US3505042A - Method of hot dip coating with a zinc base alloy containing magnesium and the resulting product - Google Patents

Method of hot dip coating with a zinc base alloy containing magnesium and the resulting product Download PDF

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Publication number
US3505042A
US3505042A US791763*A US3505042DA US3505042A US 3505042 A US3505042 A US 3505042A US 3505042D A US3505042D A US 3505042DA US 3505042 A US3505042 A US 3505042A
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United States
Prior art keywords
coating
percent
bath
magnesium
zinc
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
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US791763*A
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English (en)
Inventor
William C Sievert
Lewis J Geiger
Harvie H Lee
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Inland Steel Co
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Inland Steel Co
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Classifications

    • CCHEMISTRY; METALLURGY
    • C23COATING 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
    • C23CCOATING 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
    • C23C2/00Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor
    • C23C2/04Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor characterised by the coating material
    • C23C2/06Zinc or cadmium or alloys based thereon
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C20/00Alloys based on cadmium
    • YGENERAL 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
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/12All metal or with adjacent metals
    • Y10T428/12493Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
    • Y10T428/12771Transition metal-base component
    • Y10T428/12785Group IIB metal-base component
    • Y10T428/12792Zn-base component
    • Y10T428/12799Next to Fe-base component [e.g., galvanized]
    • YGENERAL 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
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/12All metal or with adjacent metals
    • Y10T428/12493Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
    • Y10T428/12771Transition metal-base component
    • Y10T428/12861Group VIII or IB metal-base component
    • Y10T428/12951Fe-base component
    • Y10T428/12972Containing 0.01-1.7% carbon [i.e., steel]

Definitions

  • a ferrous metal sheet hot dip coated with a zinc base alloy containing between about 3 and 5 percent by weight magnesium exhibits very good corrosion resistance against aqueous sodium chloride solutions and good adherence and formability properties.
  • the present invention relates generally to an improved method of providing a hot dip zinc base alloy protective coating on a ferrous metal and to a ferrous metal article having an improved protective hot dip zinc base alloy coating.
  • Zinc hot dip coatings have long been used to protect ferrous metal bases against attack by corrosion.
  • Various alloying metals have been added to a molten zinc bath comprised mainly of zinc to improve the properties of the metal coating or the coating process.
  • the alloying metals added to the zinc bath are generally used in an amount ranging upwardly from a fraction of one percent and serve to improve the corrosion resistance or the appearance of the coatings or reduce the amount of intermetallic compounds formed.
  • the metals which have heretofore been added to a molten zinc coating bath are lead, tin, aluminum, cadmium, antimony, and magnesium.
  • the magnesium concentration in a molten zinc bath which is required to produce a coating having optimum corrosion resistance is from about .04 percent to 0.5 percent by weight magnesium. It has also been reported that the use of magnesium at a concentration substantially above about .05 percent by weight magnesium creates serious operating difiiculties in a molten zinc bath. For example, it has been reported that a hot dip zinc bath containing in excess of about 0.1 percent by weight magnesium results in excess losses due to high flux consumption and large ash build-up on the surface of the bath. (See the paper by John A. Heath, A New Frontier in Hot- Dip Galvanizing: A Magnesium Containing Coating,
  • Hot dip zinc base alloy coatings containing up to about 1 percent magnesium have been prepared for testing purposes and found to be less formable than conventional zinc coatings and to severely crack and scale off when subjected to a conventional bend test. Moreover, the addition of magnesium up to about 1 percent by weight to a zinc coating bath was found to have no substantial favorable influence on the corrosion resistance of the resulting zinc alloy coating when exposed to damp air and only a slight favorable improvement in the corrosion resistance when exposed to industrial atmosphere (see Stahl & Eisen, v01. 84, 1964, No. 12, pages 713-8).
  • a protective zinc base alloy coating having markedly improved corrosion resistance along with good adherence and ductility properties can be provided on a ferrous metal surface by applying a hot dip zinc base alloy coating having a metallic magnesium content appreciably in excess of the amounts previously considered usable.
  • a hot dip zinc base alloy coating having a metallic magnesium content appreciably in excess of the amounts previously considered usable.
  • an adherent hot dip coating exhibiting an increase in corrosion resistance of at least about 400 percent over conventional zinc coatings of similar weight Without loss of adherence or ductility has ben obtained by applying in accordance with the present invention a hot dip zinc base alloy coating containing about 3 percent by weight magnesium.
  • Table I illustrates the significant improvement obtained where a relatively thin zinc base alloy coating which contains magnesium within the range of concentrations of the 3 present invention and compares therewith a coating of similar thickness made from a standard zinc spelter on a conventional continuous hot dip galvanizing line:
  • magnesium-zinc alloys containing between about 1.5 percent magnesium and about 5 percent magnesium have melting points below 800 F. and below the normal operating temperature of a conventional continuous zinc galvanizing bath, and coating with such alloys are within the scope of the present invention.
  • magnesium-zinc alloy mixtures containing about 3 percent by weight magnesium i.e. between 2.7 percent and about 3.6 percent magnesium by weight
  • magnesium-zinc alloy mixtures containing about 3 percent by weight magnesium have a lower melting point than those having less than 2.7 percent magnesium and greater than 3.6 percent magnesium
  • the latter more limited range of magnesiumzinc alloys containing about between 2.7 and 3.6 percent (i.e. about 3%) by weight magnesium are preferred in the present invention.
  • the desired operating conditions can be achieved by introducing the clean oxide-free metal base into the coating bath through a tube or snout in which a non-oxidizing or reducing atmosphere is maintained, and thereafter withdrawing the coated metal base from the bath through a chamber or zone having a low oxidizing potential atmosphere from which most of the oxygen of the air is excluded and maintaining the alloy coating in the substantially non-oxidized condition until the temperature falls below the melting point of the alloy (i.e. coating solidifies).
  • a zone having a low oxidizing potential of the above type can be provided by applying (i.e.
  • metal article having the improved alloy coating of the present invention is not rapidly cooled immediately after withdrawal from the hot dip bath, the surface tends to be irregular and somewhat pitted. These surface defects are substantially reduced by applying a cooling fluid, and preferably a gas which is non-reactive with the coating, such as cool gaseous nitrogen, to the surface of the alloy coating as soon as the article is withdrawn from the coating bath.
  • a cooling fluid and preferably a gas which is non-reactive with the coating, such as cool gaseous nitrogen
  • a series of 4" x 8" steel test panels were obtained from 20 gauge full hard steel sheets which has a thickness of .034" and chemical compositions of about .04 percent carbon, .29 percent to .35 percent manganese, .01 percent to .011 percent phosphorus, .019 percent to .020 percent sulphur and .04 percent copper, with the balance essentially iron. All the panels were precleaned by the oxidation method according to the following procedures: (1) vapor degreased with trichloro-ethylene for 15 minutes at 170 F., and (2) oxidized in a furnace at 1650 F. for 30 seconds. The oxidized panels were then transferred into the dry box which contained the laboratory galvanizing equipment.
  • the atmosphere inside the dry box contained 10 percent hydrogen with the balance nitrogen.
  • the dew point inside the dry box was always kept below 15 F. during the dipping operation.
  • the cleaned panel was preheated at 1800 F. for 3 minutes in the reducing atmosphere of the dry box during which surface oxides were reduced, and then cooled to the bath temperature for dipping.
  • a standard steel hot mill band having a thickness of about 0.080 inch is cold reduced on a five-stand tandem mill to form a steel strip having a thickness of about 0.0236 inch thick (24 gauge).
  • the full hard 0.0236 inch strip thus formed having a Rockwell hardness (30 T-scale) of about 80 is cleaned by passing through a continuous cleaning line, followed by conventional box annealing heat treatment to restore the ductility lost when the strip was cold reduced.
  • the annealed strip is then temper rolled to provide a suitable surface for continuous hot dip coating.
  • the annealed endless steel strip after cleaning as in Example 1 and after being enclosed in a zone having a dry reducing atmosphere of the type used in Example 1 is then immersed in a molten magnesium-zinc alloy bath having the following composition:
  • the enclosed strip was fed into the alloy bath at an angle of about 70 to the horizontal.
  • the strip was allowed to remain in the alloy bath about 5 seconds (and not more than seconds), and was continuously withdrawn from the bath at an angle of about 90 to the horizontal through coating rolls.
  • the coating rolls were flame covered to retard oxide pick-up from the bath.
  • the molten alloy coating was rapidly cooled by blowing thereover nitrogen gas at 1.5 p.s.i. and at a temperature below 100" F. and preferably at about 50 F.
  • An alloy coating was obtained having a thickness on each side of the strip between about 0.9 mil and 1.3 mils. The latter alloy coating exhibited the improved properties of the coating of Example 1.
  • Example 2 An annealed endless steel strip processed as in Example 2 was immersed in a molten bath having a temperature of 750 F. in the same manner as in Example 2, with the bath having following composition:
  • the resulting alloy coated strip has the same properties as the strip of Example 2.
  • Example 2 An annealed endless steel strip processed as in Example 2 was immersed in a molten zinc base alloy hot dip coating bath having a temperature of 800 F. in the same manner as in Example 2, with the bath having the following composition:
  • the resulting alloy coating has the same properties as the coatings in Example 1 and Example 2.
  • the top skimming losses were small, despite the higher bath temperature.
  • a method of hot dip alloy coating a ferrous metal surface which comprises; immersing a ferrous metal article having a surface thereof substantially free of oxides and substances which contain oxygen into a molten zinc base alloy hot dip coating bath consisting essentially of zinc and containing as an alloying element between about 1.5% and 5% by weight magnesium and withdrawing said article from said bath to form on said surface an adherent protective hot dip zinc base alloy coating.
  • said coating bath consists essentially of zinc, magnesium and contains as a further alloying element about 0.05% to 1.0% by weight aluminum.
  • a method as in claim 1, comprising blanketing said alloy coating as said article is withdrawn from said coating bath with a protective gaseous atmosphere which is substantially non-oxidizing to said alloy coating.
  • An article comprising a ferrous metal sheet having on a surface thereof a corrosion resistant hot dip zinc base alloy coating containing between about 3 percent and 5 percent by weight magnesium with the balance comprised essentially of zinc.
  • hot dip alloy coating consists essentially of zinc, magnesium and further contains aluminum in an amount between about 0.15 percent and 0.5 percent by weight.
  • An article comprising a ferrous metal sheet having on a surface thereof a corrosion resistance hot dip zinc base alloy coating consisting essentially of zinc and containing as alloying elements between about 1.5 percent and 5 percent by weight magnesium and between about 0.05 percent and 1.0 percent by Weight aluminum, and said coating having good adherence and formability properties.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Coating With Molten Metal (AREA)
US791763*A 1964-09-15 1969-01-16 Method of hot dip coating with a zinc base alloy containing magnesium and the resulting product Expired - Lifetime US3505042A (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US39670764A 1964-09-15 1964-09-15
US48303265A 1965-08-27 1965-08-27
US79176369A 1969-01-16 1969-01-16

Publications (1)

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US3505042A true US3505042A (en) 1970-04-07

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NL (1) NL6511999A (enrdf_load_stackoverflow)

Cited By (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2228859A1 (en) * 1973-05-09 1974-12-06 Centro Speriment Metallurg Protection of ferrous surfaces using zinc based alloys - also contg. magnesium chromium and aluminium
US3993482A (en) * 1975-01-08 1976-11-23 Dalmine S.P.A. Anticorrosion zinc based coating material
US4056366A (en) * 1975-12-24 1977-11-01 Inland Steel Company Zinc-aluminum alloy coating and method of hot-dip coating
US4057424A (en) * 1975-06-13 1977-11-08 Italsider S.P.A. Zinc-based alloy for coating steel
US4330574A (en) * 1979-04-16 1982-05-18 Armco Inc. Finishing method for conventional hot dip coating of a ferrous base metal strip with a molten coating metal
US4369211A (en) * 1980-04-25 1983-01-18 Nippon Steel Corporation Process for producing a hot dip galvanized steel strip
US4557953A (en) * 1984-07-30 1985-12-10 Armco Inc. Process for controlling snout zinc vapor in a hot dip zinc based coating on a ferrous base metal strip
US5002837A (en) * 1988-07-06 1991-03-26 Kabushiki Kaisha Kobe Seiko Sho Zn-Mg alloy vapor deposition plated metals of high corrosion resistance, as well as method of producing them
US5648177A (en) * 1995-02-28 1997-07-15 Nisshin Steel Co., Ltd. Steel sheet coated witn Zn-Mg binary coating layer excellent in corrosion resistance and manufacturing method thereof
EP1193323A4 (en) * 2000-02-29 2003-07-16 Nippon Steel Corp PLATED STEEL PRODUCTS WITH HIGH CORROSION RESISTANCE AND EXCELLENT FORMABILITY AND PRODUCTION PROCESS FOR SUCH A PRODUCT
WO2009049836A1 (de) * 2007-10-10 2009-04-23 Voestalpine Stahl Gmbh Korrosionsschutzbeschichtung mit verbesserter haftung
WO2023134665A1 (zh) 2022-01-11 2023-07-20 宝山钢铁股份有限公司 一种具有Al-Zn-Mg-Si镀层的热冲压钢板及其热冲压方法

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3164464A (en) * 1961-01-09 1965-01-05 Dow Chemical Co Method of introducing magnesium into galvanizing baths
US3245765A (en) * 1962-03-08 1966-04-12 Armco Steel Corp Process of improving general corrosion resistance of zinc coated strip
US3320040A (en) * 1963-08-01 1967-05-16 American Smelting Refining Galvanized ferrous article

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3164464A (en) * 1961-01-09 1965-01-05 Dow Chemical Co Method of introducing magnesium into galvanizing baths
US3245765A (en) * 1962-03-08 1966-04-12 Armco Steel Corp Process of improving general corrosion resistance of zinc coated strip
US3320040A (en) * 1963-08-01 1967-05-16 American Smelting Refining Galvanized ferrous article

Cited By (13)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2228859A1 (en) * 1973-05-09 1974-12-06 Centro Speriment Metallurg Protection of ferrous surfaces using zinc based alloys - also contg. magnesium chromium and aluminium
US3993482A (en) * 1975-01-08 1976-11-23 Dalmine S.P.A. Anticorrosion zinc based coating material
US4057424A (en) * 1975-06-13 1977-11-08 Italsider S.P.A. Zinc-based alloy for coating steel
US4056366A (en) * 1975-12-24 1977-11-01 Inland Steel Company Zinc-aluminum alloy coating and method of hot-dip coating
US4330574A (en) * 1979-04-16 1982-05-18 Armco Inc. Finishing method for conventional hot dip coating of a ferrous base metal strip with a molten coating metal
US4369211A (en) * 1980-04-25 1983-01-18 Nippon Steel Corporation Process for producing a hot dip galvanized steel strip
US4557953A (en) * 1984-07-30 1985-12-10 Armco Inc. Process for controlling snout zinc vapor in a hot dip zinc based coating on a ferrous base metal strip
US5002837A (en) * 1988-07-06 1991-03-26 Kabushiki Kaisha Kobe Seiko Sho Zn-Mg alloy vapor deposition plated metals of high corrosion resistance, as well as method of producing them
US5648177A (en) * 1995-02-28 1997-07-15 Nisshin Steel Co., Ltd. Steel sheet coated witn Zn-Mg binary coating layer excellent in corrosion resistance and manufacturing method thereof
EP1193323A4 (en) * 2000-02-29 2003-07-16 Nippon Steel Corp PLATED STEEL PRODUCTS WITH HIGH CORROSION RESISTANCE AND EXCELLENT FORMABILITY AND PRODUCTION PROCESS FOR SUCH A PRODUCT
US6610423B2 (en) 2000-02-29 2003-08-26 Nippon Steel Corporation Plated steel product having high corrosion resistance and excellent formability and method for production thereof
WO2009049836A1 (de) * 2007-10-10 2009-04-23 Voestalpine Stahl Gmbh Korrosionsschutzbeschichtung mit verbesserter haftung
WO2023134665A1 (zh) 2022-01-11 2023-07-20 宝山钢铁股份有限公司 一种具有Al-Zn-Mg-Si镀层的热冲压钢板及其热冲压方法

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