a comparative study of the 0.05al process
DESCRIPTION
A Comparative Study of the 0.05Al Process. October 2, 2012. Background. Al for broadband Si reactivity control H. Guttman and P. Niessen, 1975 M. Pierre, 1975 Commercialization failure of Polygalva, 1979 Al-compatible flux (G-flux) US Patent US 7,811,389 B2, 2010 - PowerPoint PPT PresentationTRANSCRIPT
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A Comparative Study of the 0.05Al ProcessOctober 2, 2012
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Background
Al for broadband Si reactivity control
H. Guttman and P. Niessen, 1975
M. Pierre, 1975
Commercialization failure of Polygalva, 1979
Al-compatible flux (G-flux)
US Patent US 7,811,389 B2, 2010
Commercial production of 12Al coating
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Parts
Steel Parts (2982 kg in total)
0.04% - 0.28% Effective Si
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Baths, Centrifuge and Products
Baths (2400 kg each)
Bath A: 0.039%Al
Bath B: 0.051%Al
Bath H: 0.005%Al
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Pretreatments
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Degrease 20 minutes Pickle 20 minutes Rinse 1 minute
Flux 1 minuteDry 120ºC 15 minutes
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Coating Thickness (4 minutes)
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450ºC (842ºF), 4 minutes
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Coating Thickness (Prior Study)
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440ºC (824ºF), 8 minutes
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Coating Thickness (10 minutes)
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450ºC (842ºF), 10 minutes
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Coating Adhesion (Part e3)
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Bath B, 10 min
Bath B, 4 minBath H, 4 min
Bath A, 4 min
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Microstructure (Part e3, 0.21%Si)
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Bath B, 10 min
Bath B, 4 minBath H, 4 min
Bath A, 4 min
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ζ
δ
Flaked-off Coating
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Bath B, 10 min
Bath H, 4 minBath H, 4 min
Bath A, 4 min
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Coating Adhesion (Part a)
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Bath H, 4 min
Bath B, 10 min
Bath A, 4 min
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Microstructure (Part a, 0.24%Si)
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Bath H, 4 min
Bath B, 10 min
Bath A, 4 min
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Zinc Consumption
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Bath AB Bath H
Coating 2.48% 2.97%
Dross 4.81% 4.11%
Ash 1.38% 1.35%
Total 8.67% 8.43%
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Drainage (Part k)
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The amount of accumulation at the bottom of Part k:
Bath W (g) W (lb)
H 3.9 0.0086
A 3.0 0.0066
B 2.9 0.0064
Student’s test indicated that there were significant differences between Baths H and AB, whereas there was no significant difference between Baths A and B.
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White Rust Test
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H08 B132
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Summary
New Process (0.04-0.05%Al) vs. HDG
Al-compatible flux (G-Flux)
Brighter, shinier and thinner coating
Improved coating adhesion
Slightly better drainage
Slightly more dross but same amount of ash
Less visible oxide skin
More localized white rust
Slightly shorter kettle life
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Questions?
Thank you for your attention!
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