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A Comparative Study of the 0.05Al Process

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

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A Comparative Study of the 0.05Al Process

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  1. A Comparative Study of the 0.05Al Process October 2, 2012

  2. 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

  3. Parts • Steel Parts (2982 kg in total) • 0.04% - 0.28% Effective Si

  4. Baths, Centrifuge and Products • Baths (2400 kg each) • Bath A: 0.039%Al • Bath B: 0.051%Al • Bath H: 0.005%Al

  5. Pretreatments Degrease 20 minutes Pickle 20 minutes Rinse 1 minute Dry 120ºC 15 minutes Flux 1 minute

  6. Coating Thickness (4 minutes) 450ºC (842ºF), 4 minutes

  7. Coating Thickness (Prior Study) 440ºC (824ºF), 8 minutes

  8. Coating Thickness (10 minutes) 450ºC (842ºF), 10 minutes

  9. Coating Adhesion (Part e3) Bath H, 4 min Bath B, 4 min Bath B, 10 min Bath A, 4 min

  10. Microstructure (Part e3, 0.21%Si) Bath H, 4 min Bath B, 4 min Bath A, 4 min Bath B, 10 min

  11. Flaked-off Coating Bath H, 4 min Bath H, 4 min ζ Bath A, 4 min Bath B, 10 min δ

  12. Coating Adhesion (Part a) Bath H, 4 min Bath A, 4 min Bath B, 10 min

  13. Microstructure (Part a, 0.24%Si) Bath H, 4 min Bath A, 4 min Bath B, 10 min

  14. Zinc Consumption

  15. Drainage (Part k) The amount of accumulation at the bottom of Part k: 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.

  16. White Rust Test H08 B132

  17. 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

  18. Questions? • Thank you for your attention!

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