US20160186284A1 - Al-coated steel sheet having excellent total reflection characteristics and corrosion resistance, and method for manufacturing same - Google Patents

Al-coated steel sheet having excellent total reflection characteristics and corrosion resistance, and method for manufacturing same Download PDF

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US20160186284A1
US20160186284A1 US14/910,043 US201414910043A US2016186284A1 US 20160186284 A1 US20160186284 A1 US 20160186284A1 US 201414910043 A US201414910043 A US 201414910043A US 2016186284 A1 US2016186284 A1 US 2016186284A1
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layer
steel sheet
mass
based alloy
dip
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Shinya Furukawa
Yasunori Hattori
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Nippon Steel Nisshin Co Ltd
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Nisshin Steel Co Ltd
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Publication of US20160186284A1 publication Critical patent/US20160186284A1/en
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    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D9/00—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor
    • C21D9/46—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor for sheet metals
    • 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
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D1/00—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
    • C21D1/26—Methods of annealing
    • 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
    • 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
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/001—Ferrous alloys, e.g. steel alloys containing N
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/002—Ferrous alloys, e.g. steel alloys containing In, Mg, or other elements not provided for in one single group C22C38/001 - C22C38/60
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/02—Ferrous alloys, e.g. steel alloys containing silicon
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/04—Ferrous alloys, e.g. steel alloys containing manganese
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/06—Ferrous alloys, e.g. steel alloys containing aluminium
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/14—Ferrous alloys, e.g. steel alloys containing titanium or zirconium
    • 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
    • C23C2/26—After-treatment
    • C23C2/28—Thermal after-treatment, e.g. treatment in oil bath
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C2/00—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor
    • C23C2/34—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor characterised by the shape of the material to be treated
    • C23C2/36—Elongated material
    • C23C2/40—Plates; Strips

Definitions

  • the present invention relates to an Al-coated steel sheet capable of being obtained by modifying a plated layer of a hot-dip Al based alloy plated steel sheet through a heat treatment, and particularly relates to the Al-coated steel sheet that exhibits a high total reflectivity and exhibits good corrosion resistance.
  • a hot-dip Al based alloy plated steel sheet is being widely used mainly for purposes requiring heat resistance.
  • Many of hot-dip Al based alloy plated steel sheets having been subjected to practical use are manufactured by using an Al based alloy plating bath containing Si.
  • the presence of Si contained may decrease the plating bath temperature, and also may decrease the thickness of the brittle alloy layer (i.e., the initial thickness of the alloy layer) formed between the base steel sheet (i.e., the base sheet for plating) and the Al based alloy plated layer in the process of hot-dip plating.
  • the alloy layer may grow in some cases in the use of the hot-dip Al based alloy plated steel sheet for purposes requiring heat resistance.
  • a heat treatment is performed after the hot-dip plating (i.e., a post heat treatment), so as to form a barrier layer of AlN between the base steel sheet and the alloy layer.
  • a base steel sheet containing N in such an amount that satisfy the formation of the AlN barrier layer is applied.
  • a plating bath composition containing approximately from 7 to 12% by mass of Si is effective from the standpoint of the reduction of the bath temperature of the Al based alloy plating bath, and many of the hot-dip Al based alloy plated steel sheets contains 7% by mass or more of Si in the plated layer.
  • some of PTLs disclose examples where a post heat treatment is applied with the use of a plating bath having a relatively low Si content of 6% or less (see PTLs 1 to 9).
  • a hot-dip Al based alloy plated steel sheet is demanded to have good heat reflection characteristics due to the aforementioned purposes requiring heat resistance.
  • a reflective plate of a lighting equipment, and the like it is demanded to have good reflection characteristics with small light absorption.
  • the reflection capabilities of heat and light roughly depend on the total reflectivity. Accordingly, in consideration of the application thereof to purposes requiring heat resistance and purposes utilizing light reflection capability, it is advantageous to have high total reflection characteristics. In the description herein, the fact that an article has high total reflection characteristics is expressed that the article is “having excellent total reflection characteristics”.
  • a hot-dip Al based alloy plated steel sheet that is manufactured with a plating bath containing Si has a tendency of decreasing the corrosion resistance, as compared to one manufactured with a pure Al based alloy plating bath.
  • an Al based alloy plated steel sheet is used after subjecting to an anodizing treatment, as similar to an Al alloy material.
  • an ordinary Al based alloy plated sheet has a defect that the appearance thereof becomes blackish after an anodizing treatment, and an anodized surface having good design quality is difficult to achieve.
  • the invention is to provide an Al-coated steel sheet that is excellent in total reflection characteristics, corrosion resistance, and appearance after subjecting to an anodizing treatment, as compared to an ordinary hot-dip Al based alloy plated steel sheet.
  • the object may be achieved by an Al-coated steel sheet having excellent total reflection characteristics and corrosion resistance, containing a base steel sheet having on a surface thereof an Al-coated layer having an average thickness of 7 ⁇ m or more with an Al—Fe—Si based alloy layer intervening therebetween, a surface layer portion of the Al-coated layer extending from the surface thereof to a depth of 3 ⁇ m having an average Si concentration of 2.0% by mass or less, and preferably 1.3% by mass or less, and an area ratio of an Al—Fe based intermetallic compound phase occupying the surface of the Al-coated layer being 10% or less.
  • the Al-coated layer may be obtained by modifying a hot-dip Al based alloy plated layer containing Si through a heat treatment.
  • the Si content of the hot-dip plating bath is preferably 1.5% by mass or more and 6.0% by mass or less, and more effectively 1.5% by mass or more and 3.0% by mass or less, and may be controlled to a range of 1.5% by mass or more and less than 3.0% by mass.
  • the Al-coated layer herein is a layer that has an Al phase as a matrix.
  • the Al-coated layer may contain an Al—Fe based intermetallic compound phase and a Si phase.
  • the average Si concentration of the surface layer portion of the Al-coated layer extending from the surface thereof to a depth of 3 ⁇ m may be obtained by performing EDX analysis (energy dispersive X-ray spectrometry analysis) for the cross sectional surface in parallel to the thickness direction of the Al-coated layer. Specifically, in an SEM observation field of the cross sectional surface with a magnification of 5,000, a rectangular area having a dimension of 3 ⁇ m ⁇ 20 ⁇ m with the edge having a length of 3 ⁇ m in the thickness direction of the Al-coated layer (i.e., the thickness direction of the steel sheet) is assumed.
  • EDX analysis energy dispersive X-ray spectrometry analysis
  • the rectangular area that entirely overlaps the Al-coated layer i.e., the rectangular area does not deviate from the Al-coated layer
  • the edge having a length of 20 ⁇ m being in contact with at least a part of the outermost surface of the Al-coated layer is set as a measurement area.
  • the measurement area is measured for the average Si concentration (conversion value in terms of percentage by mass) by EDX analysis.
  • the measurement operation above is performed for five or more fields having been randomly selected, and the average value of the average Si concentration values of the measurement areas may be designated as the “average Si concentration of the surface layer portion of the Al-coated layer extending from the surface thereof to a depth of 3 pat”.
  • the area ratio of an Al—Fe based intermetallic compound phase occupying the surface of the Al-coated layer means the ratio of the area of the portion having the Al—Fe based intermetallic compound phase present therein with respect to the projected area of the observed area obtained by viewing the surface of the Al-coated layer in the thickness direction.
  • the Al—Fe based intermetallic compound phase that is exposed to the surface of the Al-coated layer may be identified as a phase having an Fe content in terms of percentage by mass that is the second highest next to Al.
  • the invention also provides, as a method for manufacturing the Al-coated steel sheet having excellent total reflection characteristics and corrosion resistance, a manufacturing method containing:
  • the invention also provides a manufacturing method containing:
  • a step of modifying the plated layer to an Al-coated layer having a surface layer portion extending from the surface thereof to a depth of 3 ⁇ m that has an average Si concentration of 1.3% by mass or less by heating and retaining the hot-dip Al based alloy plated steel sheet to a temperature of from 300 to 460° C. to progress diffusion of Si in the plated layer.
  • the Si content of the hot-dip Al based alloy plating bath may be controlled to 1.5% by mass or more and less than 3.0% by mass.
  • an Al-coated steel sheet may be provided that has a high total reflectivity, good corrosion resistance, and an excellent appearance after subjecting to an anodizing treatment, as compared to an ordinary hot-dip Al based alloy plated steel sheet.
  • the Al-coated steel sheet is particularly excellent in heat reflection characteristics and light reflection characteristics due to the high total reflectivity thereof, and thus is considerably useful for purposes requiring heat resistance and purposes utilizing light reflection capability.
  • the Al-coated steel sheet may be obtained by subjecting a hot-dip Al based alloy plated steel sheet capable of being manufactured with an ordinary hot-dip plating line, as a base material, to a post heat treatment. Accordingly, the invention contributes to the enhancement of the purposes of a hot-dip Al based alloy plated steel sheet.
  • FIG. 1 is an illustration schematically showing the cross sectional structure of the ordinary hot-dip Al based alloy plated steel sheet manufactured by using an Al based alloy plating bath having a high Si content, intact after plating.
  • FIG. 2 is an illustration schematically showing the cross sectional structure of the plated steel sheet of FIG. 1 , after subjecting to a post heat treatment.
  • FIG. 3 is an illustration schematically showing the cross sectional structure of the hot-dip Al based alloy plated steel sheet manufactured by using an Al based alloy plating bath having a low Si content, intact after plating.
  • FIG. 4 is an illustration schematically showing the cross sectional structure according to the invention of the plated steel sheet of FIG. 3 , after subjecting to a post heat treatment.
  • FIG. 5 is an illustration schematically showing the cross sectional structure of the hot-dip Al based alloy plated steel sheet manufactured by using a pure Al plating bath.
  • FIG. 6 is a graph exemplifying the relationship between the heating temperature and the heating time required for making an average Si concentration of 2.0% by mass or less for the surface layer portion of the Al-coated layer extending from the surface thereof to a depth of 3 ⁇ m.
  • FIG. 7 is a micrograph showing the cross sectional structure of the hot-dip Al based alloy plated steel sheet manufactured by using a hot-dip Al based alloy plating bath having a Si content of 9% by mass, intact after plating.
  • FIG. 8 is a micrograph showing the cross sectional structure of the Al-coated steel sheet obtained by subjecting the hot-dip Al based alloy plated steel sheet manufactured by using a hot-dip Al based alloy plating bath having a Si content of 9% by mass to a post heat treatment in the air at 450° C. for 24 hours.
  • FIG. 9 is a micrograph showing the cross sectional structure of the hot-dip Al based alloy plated steel sheet manufactured by using a hot-dip Al based alloy plating bath having a Si content of 2.5% by mass, intact after plating.
  • FIG. 10 is a micrograph showing the cross sectional structure of the Al-coated steel sheet obtained by subjecting the hot-dip Al based alloy plated steel sheet manufactured by using a hot-dip Al based alloy plating bath having a Si content of 2.5% by mass to a post heat treatment in the air at 450° C. for 24 hours.
  • FIG. 11 is an SEM micrograph of the alloy layer portion on the cross section of the hot-dip Al based alloy plated steel sheet manufactured by using a hot-dip Al based alloy plating bath having a Si content of 2.5% by mass, intact after plating.
  • FIG. 12 is an SEM micrograph of the alloy layer portion on the cross section of the Al-coated steel sheet obtained by subjecting the hot-dip Al based alloy plated steel sheet manufactured by using a hot-dip Al based alloy plating bath having a Si content of 2.5% by mass to a post heat treatment in the air at 450° C. for 24 hours.
  • the Al-coated steel sheet of the invention can be achieved by modifying a plated layer of a hot-dip Al based alloy plated steel sheet manufactured by using an Al based alloy plating bath containing Si, through a post heat treatment. It is important herein that the post heat treatment largely enhances the diffusion of Si in the plated layer, as compared to a post heat treatment having been ordinarily performed, and thereby the Si concentration of the surface layer portion of the plated layer is reduced. Furthermore, for reducing the Si concentration of the surface layer portion of the plated layer, it is considerably effective to use a hot-dip Al based alloy plating bath having a relatively low Si content.
  • FIG. 1 schematically shows a cross sectional structure of an ordinary hot-dip Al based alloy plated steel sheet manufactured by using an Al based alloy plating bath containing Si in an amount of approximately from 7 to 10% by mass, intact after plating.
  • the Al based alloy plated layer 3 is formed on the surface of the base steel sheet 1 as a base sheet for plating with the alloy layer 2 intervening therebetween.
  • the alloy layer 2 is an “Al—Fe—Si based alloy layer” containing mainly an intermetallic compound containing Al, Fe and Si as components.
  • the Al based alloy plated layer 3 contains an Al—Fe based intermetallic compound phase 5 and a Si phase 6 present in an Al phase 4 as a matrix.
  • the Al—Fe based intermetallic compound phase 5 is present in a relatively large amount on the side close to the alloy layer 2
  • the Si phase 6 is present in a relatively large amount on the side close to the surface 10 .
  • FIG. 2 schematically shows the cross sectional structure of the plated steel sheet of FIG. 1 , after subjecting to a post heat treatment at a temperature of approximately 450° C.
  • the alloy layer 2 is slightly increased in thickness.
  • the Si phase 6 present in the plated layer 3 in FIG. 1 is formed into a spherical shape and is present in a large amount in the Al phase 4 .
  • the Al—Fe based intermetallic compound phase 5 also tends to be a spherical shape slightly.
  • the Al-coated layer thus derived from the plated layer after subjecting to the post heat treatment is shown by a numeral 30 in the figure.
  • FIG. 3 schematically shows a cross sectional structure of a hot-dip Al based alloy plated steel sheet manufactured by using an Al based alloy plating bath having a low Si content of approximately from 1.5 to 6.0% by mass, intact after plating.
  • the alloy layer 2 present on the surface of the base steel sheet 1 tends to be slightly thicker than the ordinary hot-dip Al based alloy plated steel sheet manufactured by using a hot-dip Al based alloy plating bath having a high Si content ( FIG. 1 ), but the deterioration of the characteristics, such as the workability, caused thereby does not make a problem in normal use.
  • the alloy layer 2 contains mainly an Al—Fe based intermetallic compound and an Al—Fe—Si based intermetallic compound as described later.
  • an Al—Fe based intermetallic compound phase 5 and a small amount of a Si phase 6 are observed in an Al phase 4 .
  • the amount of the Si phase 6 present varies depending on the Si content in the plating bath.
  • the Al—Fe based intermetallic compound phase 5 is present in a large amount on the side close to the alloy layer 2 and in a small amount on the side close to the surface 10 .
  • the Si phase 6 is present mainly on the side close to the surface 10 .
  • the hot-dip Al based alloy plated steel sheet obtained by using a hot-dip Al based alloy plating bath having a relatively small Si content is different in structure state of the plated layer 3 from the ordinary hot-dip Al based alloy plated steel sheet ( FIG. 1 ) in such a point that the amount of the Si phase 6 present is small. According to the investigation by the present inventors, however, only the use of this structure state cannot provide a sufficient improvement effect for total reflection characteristics, corrosion resistance, and appearance after subjecting to an anodizing treatment.
  • FIG. 4 schematically shows the cross sectional structure that is obtained by subjecting the plated steel sheet shown in FIG. 3 to a post heat treatment at a temperature of approximately 450° C. for a relatively long period of time of approximately 24 hours.
  • a post heat treatment at a temperature of approximately 450° C. for a relatively long period of time of approximately 24 hours.
  • the Al—Fe based intermetallic compound phase 5 is not largely changed in shape.
  • the average thickness of the Al-coated layer 30 per one surface of the steel sheet is necessarily 7 ⁇ m or more in order that the heat resistance and corrosion resistance inherent to the Al based alloy plated layer are sufficiently exhibited, and is more preferably 20 ⁇ m or more.
  • the upper limit of the average thickness is not particularly determined, and the average thickness may be generally in a range of 50 ⁇ m
  • the plated steel sheet manufactured by using a hot-dip Al based alloy plating bath having a small Si content as in FIG. 3 is subjected to a post heat treatment, Si in the plated layer 3 is diffused to the region having a relatively low Si concentration close to the alloy layer 2 and is incorporated in the alloy layer 2 , and in other words, Si present in the plated layer 3 is used for the reaction that changes the alloy layer 2 to an Al—Fe—Si based alloy layer containing mainly an intermetallic compound having a higher Si content.
  • the Si concentration of the surface layer portion of the Al-coated layer 30 close to the surface 10 thereof can be reduced by utilizing this phenomenon.
  • the alloy layer 2 is originally an alloy layer containing mainly an intermetallic compound having a higher Si content. Therefore, the phenomenon that Si in the plated layer 3 is incorporated in the alloy layer 2 through the post heat treatment may not largely occur.
  • the total reflectivity and the corrosion resistance due to the Al-coated layer may be enhanced particularly in the case where the Si concentration of the surface layer portion thereof close to the surface 10 is sufficiently reduced.
  • the reduction of the Si concentration of the surface layer portion is also important for improving the appearance after an anodizing treatment. Specifically, the total reflection characteristics and the corrosion resistance may be considerably improved in the case where the average Si concentration of the surface layer portion extending from the surface thereof to a depth of 3 ⁇ m is 2.0% by mass or less.
  • the total reflection characteristics and the corrosion resistance may be further considerably improved stably in the case where the average Si concentration of the surface layer portion is 1.3% by mass or less.
  • the lower limit of the average Si concentration of the surface layer portion of the Al-coated layer extending from the surface thereof to a depth of 3 ⁇ m is not necessarily determined and may be reduced to 0% by mass, but in consideration of the load in the post heat treatment process, the lower limit thereof may be in a range of 0.5% by mass or more.
  • the total reflection characteristics are improved by reducing the Si concentration of the surface layer portion since the Al purity of the surface layer portion of the plated layer is increased, and the reflection characteristics that are closer to pure Al may be imparted thereto.
  • the Al—Fe based intermetallic compound phase 5 On the surface 10 of the Al-coated layer 30 , a portion where the Al—Fe based intermetallic compound phase 5 is exposed is formed. It has been found that the Al—Fe based intermetallic compound phase 5 present on the surface may deteriorate the appearance after subjecting to an anodizing treatment. The exposed Al—Fe based intermetallic compound phase 5 may also be a factor of deteriorating the total reflection characteristics and the corrosion resistance.
  • the Al—Fe based intermetallic compound phase 5 is liable to be formed on the side close to the alloy layer 2 , and the amount of the Al—Fe based intermetallic compound phase 5 formed on the side close to the surface 10 is small.
  • the area ratio of the Al—Fe based intermetallic compound phase occupying the surface 10 of the Al-coated layer 30 is suppressed to 10% or less, coupled with the reduction of the Si concentration in the surface layer portion described above, the appearance after subjecting to an anodizing treatment may be considerably improved.
  • the heat reflection characteristics and the corrosion resistance may also be improved.
  • the condition that the area ratio of the Al—Fe based intermetallic compound phase is suppressed to 10% or less may be controlled by using a hot-dip Al based alloy plating bath having a Si content of 1.5% by mass or more.
  • FIG. 5 schematically shows the cross sectional structure of the hot-dip Al based alloy plated steel sheet manufactured by using a pure Al plating bath.
  • the alloy layer 2 formed between the base steel sheet 1 and the plated layer 3 is increased in thickness as compared to the hot-dip Al based alloy plated steel sheets using a Si-containing plating bath shown in FIGS. 1 and 3 , assuming that the base steel sheets 1 (i.e., the base sheets for plating) have the same steel composition.
  • the Al—Fe based intermetallic compound phase 5 formed in the Al-phase 4 as a matrix of the plated layer 3 is formed in a large amount on the side close to the surface 10 , which is different from the cases of FIGS. 1 and 3 . Even after subjecting to a post heat treatment, the cross sectional structure undergoes no large apparent change. Accordingly, a numeral 30 , which corresponds to the Al-coated layer after subjecting to a post heat treatment, is also shown in FIG. 5 .
  • the hot-dip Al based alloy plated steel sheet having the cross sectional structure shown in FIG. 5 manufactured by using a pure Al plating bath a large amount of the Al—Fe based intermetallic compound phase 5 is exposed to the surface of the plated layer 3 .
  • This structure state is similarly maintained even after subjecting to a post heat treatment.
  • the Al—Fe based intermetallic compound phase 5 that is present on the surface may be a factor of deteriorating the appearance after subjecting to an anodizing treatment and the corrosion resistance, as described above.
  • FIG. 6 exemplifies the relationship between the heating temperature and the heating time required for making an average Si concentration of 2.0% by mass or less for the surface layer portion of the Al-coated layer extending from the surface thereof to a depth of 3 ⁇ m in the case where a hot-dip Al based alloy plated steel sheet manufactured by using a hot-dip Al based alloy plating bath having a Si content of 2.5% by mass is subjected to a post heat treatment.
  • a post heat treatment of a hot-dip Al based alloy plated steel sheet has been ordinarily known, as described above.
  • the ordinary post heat treatment is difficult to reduce sufficiently the Si concentration of the surface layer portion of the Al-coated layer, as described above.
  • FIGS. 7 to 10 exemplify micrographs of the cross sectional structures after a post heat treatment.
  • FIG. 7 is a micrograph showing the cross sectional structure of the hot-dip Al based alloy plated steel sheet manufactured by using a hot-dip Al based alloy plating bath having a Si content of 9% by mass, intact after plating.
  • the Al—Fe based intermetallic compound phase looking light gray and the Si phase looking blackish are dispersed in the Al phase looking white.
  • FIG. 8 is a micrograph showing the cross sectional structure of the Al-coated steel sheet obtained by subjecting the hot-dip Al based alloy plated steel sheet manufactured by using a hot-dip Al based alloy plating bath having a Si content of 9% by mass to a post heat treatment in the air at 450° C. for 24 hours.
  • the Al-coated layer derived from the plated layer the Al—Fe based intermetallic compound phase looking light gray and the Si phase looking blackish are dispersed in the Al phase looking white.
  • the phases are formed into a spherical shape due to the application of heat.
  • FIG. 9 is a micrograph showing the cross sectional structure of the hot-dip Al based alloy plated steel sheet manufactured by using a hot-dip Al based alloy plating bath having a Si content of 2.5% by mass, intact after plating.
  • the Al—Fe based intermetallic compound phase looking light gray is dispersed in the Al phase looking white.
  • the Si phase looking blackish is also present.
  • the amount of the Si phase is considerably decreased, as compared to the case shown in FIG. 7 .
  • FIG. 10 is a micrograph showing the cross sectional structure of the Al-coated steel sheet obtained by subjecting the hot-dip Al based alloy plated steel sheet manufactured by using a hot-dip Al based alloy plating bath having a Si content of 2.5% by mass to a post heat treatment in the air at 450° C. for 24 hours.
  • the Al-coated layer derived from the plated layer the Al—Fe based intermetallic compound phase looking light gray is dispersed in the Al phase looking white. The presence of a Si phase cannot be confirmed from the micrograph.
  • FIG. 11 exemplifies an SEM micrograph of the alloy layer portion on the cross section of the hot-dip Al based alloy plated steel sheet manufactured by using a hot-dip Al based alloy plating bath having a Si content of 2.5% by mass, intact after plating.
  • the alloy layer shows a two-layer structure constituted by an upper layer shown by a numeral 21 and a lower layer shown by a numeral 22 . What is found under the lower layer is the base steel sheet.
  • four analysis positions are shown by symbols a to d. The measurement results of EDX quantitative analysis of the four positions are shown in Table 1 below.
  • Both the upper layer and the lower layer have a Si concentration of less than 3.0% by mass intact after plating, and the major intermetallic compound constituting the phases is estimated as an Al—Fe based intermetallic compound, as shown in Table 1.
  • FIG. 12 shows an SEM micrograph of the alloy layer portion on the cross section of the Al-coated steel sheet obtained by subjecting the hot-dip Al based alloy plated steel sheet manufactured by using a hot-dip Al based alloy plating bath having a Si content of 2.5% by mass to a post heat treatment in the air at 450° C. for 24 hours.
  • the micrograph four analysis positions are shown by symbols e to h.
  • the measurement results of EDX quantitative analysis of the four positions are shown in Table 2 below.
  • the Si content of the upper layer is greatly increased through the post heat treatment. Such a phenomenon may be observed that Si present in the plated layer is incorporated in the upper layer, and the upper layer is changed to the structure containing mainly an Al—Fe—Si based intermetallic compound.
  • the base steel sheet as the base sheet for plating applied to the invention may be various steel species that have been applied to hot-dip Al based alloy plated steel sheets.
  • a steel having a N content of from 0.04 to 0.015% by mass is preferably used for preventing the alloy layer from growing.
  • Specific examples of the contents of the steel components comprise from 0.001 to 0.06% of C, 0.5% or less of Si, 1.0% or less of Mn, 0.016% or less of P, 0.007% or less of S, 0.012% or less of Al, 0.015% or less of N, and from 0 to 0.03% of Ti (all in terms percentage by mass), with the balance of Fe and unavoidable impurities.
  • the thickness of the base sheet for plating may be in a range of from 0.1 to 3.5 mm, and may be controlled to a range of from 0.2 to 1.6 mm.
  • the hot-dip Al based alloy plated steel sheet that is applied to the invention may be manufactured with an ordinary hot-dip plating line.
  • the plating bath composition is preferably an Al based alloy plating bath having a Si content of 1.5% by mass or more and 6.0% by mass or less.
  • Si content of the bath is too large, it may be difficult to reduce sufficiently the Si concentration of the surface layer portion through the post heat treatment as the subsequent process step.
  • the Si content is too small, the structure of the plated layer becomes close to pure Al plating to enhance the tendency that the Al—Fe based intermetallic compound phase 5 is formed on the side close to the surface 10 as shown in FIG. 5 , whereby it may be difficult to reduce sufficiently the area ratio of the Al—Fe based intermetallic compound phase.
  • the Si content of the bath is more effectively 1.5% by mass or more and 3.0% by mass or less.
  • the upper limit of the Si content of the bath may be strictly controlled to less than 3.0% by mass.
  • Fe is generally incorporated in the bath.
  • the Fe content is preferably controlled 3.0% by mass or less, and more preferably 2.5% by mass or less.
  • the bath may contain at least one of 1.0% by mass or less of Ti, 1.0% by mass or less of B, 1.0% by mass or less of Zr, 1.0% by mass or less of Sr, and 5.0% by mass or less of Mg.
  • Ti, B and Zr are effective for enhancing the surface appearance through miniaturization of the spangle size
  • Sr is effective for miniaturizing the Si phase
  • Mg is effective for enhancing the corrosion resistance.
  • the balance of the aforementioned elements may be Al and unavoidable impurities.
  • the plating deposition amount is preferably 7 ⁇ m or more, and more preferably 20 ⁇ m or more, in terms of the thickness of the plated layer per one surface (exclusive of the alloy layer).
  • the upper limit thereof is not particularly determined, and in general, the average thickness may be in a range of 50 ⁇ m or less, and may be controlled to 40 ⁇ m or less.
  • the hot-dip Al based alloy plated steel sheet is subjected to a heat treatment for providing the Al-coated layer having a low Si concentration through modification of the Al based alloy plated layer.
  • the heat treatment is performed after the hot-dip plating, and thus is referred to as a “post heat treatment” in the description herein.
  • the Al based alloy plated layer is preferably modified to the Al-coated layer having an average Si concentration of the surface layer portion extending from the surface thereof to a depth of 3 ⁇ m of 2.0% by mass or less, and more preferably 1.3% by mass or less.
  • a hot-dip Al based alloy plated steel sheet manufactured by using a hot-dip Al based alloy plating bath having a Si content of 2.0% by mass or more and 6.0% by mass or less may be used. It may be controlled to use a hot-dip Al based alloy plated steel sheet manufactured by using a hot-dip Al based alloy plating bath having a Si content of more than 2.0% by mass and 6.0% by mass or less.
  • an Al-coated layer having an average Si concentration of the surface layer portion extending from the surface thereof to a depth of 3 ⁇ m of 1.3% by mass or less as a preferred embodiment is to be obtained through the modification, it is effective to use a hot-dip Al based alloy plated steel sheet manufactured by using a hot-dip Al based alloy plating bath having a Si content of 1.5% by mass or more and 3.0% by mass or less. It may be controlled to use a hot-dip Al based alloy plated steel sheet manufactured by using a hot-dip Al based alloy plating bath having a Si content of 1.5% by mass or more and less than 3.0% by mass.
  • the heating temperature of the post heat treatment may be set in a range of from 300 to 460° C., and more effectively in a range of from 380 to 460° C.
  • the heating temperature is too low, the Si concentration of the surface layer portion of the plated layer may be difficult to reduce.
  • the heating temperature is too high, the alloy layer may excessively grow.
  • the atmosphere of the post heat treatment may be in the air.
  • the Si phase formed in the plated layer tends to be distributed on the side close to the surface.
  • the Si phase is consumed for the reaction of increasing the Si content of the alloy layer, and thereby the Si concentration of the surface layer portion of the plated layer is reduced.
  • the suitable heating time may be determined by comprehending in advance the relationship between the heating temperature and the heating time that are sufficient for reducing the Si concentration of the surface layer portion of the plated layer (see FIG. 6 ).
  • the average Si concentration of the surface layer portion of the Al-coated layer extending from the surface thereof to a depth of 3 ⁇ m intact after plating (i.e., before subjecting to the post heat treatment) is generally as large as approximately 2.5% by mass. Accordingly, it is insufficient to reduce only the Si content of the plating bath, and the target Al-coated steel sheet having a surface layer portion with a reduced Si concentration may be obtained by performing the post heat treatment thoroughly.
  • a cold-rolled annealed steel sheet having the following chemical composition having a thickness of 0.8 mm was prepared.
  • hot-dip Al based alloy plated steel sheets having an average thickness of the plated layer (exclusive of the alloy layer) in a range approximately from 30 to 50 ⁇ m were manufactured.
  • Si content in Al bath shown in Tables 3 and 4 Fe content in Al bath: approximately 2% by mass Contents of additional elements other than Si and Fe in Al bath: shown in Tables 3 and 4 Components in bath other than above: Al and unavoidable impurities
  • Plating bath temperature 660° C.
  • Plating bath dipping time 2 seconds Average cooling rate until complete solidification of plated layer: 13° C. per second
  • the resulting hot-dip Al based alloy plated steel sheet was subjected to a post heat treatment at the heating temperature for the heating time shown in Tables 3 and 4 to prepare a specimen, which was then investigated as follows.
  • the atmosphere of the post heat treatment was in the air.
  • a specimen that was not subjected to a post heat treatment was prepared.
  • EDX analysis was performed for the cross sectional surface in parallel to the thickness direction of the specimen.
  • a rectangular area having a dimension of 3 ⁇ m ⁇ 20 ⁇ m with the edge having a length of 3 ⁇ m in the thickness direction of the Al-coated layer was assumed.
  • the rectangular area that entirely overlapped the Al-coated layer and had the edge having a length of 20 ⁇ m being in contact with at least a part of the outermost surface of the Al-coated layer was set as a measurement area.
  • the measurement area was measured for the average Si concentration (conversion value in terms of percentage by mass) by EDX analysis.
  • the measurement operation above was performed for five fields having been randomly selected, and the average value of the average Si concentration values of the measurement areas was designated as the average Si concentration of the surface layer portion of the Al-coated layer extending from the surface thereof to a depth of 3 ⁇ m.
  • the surface of the Al-coated layer of the specimen was observed with SEM in the thickness direction thereof, and the area ratio of the Al—Fe based intermetallic compound phase occupying the projected area of the observed area obtained by viewing the surface of the Al-coated layer in the thickness direction was obtained.
  • the Al—Fe based intermetallic compound phase exposed to the surface may be identified by EDX analysis.
  • the area ratio was measured for five fields having been randomly selected, and the average value thereof was designated as the area ratio (%) of the Al—Fe based intermetallic compound phase occupying the surface.
  • the surface of the Al-coated layer of the specimen was measured for total reflectivity.
  • the measurement was performed with MCP 3100, produced by Shimadzu Corporation, under conditions of a reflection angle of 8° and a measurement wavelength of 550 nm, and the total reflection characteristics were evaluated by the following standard. The evaluation of
  • the specimen was subjected to a humidity test of retaining in an environment of a temperature of 90° C. and a relative humidity of 95% for 500 hours, and the rust formation ratio was measured from the area where rust was formed on the surface, and evaluated for the corrosion resistance by the following standard. The evaluation of ⁇ or better was judged as passed.
  • ⁇ rust formation ratio of less than 10%
  • ⁇ rust formation ratio of 10% or more and less than 20%
  • ⁇ rust formation ratio of 20% or more and less than 50%
  • X rust formation ratio of 50% or more Evaluation of Appearance after Subjecting to Anodizing Treatment
  • the specimen was subjected to an anodizing treatment, and the resulting anodized surface was measured for L value (luminosity).
  • the anodizing treatment conditions were a treatment solution containing 150 g/L of sulfuric acid and 5 g/L of aluminum sulfate, a treatment temperature of 25° C., an electric current density of 5 A/dm 2 , and a treating time of 10 minutes. The appearance after subjecting to the anodizing treatment was evaluated, and the evaluation of 0 or better was judged as passed.
  • the specimen was subjected to a cylinder drawing process, and the vertical wall portion of the processed article was evaluated for peeled off state of the Al-coated layer.
  • the cylinder drawing conditions were a drawing ratio of 2.0, a blank diameter of 80 mm, a die diameter of 42 mm, a die corner radius of 5 mm, a punch diameter of 40 mm, and a punch corner radius of 5 mm.
  • the workability was evaluated by the following standard, and the evaluation of ⁇ or better was judged as passed.
  • the surface of the Al-coated layer of the specimen was evaluated for refinement of the spangle in terms of the spangle density.
  • the evaluation of ⁇ or better was judged as passed.
  • the specimens according to the invention were improved in total reflection characteristics, corrosion resistance, and appearance after subjecting to an anodizing treatment, and also were good in workability and surface appearance.
  • the specimens having an average Si concentration of the surface layer extending to a depth of 3 ⁇ m of the Al-coated layer of 1.3% by mass or less were considerably excellent in total reflection characteristics, corrosion resistance, and appearance after subjecting to an anodizing treatment.
  • Nos. 31 and 32 as comparative examples were manufactured by using a pure Al plating bath, in which a large amount of an Al—Fe based intermetallic compound phase was formed in the vicinity of the surface of the plated layer.
  • the Al—Fe based intermetallic compound phase remained substantially unchanged after subjecting to the post heat treatment (No. 32).
  • These specimens had no Si present in the surface layer portion of the Al-coated layer, but were not improved in total reflection characteristics and corrosion resistance and were inferior in appearance after subjecting to an anodizing treatment, due to the large area ratio of the Al—Fe based intermetallic compound phase occupying the surface.
  • the specimens were also inferior in workability due to the alloy layer formed to have a large thickness.
  • No. 33 maintained the tendency that a large amount of an Al—Fe based intermetallic compound phase was formed in the vicinity of the surface of the plated layer, due to the too small Si content in the plating bath. Accordingly, the specimen was inferior in various characteristics as similar to the specimens using a pure Al bath. This specimen was not subjected to a post heat treatment. However, it is difficult to reduce the area ratio of the Al—Fe based intermetallic compound phase occupying the surface through a post heat treatment.
  • Nos. 34, 37, 38 and 41 had a high average Si concentration of the surface layer portion of the Al-coated layer since a post heat treatment was not performed, and the heating conditions were not proper, although the plating bath had the appropriate Si content.
  • the specimens were inferior in total reflection characteristics and appearance after subjecting to an anodizing treatment and were insufficient in improvement of corrosion resistance.
  • Nos. 35 and 39 were hot-dip Al based alloy plated steel sheets manufactured by using a plating bath having a high Si content, and were inferior in total reflection characteristics, corrosion resistance, and appearance after subjecting to an anodizing treatment due to the large average Si concentration in the surface layer portion of the Al-coated layer (the Al-coated layers in these specimens were the Al based alloy plated layers intact after plating).
  • Nos. 36 and 40 were obtained by subjecting a hot-dip Al based alloy plated steel sheet manufactured by using a plating bath having a high Si content to a post heat treatment, but the average Si concentration of the surface layer portion of the Al-coated layer did not sufficiently reduced, and thus the specimens were not improved in total reflection characteristics, corrosion resistance, and appearance after subjecting to an anodizing treatment.

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CA2918863A1 (en) 2015-02-19
AU2014307526A1 (en) 2016-03-03
KR102150841B1 (ko) 2020-09-02
CA2918863C (en) 2020-04-21
MX2016001657A (es) 2016-06-02
MY177097A (en) 2020-09-05
EP3034647A1 (en) 2016-06-22
CN105555986B (zh) 2020-08-04
AU2014307526B2 (en) 2018-10-18
RU2016108542A (ru) 2017-09-19
EP3034647A4 (en) 2017-04-05
NZ716829A (en) 2018-06-29
JP2015036447A (ja) 2015-02-23

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