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The Metallurgy of Zinc Coated Steels

1st Edition - February 22, 2023

Authors: Arnold Marder, Frank Goodwin

Paperback ISBN:

9 7 8 - 0 - 3 2 3 - 9 9 9 8 4 - 7

eBook ISBN:

9 7 8 - 0 - 3 2 3 - 9 8 4 8 9 - 8

The Metallurgy of Zinc Coated Steels provides a comprehensive overview of the science and engineering of zinc coatings. Beginning with a look at new innovations made in the… Read more

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The Metallurgy of Zinc Coated Steels provides a comprehensive overview of the science and engineering of zinc coatings. Beginning with a look at new innovations made in the hot-dip coating methods (CGL), the book goes on to discuss phase equilibria, Zn bath phenomena and overlay coating formations. Both processing methods and controls are covered, as well as corrosion resistance and coating product properties. The book concludes with a discussion of future opportunities for zinc coatings. This book is a vital resource for both individuals new to this area while also serving as a handbook for users and producers of zinc coatings.

Cover
Title page
Table of Contents
Copyright
Dedication
Foreword
Preface
Acknowledgments
Introduction
Reference
Chapter 1: History of zinc-coated steel
Abstract
1.1: Zinc
1.2: In the beginning
1.3: Zinc coating processing
1.4: Zinc coating alloy development
A: Appendix
References
Chapter 2: Hot-dip coating methods: Continuous processing (CGL)
Abstract
2.1: History and overview
2.2: Cleaning
2.3: Steel types for continuous galvanizing
2.4: Galvanizing pretreatment steps for AHSS
2.5: Overaging in the CGL
2.6: Metallic coating pretreatments
2.7: Galvanizing of hot rolled strip
2.8: Furnace temperature control
2.9: CGL rapid cooling section developments
2.10: Strip entry snout control
2.11: Alloy coating developments
2.12: Zinc coating wetting behavior during galvanizing
2.13: Phase transformations after zinc coating
2.14: Coating solidification developments
2.15: Temper rolling and tension leveling
2.16: Passivation and lubrication treatments
2.17: Improvements in inspection practice
References
Chapter 3: Zn coating phase equilibria
Abstract
3.1: The formation of a Zn coating
3.2: Zn-based coating systems
3.3: Equilibrium phase diagrams
References
Chapter 4: Zinc bath phenomena
Abstract
4.1: Introduction
4.2: Typical continuous galvanizing bath characteristics
4.3: Fluid flow and temperature patterns in the galvanizing bath
4.4: Bath chemistry
4.5: Effect of bath geometry and operating variables on dross production
4.6: Dross precipitation and dissolution
4.7: Bath management during transitions between galvanneal and galvanize (GA → GI), galvanize and galvanneal (GI → GA)
4.8: Entry snout phenomena and control of coating quality
4.9: Galvanizing bath top skimmings and bottom dross removal
4.10: The metallurgy of galvanizing bath hardware
4.11: Production of exposed quality GI
4.12: Summary of effects of bath Al composition
References
Further reading
Chapter 5: Interface reactions
Abstract
5.1: Introduction
5.2: The hot-dip process review
5.3: Interface reactions
5.4: Wettability
5.5: Interface response
5.6: Composition effects on interface reactions
5.7: Kinetics of the interfacial reaction
5.8: Summary
References
Chapter 6: Overlay coating formation
Abstract
6.1: Introduction
6.2: Phase equilibria
6.3: Galvanized (GI) coatings (< 1 wt% Al)
6.4: Coatings with Al (5–55 wt% Al)
6.5: Coatings with Al and Mg
6.6: Substrate alloy additions
References
Chapter 7: Hot-dip galvanized coating weight control
Abstract
7.1: Introduction
7.2: Liquid metal properties affecting coating control
7.3: History of development of coating controls
7.4: Development of process models and operation correlations: Steady-state models
7.5: Gas knife designs affecting coating control
7.6: Factors affecting coating weight variability
7.7: Splashing and the limit to line speed
7.8: Production of thick coating weights on heavy gauge cold and hot rolled steels
7.9: Strip roughness effects
7.10: Coating weight measurement and online control
7.11: Nitrogen gas wiping
7.12: Other technical considerations
7.13: Coating weight standards
A: Appendix
References
Chapter 8: Galvannealing
Abstract
8.1: Introduction—History
8.2: Galvanneal processing
8.3: Phase equilibria
8.4: Diffusion
8.5: Kinetics
8.6: Galvanneal microstructure
8.7: Substrate steel chemistry
References
Chapter 9: Electrogalvanizing processes (EG coatings)
Abstract
9.1: Introduction
9.2: Processing methods
9.3: Zn-M coatings and phase formation
9.4: Electrodeposited nanocrystalline Zn coatings
9.5: Summary of ED processing
References
Chapter 10: Physical vapor deposited coatings
Abstract
10.1: Introduction
10.2: PVD properties of zinc
10.3: PVD process basics
10.4: Electron beam vaporization and deposition
10.5: Jet vapor deposition (JVD)
10.6: Performance of vapor deposited coated steels
10.7: Summary
References
Chapter 11: Corrosion behavior
Abstract
11.1: Introduction
11.2: The nature of the surface of zinc and zinc alloy coated sheet steel and initial reactions with the environment
11.3: Corrosion mechanisms and coating microstructure
11.4: Galvanic corrosion and cut edge protection
11.5: Corrosion behavior in atmospheric exposures
11.6: Corrosion in automobile environments
11.7: Corrosion of galvanized press-hardened steels
11.8: Corrosion and hydrogen uptake in the steel
11.9: White rust (storage stain)
References
Chapter 12: Zn-coated steel product properties
Abstract
12.1: Corrosion performance of painted Zn and Zn alloy coated sheet
12.2: Formability of zinc-coated sheet steels
12.3: Joining zinc-coated steels
References
Chapter 13: Zn-coated high-strength steel
Abstract
13.1: High-temperature Zn-coated steel processing
13.2: Zn coating formation
13.3: Hot press forming of Zn-coated steel
References
Chapter 14: Defect identification and remediation in zinc coated steel sheet
Abstract
14.1: Introduction
14.2: Defects related to strip processing
14.3: Defects relating to chemical cleaning
14.4: Defects related to annealing furnace
14.5: Defects related to the snout, zinc bath condition, and bath hardware
14.6: Wiping related defects
14.7: Temper mill related defects
14.8: Galvanneal-specific defects
14.9: Delivery end and other defects
14.10: Defect modeling and control
14.11: Effect of automotive paint systems on zinc coating appearance
References
Chapter 15: General galvanizing
Abstract
15.1: Introduction
15.2: General galvanizing pretreatment steps
15.3: Hot-dip coating with zinc and zinc alloys
15.4: Hydrogen effects in general galvanized articles
15.5: Management of general galvanizing baths
References
Further reading
Chapter 16: New opportunities
Abstract
16.1: Introduction
16.2: Environmental performance
16.3: Process integration and quality assurance—“Industry 4.0”
16.4: Emerging generations of Zn-coated steels
16.5: Extending capabilities of existing coating processes
16.6: New coating processes
16.7: New performance capabilities for zinc-coated steel
References
Index