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Outline
Aluminum in galvanizing
The past brightener
The present reactivity control
The future improved corrosion performance
Status of development
Next steps
2
Aluminum as a Brightener
Use of aluminum dates back to early 1900s
Improves brightness of galvanized coating
Low levels added to zinc bath: 0.001 0.005%
Myth 1: Aluminum added to deoxidize the molten zinc bath
Myth 2: Aluminum added to improve fluidity of the molten zinc bath
St
Structure
t
off the
th mixed
i d oxides
id prevents
t oxidation
id ti off underlying
d l i zinc
i b
bath
th
Prevents yellowish coloring associated with oxidation of zinc and other
minor elements in the bath
Aluminum as a Brightener
Aluminum consumption
Oxidation
Flux interaction
Coating formation
Aluminum maintenance
Pure aluminum (sheet,
(sheet bar/ingot)
Brightener bar
Zn5Al vs
vs. Zn10Al
4
Aluminum for
Reactivity Control
Alternative method to Zn-Ni process
Can
C b
be used
d iin ttandem
d
with
ith other
th galvanizing
l
i i alloys
ll
Pretreatment dependent
Required
q
new flux development
p
effort
5
Controlling Reactivity
350
HDG
300
CoatinggThickness (m)
BPNi
AlBiSn
250
200
150
100
50
0
0.00
0.05
0.10
0.15
0.20
0.25
0.30
SteelEffectiveSiContent(wt.%)
6
0.35
0.40
Controlling Reactivity
Mid Reactivity
BritePlus Ni
SHG
BritePlus Al
Controlling Reactivity
High Reactivity
SHG
BritePlus Ni
BritePlus Al
0.01Al
0.032Al
Stack Test
0.001Al
0.01Al
0.032Al
Improving Corrosion
Performance
Operating levels above 5%Al
Development focused on application of single dip
process
Process very dependent on steel surface condition
Pretreatment maintenance
Flux
Fl modification
difi ti
Improving Corrosion
Resistance
Atmospheric work
coordinated by
Australian Tube Mills
CSIRO test site
12
Corrosion Rate (m
m/yr)
Improving Corrosion
Resistance
12
South Rack
North Rack
Sheltered Rack
10
8
6
4
2
0
GL
0 2Al
0.2Al
7Al
10Al
12Al
15Al
Coating
Normalized Annual Corrosion Rate (m/year)
13
GL
0.2Al
7Al
10Al
12Al
15Al
South Rack
1.868
2.800
1.271
2.252
2.600
3.117
North Rack
1.403
2.814
1.462
2.608
2.802
2.971
Sheltered Rack
5.023
11.279
7.385
7.593
7.282
6.558
Current Development
- Flux
Patent application allowed in July 2010
Galvcast Manufacturing plant trial
Drying
D i off parts
t becomes
b
more critical
iti l flux
fl iis h
hygroscopic
i
Current Development
- Alloys
Corrosion resistant alloy trialed on semi-continuous
flux-based
flux
based flow coat profile mill in Australia in 2010
Coatings exhibited minimal defects indicating successful interaction between flux
and alloy
Subsequent forming tests confirmed coating formability
Corrosion results confirmed initial test data
Results were very encouraging
Customer moving ahead with full conversion of line to high aluminum alloy
Adoption of new flux and new alloy technology
15
Acknowledgements
Thank you to all who contributed to the development work:
Pat Ginnetti
Dr. Daniel Liu
Steve Murray
Dr. Nai-Yong Tang
Adam Ziemiak