Method for producing molten Al plated steel wire

Abstract

A method of producing an Al plated steel wire comprises a first step of continuously immersing a material steel wire formed of a steel core into a molten Al plating bath and then withdrawing the material steel wire to a gas phase space. The material steel wire plated with a plating metal is brought into contact with a contact member at the plating bath rising portion to produce the Al plated steel wire, the Al plated steel wire having an average diameter D.sub.A (mm) and a minimum diameter D.sub.MIN (mm) in the longitudinal direction of the wire satisfying the following expression (1)
(D.sub.AD.sub.MIN)/D.sub.A0.10,(1).
The Al plated steel wire is then wound.

Claims

1. A method of producing an Al plated steel wire comprises: a step of continuously immersing a material steel wire formed of a steel core into a molten Al plating bath and then withdrawing the material steel wire to a gas phase space; a step of bringing the material steel wire plated with a plating metal into contact with a contact member at the plating bath rising portion to produce the Al plated steel wire, the Al plated steel wire having an average diameter D.sub.A (mm) and a minimum diameter D.sub.MIN (mm) in the longitudinal direction of the Al plated steel wire satisfying the following expression (1)
(D.sub.AD.sub.MIN)/D.sub.A0.10(1); and a step of winding the Al plated steel wire.

2. The method of producing a molten Al plated steel wire according to claim 1, wherein the material steel wire has a diameter of from 0.05 to 0.50 mm.

3. The method of producing a molten Al plated steel wire according to claim 2, wherein the material steel wire has on the surface thereof a Zn plated layer or an Ni plated layer having an average thickness of 5 m or less.

4. The method of producing a molten Al plated steel wire according to claim 1, wherein the material steel wire has on the surface thereof a Zn plated layer or an Ni plated layer having an average thickness of 5 m or less.

Description

BRIEF DESCRIPTION OF DRAWINGS

(1) FIG. 1 is an illustration conceptually showing an ordinary production method of a strand wire with torsion applied to element wires.

(2) FIG. 2 is an illustration conceptually showing a production method of a strand wire by a planetary method with no torsion applied to element wires.

(3) FIG. 3 is an illustration schematically showing a structure of a torsional test equipment.

(4) FIG. 4 is a graph showing the relationship between (D.sub.AD.sub.MIN)D.sub.A and the breaking number of torsion of the molten Al plated steel wire.

(5) FIG. 5 is an illustration schematically showing an example of a structure of a production equipment of a molten Al plated steel wire.

(6) FIG. 6 is an illustration schematically showing a cross section of a rising portion of a plating bath in parallel to the vertical direction.

(7) FIG. 7 is an illustration schematically showing a cross section of a rising portion of a plating bath in parallel to the vertical direction, in which a contact member is provided.

DESCRIPTION OF EMBODIMENTS

(8) As the molten Al plated steel wire that assumes a role of reinforcing a strand wire for a wire harness, a steel core wire having a diameter in a range of from 0.05 to 0.50 mm is useful. When the steel core wire is too thin, the strength enhancing effect of the strand wire may be small, and when the steel core wire is too thick, not only the strength may be excessive, but also the total diameter of the strand wire may be larger, which is contrary to the needs of a thin wire and a light weight of a wire harness.

(9) According to the investigations made by the present inventors, it has been found that the molten Al plated steel wire having a steel core wire having such a small diameter as above tends to have a wire diameter that is uneven in the longitudinal direction in the production thereof, which is a cause of the reduction of the durability to a torsional process (which may be hereinafter referred to as torsional resistance) in a state untouched after the molten Al plating. However, it has been difficult to find a condition for providing good torsional resistance stably only by evaluating the torsional characteristics with the difference between the maximum diameter and the minimum diameter in the longitudinal direction as the parameter. As a result of the further investigations under the circumstances, it has been clarified that in the fluctuation of the wire diameter in the longitudinal direction, the portion having an increased wire diameter has no particular adverse effect on the torsional resistance of the molten Al plated steel wire. Accordingly, such a parameter is necessarily determined that excludes the effect of the increased wire diameter. As a result of the detailed studies, it has been confirmed that the torsional resistance of the molten Al plated steel wire can be favorably evaluated by the expression (D.sub.AD.sub.MIN)/D.sub.A, which is a function of the average diameter D.sub.A (mm) and the minimum diameter D.sub.MIN (mm) in the longitudinal direction of the molten Al plated steel wire.

(10) As a torsional test method of a wire material, for example, there has been the rule for a hard drawn steel wire in JIS G3521. However, the method targets a material having a wire diameter of 0.70 mm or more, and there is no general standard for evaluating the torsional resistance of a wire material that is thinner than that. Under the circumstances, the inventors referring to the JIS document have investigated the torsional resistance of various molten Al plated steel wires (that are not subjected to a wire drawing process after applying to the Al plating) by using a torsional test equipment shown schematically in FIG. 3. Specifically, a wire material specimen 42 is held with chucks 41a and 41b, to which a load of 50 g is applied to prevent the wire material specimen from deflecting, and in this state, one chuck 41b is rotated to measure the maximum rotation number (integer) until the wire material is broken, which is designated as the breaking number of torsion of the wire material. For example, in the case where the wire material is not broken until the completion of the eleventh rotation but is broken until the completion of the twelfth rotation, the breaking number of torsion is 11. The distance of the chucks is 100 mm. In most cases, the existing strand wire used in a wire harness for an automobile is subjected to a number of torsion of approximately from 5 to 20 per 100 mm. Accordingly, a molten Al plated steel wire that has torsional resistance providing a breaking number of torsion of 50 or more in the torsional test method used herein can be evaluated to have a practical capability capable of avoiding breakage in the case where a strand wire for a wire harness is produced with an ordinary production equipment for a strand wire with torsion applied to element wires. The breaking numbers of torsion of the conventional molten Al plated wires are from several rotations to approximately 15 in many cases for the wire that is not subjected to a wire drawing process after applying to the Al plating.

(11) FIG. 4 exemplifies the relationship between (D.sub.AD.sub.MIN)/D.sub.A and the breaking number of torsion by the aforementioned torsional test of the molten Al plated steel wires (that are not subjected to a wire drawing process after applying to the Al plating). The graph shows the data of the examples shown in Table 1 described later. The average diameter D.sub.A herein is a value based on the wire diameter data in the x direction and the y direction measured with a pitch of 0.1 mm over the entire length (approximately 8,000 m) of the molten Al plated steel wire produced under the same production condition. The minimum diameter D.sub.MIN is a value based on the wire diameter data measured in the same manner over 100 mm, which is the distance of the chucks, of the specimen that is actually subjected to the torsional test.

(12) It is understood from FIG. 4 that there is a correlative relationship between (D.sub.AD.sub.MIN)/D.sub.A and the breaking number of torsion. For ensuring the torsional resistance providing a breaking number of torsion of 50 or more, it suffices that the fluctuation of the wire diameter satisfies the following expression (1).
(D.sub.AD.sub.MIN)/D.sub.A0.10(1)

(13) While the minimum diameter D.sub.MIN used herein is a value over the distance between the chucks, i.e., 100 mm, as described above, the portion that is most liable to be broken in the production of a strand wire is a portion having the smallest diameter over the entire length in the longitudinal direction. Accordingly, in the case where D.sub.A and D.sub.MIN based on the measurement data of the wire diameter over the entire length in the longitudinal direction satisfy the expression (1), it can be evaluated that the molten Al plated steel wire has a capability that is capable of avoiding breakage in the production of a strand wire over the entire length.

(14) The molten Al plated steel wire that satisfies the expression (1) can be produced directly through a molten Al plating process by applying a measure for uniformizing the depositing amount of the Al plating on molten Al plating, without performing a wire drawing process thereafter. For example, it has been confirmed that the molten Al plated steel wire can be produced by the following method.

(15) The molten Al plated steel wire can be produced in such a manner that a material steel wire formed of a steel core wire having a diameter of from 0.05 to 0.50 mm or a material steel wire formed of a plated steel wire containing the steel core wire having on the surface thereof a Zn plated layer or an Ni plated layer having an average thickness of 5 m or less is immersed in a molten Al plating bath and then continuously withdrawing to a gas phase space.

(16) FIG. 5 schematically shows an example of a structure of a production equipment of a molten Al plated steel wire capable of being applied to practice of the aforementioned production method. A molten Al plating bath 1 is housed in a plating bath tank 50. A steel wire 3 supplied from a supplying device 51 is continuously conveyed in the direction shown by the arrow to pass through the molten Al plating bath 1, and then withdrawn upward in the vertical direction from the bath surface 10 to pass through a gas phase space 8, which is partitioned from the atmospheric environment 2 with a shield 4. The shield 4 has in an upper part thereof an opening 7, through which the steel wire 3 passes. The plated metal on the surface of the steel wire is solidified through the process of withdrawing to provide a molten Al plated steel wire, which is wound by a winding device 52.

(17) FIG. 6 schematically shows the state of the position on the bath surface, at which the steel wire 3 having passed through the molten Al plating bath 1 is withdrawn in the vertical direction from the bath surface 10. The plating bath 1 is raised along with the steel wire 3, whereby a meniscus 70 is formed around the steel wire 3, and in the portion apart from the meniscus 70, the height of the bath surface 10 is retained substantially horizontally. The height is referred to as an average bath surface height. The position on the bath surface, at which the steel wire 3 is withdrawn, is referred to as a plating bath rising portion (5).

(18) In the gas phase space 8 inside the shield 4, a nozzle 61 for blowing an inert gas to the position on the bath surface, at which the steel wire 3 is withdrawn, (i.e., the plating bath rising portion 5) is disposed. The inert gas is supplied to the nozzle 61 from an inert gas supplying device 57 via a pipe line 56. A gas flow rate controlling mechanism (which is not shown in the figure) is provided in the course of the pipe line 56 or inside the inert gas supplying device 57, with which the flow rate of the inert gas discharged from the nozzle 61 can be controlled. The nozzle 61 is adjusted in the inert gas discharge direction to prevent the inert gas discharge stream from the nozzle 61 from striking on the portion of the withdrawn steel wire at a height of 20 mm or more from the average bath height. Accordingly, the inert gas discharged from the nozzle 61 directly strikes a part of the plating bath surface 6 including the plating bath rising portion 5 and a part of the region of the steel wire 3 withdrawn from the plating bath rising portion 5 at a height of less than 20 mm from the average bath height, and thereby the oxygen concentrations in these parts are kept lower. The nozzle 61, the pipe line 56, the inert gas supplying device 57, and the gas flow rate controlling mechanism (which is not shown in the figure) constitute an inert gas supplying system. Examples of the inert gas include nitrogen gas, argon gas, and helium gas. In the gas phase space 8 inside the shield 4, a pipe line 63 having a discharge port 62 for introducing an oxygen-containing gas, and thereby the oxygen concentration inside the shield 4 is controlled depending on necessity.

(19) The steel wire 3 withdrawn through the gas phase space 8 inside the shield 4 is cooled during the process of withdrawing, and thereby the plated layer is solidified. In the withdrawing process, a cooling device 53 may be provided depending on necessity, with which the steel wire can be forcibly cooled by blowing gas or liquid mist. A heat treatment device may be inserted between the supplying device 51 and the plating bath 1. The heat treatment atmosphere used may be, for example, a reductive gas atmosphere (such as an H.sub.2N2 mixed gas). In the region from the heat treatment device to the position where the wire is immersed in the plating bath 1, a snout for shielding from the air may be provided in some cases. In the case where preliminary plating or wire drawing is performed as a preceding step, the equipment for the preceding step and the plating equipment may be disposed in series to constitute a continuous line.

(20) For uniformizing the depositing amount of the molten Al plating to satisfy the above expression (1) by using the equipment shown in FIG. 5, it is effective to employ, for example, such a measure that a contact member is disposed at the plating bath rising portion, and the withdrawn steel wire 3 is made in contact with the contact member.

(21) FIG. 7 schematically exemplifies the measure. A contact member 31 is provided to be in contact with the steel wire 3 withdrawn in the vertical direction from the plating bath rising portion 5. The contact part of the contact member 31 to the steel wire 3 may be constituted, for example, by a heat resistant cloth. By withdrawing the steel wire 3 while retaining the contact state with the contact member 31, microvibration of the steel wire 3 is suppressed, and thereby the molten Al plated steel wire with less wire diameter fluctuation satisfying the expression (1) can be produced.

(22) The material steel wire subjected to the molten Al plating may be a wire having preliminary plating, such as a Zn plated steel wire and an Ni plated steel wire, as described above. In the case where a naked steel wire having no preliminary plating is subjected to the molten Al plating, it is preferred that the steel wire is subjected to a reductive heat treatment, and then continuously charged in the molten Al plating bath without exposure to the air by passing through a snout. The steel core wire may also be a stainless steel wire depending on necessity, in addition to a steel types having been used as a Zn plated steel wire and an Ni plated steel wire. A stainless steel is an alloy steel containing Cr in an amount of 10% by mass or more. Examples thereof include the stainless steel types of an austenite series, a ferrite series, a martensite series and the like, defined in JIS G4309:2013. Specific examples thereof include a stainless steel where an austenite phase is said to be metastable, such as SUS301 and SUS304, a stable austenitic stainless steel, such as SUS305, SUS310, and SUS316, a ferritic stainless steel, such as SUS405, SUS410, SUS429, SUS430, SUS434, SUS436, SUS444, and SUS447, a martensitic stainless steel, such as SUS403, SUS410, SUS416, SUS420, SUS431, and SUS440, and also include a chromium-nickel-manganese based stainless steel classified into the SUS200 series, but the stainless steel is not limited thereto. The stainless steel that is applied to the core wire is preferably subjected to Ni plating as preliminary plating.

(23) The molten Al plating bath may have a Si content of from 0 to 12% by mass. In other words, a pure Al plating bath having no Si added may be used, and an Al plating bath containing Si in a range of 12% by mass or less may also be used. The addition of Si can suppress the growth of the brittle FeAl based alloy layer formed between the steel core wire and the Al plated layer. The addition of Si also lowers the melting point to facilitate the production. However, the increase of the Si content may deteriorate the workability of the Al plated layer itself, and also may lead reduction of the conductivity. Accordingly, in the case where Si is contained in the Al plating bath 1, the content thereof is preferably in a range of 12% by mass or less. The bath may unavoidably have impurity elements, such as Fe, Cr, Ni, Zn, and Cu, mixed therein in some cases.

(24) The depositing amount of the Al plating is preferably from 5 to 50 m in terms of the average thickness of the molten Al plated layer in the longitudinal direction. When the depositing amount of the Al plating is too small, there is a possibility that the steel base is exposed in the stranding process and a subsequent crimping process or the like, which may be a cause of deterioration of the corrosion resistance. When the depositing amount of the Al plating is excessive, on the other hand, the proportion of the steel core wire in the cross section is relatively lowered, and the strength per unit wire diameter may be lowered.

EXAMPLE

(25) A molten Al plated steel wire was produced by using a production equipment of a molten Al plated steel wire having the structure shown in FIG. 5. The gas phase space, through which the steel wire was withdrawn from the bath surface, was partitioned with the shield, and the oxygen concentration in the gas phase space was made to be 0.1% by volume or less. Production examples where the contact member (see FIG. 7) was provided at the plating bath rising portion, and the steel wire was withdrawn while making into contact with the contact member, and production examples where the steel wire was withdrawn from the bath surface without the use of the contact member were performed. The contact member used contained a stainless steel square bar having a heat resistant cloth wound on the surface thereof. The square bar of the contact member was fixed to the bath tank. The Al plating bath was a pure Al bath or an AlSi bath having Si added thereto.

(26) The material steel wires subjected to the molten Al plating were a Zn plated steel wire, an Ni plated steel wire, and a naked steel wire, each containing a hard drawn steel wire according to JIS G3560 as the core material. Among these, the Zn plated steel wire was obtained by subjecting a molten Zn plated hard drawn steel wire having a diameter of 1.0 mm to a wire drawing process to make the prescribed diameter. The Ni plated steel wire and the naked steel wire were also adjusted to have the prescribed diameter by a wire drawing process. The thickness of the Zn plating or Ni plating (preliminary plating) of the material core wire can be found by (outer diameter D.sub.1 of material core wirediameter D.sub.0 of steel core wire)/2.

(27) The resulting molten Al plated steel wires were measured for the breaking number of torsion by the aforementioned method (chuck distance: 100 mm, load: 50 g) with the torsional test equipment shown in FIG. 3. The results are shown in Table 1. The relationship between (D.sub.AD.sub.MIN)/D.sub.A and the breaking number of torsion is shown in FIG. 4.

(28) For the diameters of the resulting molten Al plated steel wires, as described above, the average diameter D.sub.A was a value based on the measurement data of the entire length of approximately from 100 to 8,000 m of the molten Al plated steel wire, and the minimum diameter D.sub.MIN was a value based on the measurement data of the chuck distance of 100 mm of the wire material that was actually subjected to the torsional test.

(29) TABLE-US-00001 TABLE 1 Material steel wire Steel core Resulting Al plated steel wire Al plating bath wire Outer Average Minimum Bath Kind of diameter diameter Use of diameter diameter Breaking temperature preliminary D.sub.0 D.sub.1 Reductive contact D.sub.A D.sub.MIN (D.sub.A-D.sub.MIN)/ number of No. Composition ( C.) plating (mm) (mm) treatment member (mm) (mm) D.sub.A torsion Class 1 Al 700 Zn 0.067 0.07 no no 0.080 0.070 0.125 18 comparison 2 Al 700 Zn 0.067 0.07 no yes 0.080 0.075 0.063 139 invention 3 Al 700 Zn 0.097 0.10 no no 0.117 0.097 0.171 5 comparison 4 Al 700 Zn 0.097 0.10 no no 0.117 0.101 0.137 9 comparison 5 Al 700 Zn 0.097 0.10 no no 0.117 0.105 0.103 48 comparison 6 Al 700 Zn 0.097 0.10 no yes 0.117 0.108 0.077 101 invention 7 Al 700 Zn 0.097 0.10 no yes 0.117 0.110 0.060 154 invention 8 Al 700 Zn 0.097 0.10 no yes 0.117 0.115 0.017 294 invention 9 Al-4% Si 685 Zn 0.097 0.10 no no 0.115 0.102 0.113 29 comparison 10 Al-4% Si 685 Zn 0.097 0.10 no yes 0.115 0.104 0.096 75 invention 11 Al-11% Si 660 Zn 0.097 0.10 no no 0.116 0.100 0.138 8 comparison 12 Al-11% Si 660 Zn 0.097 0.10 no yes 0.116 0.105 0.095 60 invention 13 Al-11% Si 660 Zn 0.097 0.10 no yes 0.116 0.109 0.060 183 invention 14 Al 700 Zn 0.196 0.20 no no 0.233 0.198 0.150 5 comparison 15 Al 700 Zn 0.196 0.20 no no 0.233 0.201 0.137 12 comparison 16 Al 700 Zn 0.196 0.20 no no 0.233 0.207 0.112 39 comparison 17 Al 700 Zn 0.196 0.20 no yes 0.233 0.212 0.090 58 invention 18 Al 700 Zn 0.196 0.20 no Yes 0.233 0.219 0.060 99 invention 19 Al 700 Zn 0.196 0.20 no yes 0.233 0.218 0.064 109 invention 20 Al 700 no 0.20 0.20 yes no 0.230 0.205 0.109 45 comparison 21 Al 700 no 0.20 0.20 yes yes 0.230 0.220 0.043 168 invention 22 Al 700 Ni 0.196 0.20 no no 0.228 0.204 0.105 46 comparison 23 Al 700 Ni 0.196 0.20 no yes 0.215 0.205 0.047 148 invention 24 Al 700 Ni 0.196 0.20 no yes 0.227 0.217 0.044 151 invention 25 Al 700 Ni 0.196 0.20 yes yes 0.240 0.218 0.092 70 invention 26 Al 700 Zn 0.294 0.30 no no 0.350 0.298 0.149 3 comparison 27 Al 700 Zn 0.294 0.30 no no 0.350 0.310 0.114 38 comparison 28 Al 700 Zn 0.294 0.30 no yes 0.350 0.318 0.091 68 invention 29 Al 700 Zn 0.294 0.30 no yes 0.350 0.320 0.086 81 invention 30 Al 700 Zn 0.49 0.50 no no 0.580 0.500 0.138 10 comparison 31 Al 700 Zn 0.49 0.50 no yes 0.580 0.530 0.086 71 invention

(30) It was understood from Table 1 that in the case where the steel wire was withdrawn from the bath surface without the use of the contact member, the uniformization of the depositing amount of the molten plating satisfying the expression (1) was not realized. As a result, the torsional resistance was deteriorated.

(31) On the other hand, in the examples of the invention using the contact member, the depositing amount of the molten Al plating was uniformized to satisfy the expression (1). The examples exhibited a breaking number of torsion exceeding 50, and thus evaluated to have torsional resistance capable of resisting to a stranding process with torsion applied thereto in a state untouched after the molten Al plating.

REFERENCE SIGN LIST

(32) 1 molten Al plating bath 2 atmospheric environment 3 steel wire 4 shield 5 plating bath rising portion 6 bath surface portion inside shield 7 opening 8 gas phase space 10 bath surface 21 core element wire 22 peripheral element wire 23, 24 supplying bobbin 25 rotating disk 30 strand wire 31 contact member 41a, 41b chuck 42 wire material specimen 43 weight 50 plating bath tank 51 supplying device 52 winding device 53 cooling device 56 inert gas supplying pipe 57 inert gas supplying device 58 reel 61 inert gas discharge nozzle 62 oxygen-containing gas discharge port 63 oxygen-containing gas supplying pipe 64 oxygen-containing gas supplying device