
圖4顯示出在MAZ合金被覆上的進一步實驗工作之結果，其聚焦在下列樣品的鋼帶13與覆蓋合金層11間之中間合金層12的貢獻上：
‧MCL MAZ125-在金屬被覆線上製造之具有125克/平方公尺雙面被覆質量的MAZ合金被覆。
‧HDPS MAZ125-在熱浸漬方法模擬器中製造之具有125克/平方公尺雙面被覆質量的MAZ合金被覆。
圖4的左手邊為通過二個樣品的厚度斷面之二個SEM背散射電子影像。圖4的右邊係樣品之Q-Fog壽命(至5% 表面紅鏽的時間，以小時計)圖表。二個樣品係被覆相同熔融合金組成物-MAZ合金。一個樣品係在金屬被覆線上製造及其它樣品係在熱浸漬方法模擬器上製造。二個樣品具有實質上相同被覆厚度，大約18微米。該圖表顯示出該HDPS MAZ125合金被覆樣品具有明顯較長的Q-Fog壽命，因此明顯比MCL MAZ125合金被覆樣品好的抗腐蝕性。SEM影像顯示出該HDPS MAZ125被覆樣品由於較長的沈浸時間而具有比MCL MAZ125被覆樣品厚的中間合金層(在HDPS上2.5秒對在MCL上1.0秒)。圖4係中間合金層12促成該HDPS MAZ125被覆樣品之較好的抗腐蝕性的指示，即，較厚的中間合金層12產生較長的Q-Fog壽命。
圖5顯示出進一步實驗工作的結果，其聚焦在Cr於下列樣品的腐蝕性能上之貢獻：
‧HDPS MAZ125+0.1%Cr-在熱浸漬方法模擬器上製造之具有125克/平方公尺雙面被覆質量的MAZ+0.1%Cr合金被覆。
‧HDPS MAZ125-在熱浸漬方法模擬器上製造之具有125克/平方公尺雙面被覆質量的MAZ合金被覆。
圖5的左手邊為通過二個樣品的厚度斷面之二個SEM背散射電子影像及二個SEM-EDS元素地圖，其顯示出該等斷面的微結構及通過該斷面的Cr分佈。圖5的右邊係樣品之Q-Fog壽命(至5%表面紅鏽的時間，以小時計)圖表。二個樣品係在熱浸漬方法模擬器上製造。二個樣品具有實質上相同的被覆厚度及實質上相同的中間合金層厚度。實際 上，在樣品間的唯一差異為在樣品之一中的0.1%Cr。已從圖表明瞭Cr造成該HDPS MAZ125+0.1%Cr合金被覆樣品具有明顯較長的Q-Fog壽命，因此明顯比HDPS MAZ125合金被覆樣品好的抗腐蝕性。亦從SEM-EDS地圖明瞭在該HDPS MAZ125+0.1%Cr合金被覆樣品的中間合金層中有較高的Cr濃度。其遵循在該HDPS MAZ125+0.1%Cr被覆樣品的中間合金層中之Cr促成改良此樣品的抗腐蝕性。
該研究及開拓包括大量工作來建立該中間合金層係藉由該中間合金層之組成物或藉由該中間合金層之結晶結構對Al-Zn-Si-Mg合金被覆之抗腐蝕性的貢獻。
此工作鑑別該中間合金層的下列組成物範圍，以重量計，其提供最理想的Al-Zn-Si-Mg合金被覆腐蝕性能：Zn 4.0-12.0%，Si 6.0-17.0%，Fe 20.0-40.0%，Mg 0.02-0.50%，剩餘部分 Al及無法避免的雜質。
該被覆的中間合金層之組成物在上述範圍外時，該Al-Zn-Si-Mg合金被覆的腐蝕性能係較差。
該中間合金層的上述組成物範圍係藉由使用貫穿AZ+0-5.0%Si，0-5.0%Mg，0-0.1%Cr，0-0.4%Mn，0-0.1%V及0-0.1%Ca之範圍的熔融合金槽組成物，在0.3-20秒的帶沈浸時間及鍋溫595-640℃下，大量測試在鋼樣品上的Al-Zn-Si-Mg合金被覆(包括但不限於經由Q-Fog測試及戶 外曝露的被覆腐蝕，經由T彎曲測試等等的被覆延性)來鑑別出實現想要的性能之樣品而決定。使用廣泛範圍的分析技術來(a)研究該中間合金層之化學組成物、厚度及結晶結構；及(b)發展出該中間合金層其促成最後被覆產物的性能之關鍵性質的了解。圖2-9係此研究及開拓的結果之樣品。
該研究及開拓亦發現該中間合金層的上述組成物範圍並非熔融Al-Zn-Si-Mg合金槽組成物之選擇之不可避免的結果，及諸如但不限於熔融Al-Zn-Si-Mg合金組成物及熱浸漬製程條件，典型為帶沈浸時間及被覆鍋溫之因素係形成具有所需要的組成物之中間合金層的相關因素。特別是，雖然可不需由熟知此技藝者明瞭，在圖形中所闡明之中間合金層的化學組成物、厚度及結晶結構全部有互相關係及促成該被覆帶的性能。
圖6係一圖表，其顯示出被覆鍋溫在該中間合金層之組成物上，及依次，在二種Al-Zn-Si-Mg合金被覆的Q-Fog質量損失上之效應。樣品係在二種不同鍋溫各別為600℃及620℃下，在被覆槽中使用相同熔融Al-Zn-Si-Mg合金及相同沈浸時間(1秒)而製備。分析該等被覆樣品以決定該中間合金層之組成物。該中間合金組成物在圖6的長條圖下之表中闡述。該中間合金層的厚度亦顯現在表中。該等樣品接受相同Q-Fog腐蝕測試程序。圖6顯示出610℃及620℃鍋溫產生不同的中間合金層組成物。在620℃鍋溫下，該中間合金層組成物係在本發明之組成物範圍外(特別是Si<6%)。結果，雖然具有較大的中間合金層厚度， Al-Zn-Si-Mg合金被覆的腐蝕性能受損失，若該中間合金層的組成物係與在600℃鍋溫下者相同(或在本發明範圍內)時，這將會是有利的。使用誘導耦合電漿光譜儀(ICP)技術來分析該中間合金層的組成物。根據此技術，首先藉由將樣品浸入藉由亞砷酸鈉(每升9克)抑制之1：9的HCl水溶液中來移除Al-Zn-Si-Mg合金被覆覆蓋層。然後，使用經RODINE®抑制的HCl溶液來溶解該中間合金層及藉由ICP分析所產生的溶液。
圖7係根據本發明在相同熱浸漬製程條件(在600℃鍋溫下1秒沈浸時間)下所獲得之金屬被覆鋼帶樣品的中間合金層質量對在使用來於樣品上形成被覆之Al-Zn-Si-Mg合金被覆槽中的Mg及Si濃度之圖表。圖7顯示出該中間合金層的質量隨著在被覆槽中的Mg及Si濃度增加而減少。
圖8係一根據本發明的金屬被覆帶樣品之中間合金層厚度對在使用來於樣品上形成被覆的被覆合金之被覆槽中的沈浸時間之圖表。圖8顯示出在3種不同熔融合金槽組成物上工作的結果。一種熔融合金係已知的Al-Zn-Si合金(在圖形中係”AZ”合金)。另一種熔融合金係Al-Zn-Si-Mg合金，其根據本發明亦包含Ca(在圖形中係”AMCa合金”)。第3種熔融合金係已知具有5.0%Mg及4.0%Si的Al-Zn-Si-Mg合金(在圖形中係”5.0%Mg4.0%Si”合金)。圖8顯示出該熔融合金槽組成物及在熔融合金槽中的沈浸時間在被覆鋼帶之中間合金層的厚度上具有影響。
圖9係一根據本發明之金屬被覆帶樣品的被覆之中間合金層厚度對在該樣品上的被覆之覆蓋合金層厚度的圖表。圖9顯示出該中間合金層厚度隨著覆蓋合金層厚度而增加。觀察圖9的結果為，因此想要最小化遍及整體被覆帶的表面之任何被覆質量變化，以維持一致的腐蝕性能。
該中間合金層除了藉由該中間合金層的組成物及/或厚度直接對Al-Zn-Si-Mg合金被覆之腐蝕性能起影響外，本申請人亦已發現該中間合金層的結晶結構可藉由破裂而在整體MAZ合金被覆之腐蝕性能上具有間接影響。本申請人已發現當該Al-Zn-Mg-Si合金被覆帶接受高張力操作諸如輥形成時，該中間合金層係一破裂起始的明顯來源。粗糙的中間合金層結晶結構產生較寬及更多貫穿過該被覆的覆蓋合金層之裂痕，及該Al-Zn-Mg-Si合金被覆帶的腐蝕性能將受損害。雖然該中間合金層可包括等軸、柱狀或等軸與柱狀結晶之混合物以最小化破裂，但想要的是將柱狀結晶的尺寸控制成短直徑不超過1000奈米，如在通過該被覆的厚度之截面上測量；及/或等軸結晶的長直徑尺寸不超過4000奈米，如在通過該被覆的厚度之截面上測量。
雖然從腐蝕性能的觀點來看，想要具有一實質中間合金層存在(或不薄於0.1微米)，但若該中間合金層太厚(或厚於5微米)時，其係不利的，因為此將引發破裂及減弱該被覆帶的輥成形性。
可對上述發明製得許多改質而沒有離開本發明的精神及範圍。
以實施例說明之，雖然上述與圖2-9相關的研究及開拓集中在從特別的Al-Zn-Si-Mg合金之被覆槽形成的被覆，但本發明不侷限於這些特別的合金。
1‧‧‧去捲繞站
2‧‧‧焊接器
3‧‧‧累積器
4‧‧‧帶清潔部分
5‧‧‧爐組合
6‧‧‧被覆鍋
7‧‧‧冷卻部分
8‧‧‧輥部分
10‧‧‧捲繞站

Claims (23)

  1. 一種金屬被覆鋼帶，其包括一鋼帶及一在該帶的至少一邊上之金屬被覆，其中該金屬被覆包括一Al-Zn-Mg-Si覆蓋合金層及一在該鋼帶與該覆蓋合金層間之中間合金層，其中該中間合金層具有下列之組成物，以重量計：4.0-12.0%Zn、6.0-17.0%Si、20.0-40.0%Fe、0.02-0.50%Mg，及剩餘部分係Al與無法避免的雜質，其中，該中間合金層具有厚度0.1-5.0微米，如在通過該被覆的厚度之截面上測量，且其中用以形成該金屬被覆之熔融Al-Zn-Si-Mg合金包含多於0.3%Mg以重量計且少於3%Mg以重量計。
  2. 如請求項1之帶，其中該中間合金層包含0.01-0.2%Ca，以重量計。
  3. 如請求項1或2之帶，其中該中間合金層包含0.1-3.0%Cr，以重量計。
  4. 如請求項1或2之帶，其中該中間合金層包含0.1-13.0%Mn，以重量計。
  5. 如請求項1或2之帶，其中該中間合金層包含0.1-2.0%V，以重量計。
  6. 如請求項1或2之帶，其中該中間合金層具有厚度0.3-2.0微米，如在通過該被覆的厚度之截面上測量。
  7. 如請求項6之帶，其中該中間合金層具有厚度0.5-1.0微米，如在通過該被覆的厚度之截面上測量。
  8. 如請求項1或2之帶，其中該中間合金層包括實質上柱狀結晶，其短直徑測量係50-1000奈米，如在通過該被覆的厚度之截面上測量。
  9. 如請求項1或2之帶，其中該中間合金層包括實質上等軸結晶，其長直徑測量係50-4000奈米，如在通過該被覆的厚度之截面上測量。
  10. 如請求項1或2之帶，其中該中間合金層包括柱狀結晶與等軸結晶之混合物。
  11. 如請求項1或2之帶，其中該中間合金層包括體心立方結晶。
  12. 如請求項1或2之帶，其中該中間合金層之Al、Zn、Si及Fe濃度滿足式Fe10Al32Si5Zn3。
  13. 如請求項1或2之帶，其中該中間合金層之Al、Zn、Si及Fe濃度滿足式Fe10Al34Si4Zn2。
  14. 如請求項1或2之帶，其係一使用含Cr或無Cr鈍化系統之經鈍化的帶。
  15. 如請求項1或2之帶，其中該等帶包括一在該金屬被覆的曝露表面上之樹脂被覆。
  16. 如請求項1或2之帶，其中用以形成該金屬被覆之熔融Al-Zn-Si-Mg合金包含多於1.0%Mg，以重量計。
  17. 如請求項1或2之帶，其中用以形成該金屬被覆之熔融Al-Zn-Si-Mg合金包含多於1.3%Mg，以重量計。
  18. 如請求項1或2之帶，其中用以形成該金屬被覆之熔融Al-Zn-Si-Mg合金包含多於1.5%Mg，以重量計。
  19. 如請求項1或2之帶，其中用以形成該金屬被覆之熔融Al-Zn-Si-Mg合金包含少於2.5%Mg，以重量計。
  20. 如請求項1或2之帶，其中用以形成該金屬被覆之熔融Al-Zn-Si-Mg合金包含多於1.2%Si，以重量計。
  21. 如請求項1或2之帶，其中用以形成該金屬被覆之熔融Al-Zn-Si-Mg合金包含下列範圍之Al、Zn、Si及Mg元素，以重量%計：Zn：30至60% Si：0.3至3% Mg：0.3至3%剩餘部分 Al及無法避免的雜質。
  22. 如請求項1或2之帶，其中用以形成該金屬被覆之熔融的Al-Zn-Si-Mg合金包含下列範圍之Al、Zn、Si及Mg元素，以重量%計：Zn：35至50% Si：1.2至2.5% Mg：1.0至3.0%剩餘部分 Al及無法避免的雜質。
  23. 一種在鋼帶上形成金屬被覆以形成如請求項1至22之任何一項的金屬被覆鋼帶之方法，該方法包括將鋼帶浸入一熔融Al-Zn-Si-Mg合金槽中及在該鋼帶的曝露表面上形成合金的金屬被覆，及該方法包括控制該熔融合金槽的組成物之任何一或多種、熔融合金槽的溫度、及該鋼帶在熔融合金槽中的沈浸時間，以在該鋼帶與 Al-Zn-Mg-Si覆蓋合金層間形成該中間合金層。
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