Metal-coated steel strip

Abstract

An AlZnSiMg alloy coated strip that has Mg.sub.2Si phase particles that are 2 m and have a globular shape. A method of forming an AlZnSiMg alloy coated strip comprises (a) heat treating a solidified coating to facilitate globularisation of Mg.sub.2Si phase particles in the coating and/or (b) changing the coating bath chemistry to form intermetallic compound phases that act as nucleation sites for Mg.sub.2Si phase particles with the result that small Mg.sub.2Si particles form on solidification of the coating.

Claims

1. A method of forming a steel coated strip that comprises: (a) passing the strip through a hot dip coating bath that contains Al, Zn, Si, and Mg and optionally other elements and forming a molten AlZnSiMg alloy coating of 3-30 m in thickness on the strip, wherein the AlZnSiMg alloy coating comprises 40-60% by weight Al, 40-60% by weight Zn, 0.3-3% by weight Si, 0.3-10% by weight Mg; (b) solidifying the molten AlZnSiMg alloy on the strip to form a solidified coating by a cooling step consisting of cooling the coated strip only at a rate of at least 300 C./sec, the solidified coating having a microstructure that comprises alpha-Al phase dendrites, Zn-rich phases in interdendritic regions, and Mg.sub.2Si phase particles in interdendritic regions, with the Mg.sub.2Si phase particles being at least partially fragmented Mg.sub.2Si phase particles or being formed as fine Mg.sub.2Si phase particles in the first instance as a consequence of the cooling rate; (c) heat treating the coated strip in a furnace at a temperature of at least 300 C. and less than 600 C. and for a time less than 30 minutes and forming (i) an AlZn phase solid solution from the as-cast microstructure of alpha-Al phase dendrites and the Zn-rich interdendritic phases and (ii) globular-shaped Mg.sub.2Si phase particles dispersed in the AlZn phase solid solution, with the Mg.sub.2Si phase particles having a particle size of 2 m or less; and (d) water cooling the heat treated strip at a rate that minimizes growth of Mg.sub.2Si phase particles and at least substantially retains the globular Mg.sub.2Si phase particles that form in the heat treatment step (c).

2. The method defined in claim 1 wherein heat treatment step (c) is for at least 15 minutes.

3. The method defined in claim 1 wherein cooling step (b) comprises cooling the strip at a rate of at least 600 C./sec.

4. The method defined in claim 1 wherein coating step (a) comprises providing the hot dip coating bath with an element or a compound that can act as nucleation sites for Mg.sub.2Si particles.

5. The method of claim 1, wherein the heat treatment step (c) is at a temperature of 320-500 C.

Description

(1) The present invention provides an AlZnSiMg alloy coated strip that has Mg.sub.2Si phase particles dispersed in the coating having any one or more of the following features:

(2) (a) a particle size of 2 m, and

(3) (b) a more globular shape than the Chinese script particles described above.

(4) In addition, the present invention provides a method of forming such an AlZnSiMg alloy coated strip with Mg.sub.2Si phase particles dispersed in the coating that comprises:

(5) (a) heat treating a solidified coating to facilitate globularisation of Mg.sub.2Si phase particles in the coating, and/or

(6) (b) changing the coating bath chemistry to form intermetallic compound phases that act as nucleation sites for Mg.sub.2Si particles with the result that small Mg.sub.2Si particles form on solidification of the coating.

(7) According to the present invention there is provided a method of forming a metal coated strip, such as a steel strip, that comprises:

(8) (a) passing the strip through a hot dip coating bath that contains Al, Zn, Si, and Mg and optionally other elements and forming a molten AlZnSiMg alloy coating on the strip,

(9) (b) cooling the coated strip to solidify the molten AlZnSiMg alloy on the strip and form a solidified coating having a microstructure that comprises alpha-Al phase dendrites, Zn-rich phases in interdendritic regions, and Mg.sub.2Si phase particles in interdendritic regions; and

(10) (c) heat treating the coated strip at a temperature and for a time to form an AlZn phase solid solution from the as-cast microstructure of alpha-Al phase dendrites and the Zn-rich interdendritic phases and to facilitate globularisation of the Mg.sub.2Si phase particles that are dispersed in the coating; and

(11) (d) cooling the heat treated strip.

(12) Heat treatment step (c) may be at a temperature of at least 300 C.

(13) Heat treatment step (c) may be at a temperature of at least 350 C.

(14) Heat treatment step (c) may be at a temperature of at least 450 C.

(15) Heat treatment step (c) may be at a temperature of less than 600 C.

(16) Heat treatment step (c) may be for at least 15 minutes.

(17) Heat treatment step (c) may be for 15-30 minutes.

(18) Heat treatment step (c) may be for less than 30 minutes.

(19) Cooling step (b) may comprise cooling the strip at a rate that is sufficiently high to at least partially fragment Mg.sub.2Si phase particles to form fine particles or form fine Mg.sub.2Si phase particles in the first instance in the solidified coating.

(20) The fine Mg.sub.2Si particles may be less than 2 m in size.

(21) Cooling step (b) may comprise cooling the strip at a rate of at least 150 C./sec.

(22) The cooling rate may be at least 200 C./sec.

(23) The cooling rate may be at least 400 C./sec.

(24) The cooling rate may be at least 600 C./sec.

(25) Cooling step (b) may comprise cooling the strip with a water mist or a refrigerated gas.

(26) Cooling step (d) may comprise cooling the heat treated strip at a rate that minimises growth of Mg.sub.2Si phase particles and at least substantially retains the more globular Mg.sub.2Si phase particles that form in the heat treatment step (c).

(27) The coating may be 3-30 microns in thickness.

(28) Coating step (a) may comprise providing the hot dip coating bath with an element or a compound that can act as nucleation sites for Mg.sub.2Si particles.

(29) The other element may be antimony.

(30) The method may comprise forming a coating of a paint on the coated strip.

(31) According to the present invention there is also provided a method of forming a metal coated strip, such as a steel strip, that comprises:

(32) (a) passing the strip through a hot dip coating bath that contains Al, Zn, Si, and Mg, another element or elements or a compound or compounds that can act as nucleation sites for Mg.sub.2Si particles, and optionally other elements and forming a molten AlZnSiMg alloy coating on the strip,

(33) (b) cooling the coated strip to solidify the molten AlZnSiMg alloy on the strip and form a solidified coating having a microstructure that comprises alpha-Al phase dendrites, Zn-rich phases in interdendritic regions, and Mg.sub.2Si phase particles in interdendritic regions of the coating.

(34) The other element may be antimony.

(35) The Mg.sub.2Si particles may be less than 2 m.

(36) The Mg.sub.2Si particles may be a more globular shape and less Chinese script morphology with sharp edges.

(37) According to the present invention there is also provided a strip, such as a steel strip, that has a coating of an AlZnSiMg alloy on the strip that has a microstructure that comprises a solid solution of an AlZn phase and a dispersion of particles of Mg.sub.2Si phase in the coating, with the Mg.sub.2Si particles having:

(38) (a) a particle size of 2 m, and

(39) (b) a globular shape.

(40) The coating may have a thickness of 5-30 microns on at least one side of the strip.

(41) The coating microstructure produced by the present invention is advantageous in terms of improved coating ductility and enhanced corrosion resistance. Improved coating ductility.

(42) Fine, more globular Mg.sub.2Si particles than the Chinese script morphology with sharp edges described above reduces stress concentration in high strain fabrication and thus reduces the potential for crack initiation and propagation. Enhanced coating corrosion resistance.

(43) The modification of the Mg.sub.2Si phase to be fine, more globular particles than the Chinese script morphology with sharp edges described above reduces the potential for coating cracking. Greater dispersion of Mg.sub.2Si phase particles in the coating is also beneficial in terms of promoting uniform blocking and activation of corrosion channels. Consequently, there is enhanced corrosion resistance of the coating.

(44) The present invention is described further by way of example with reference to the accompanying Figure which is a schematic drawing of one embodiment of a continuous production line for producing steel strip coated an AlZnSiMg alloy in accordance with the method of the present invention.

(45) With reference to the Figure, in use, coils of cold rolled steel strip are uncoiled at an uncoiling station (not shown) and successive uncoiled lengths of strip are welded end to end by a welder (not shown) and form a continuous length of strip 3.

(46) The strip 3 is then passed successively through an accumulator (not shown), a strip cleaning section (not shown) and a furnace assembly 4. The furnace assembly 4 includes a preheater, a preheat reducing furnace, and a reducing furnace.

(47) The strip is heat treated in the furnace assembly 4 by careful control of process variables including: (i) the temperature profile in the furnaces, (ii) the reducing gas concentration in the furnaces, (iii) the gas flow rate through the furnaces, and (iv) strip residence time in the furnaces (ie line speed).

(48) The process variables in the furnace assembly 4 are controlled so that there is removal of iron oxide residues from the surface of the strip and removal of residual oils and iron fines from the surface of the strip.

(49) The heat treated strip is then passed via an outlet snout downwardly into and through a molten bath containing an AlZnSiMg alloy held in a coating pot 5 and is coated with AlZnSiMg alloy. The bath may contain one or more elements or compounds that promote the formation of intermetallic compound phases that act as nucleation sites for Mg.sub.2Si particles with the result that small Mg.sub.2Si particles form on solidification of the coating. Preferably the AlZnSiMg alloy is maintained molten in the coating pot by use of heating inductors (not shown). Within the bath the strip passes around a sink roll and is taken upwardly out of the bath. Both surfaces of the strip are coated with the aluminium-zinc-silicon alloy as it passes through the bath.

(50) After leaving the coating bath 5 the strip passes vertically through a gas wiping station 6 at which its coated surfaces are subjected to jets of wiping gas to control the thickness of the coating.

(51) The coated strip is then passed through a cooling section 7 and subjected to forced cooling. Preferably, the strip is cooled at a rate that is sufficiently high to at least partially fragment Mg.sub.2Si phase particles to form fine particles or form fine Mg.sub.2Si phase particles in the first instance in the solidified coating. Typically, this will mean cooling the strip at a rate of at least 300 C./sec.

(52) The cooled, coated strip, is then passed through a rolling section 8 that conditions the surface of the coated strip.

(53) Finally, the conditioned strip is passed through a heat treatment furnace 9 and heat treated in the furnace. Specifically, the strip is heat treated at a temperature in the range of 320-500 C. for 15-30 minutes to facilitate globularisation of the Mg.sub.2Si phase particles in the coating. The heat treated strip is then cooled, typically water-cooled, to maintain the Mg.sub.2Si phase particles as close as possible to the size and shape at the end of the heat treatment step.

(54) Many modifications may be made to the present invention as described above without departing from the spirit and scope of the invention.