钴对含硅钢镀锌层的组织和生长动力学的影响

利用扫描电镜及波谱,研究锌浴中的钴对Q235和Q345钢热浸镀锌层组织及其生长动力学的影响.结果表明:锌浴中含0.075%(质量分数)钴时,能完全抑制Q235镀层组织发生硅反应性;而对于Q345,则需要在锌浴中加入0.3%钴才能部分抑制硅反应性;在锌浴中加入少量的钴后,镀层组织中疏松ζ层转变成与液相直接接触的富钴ζ相和由消耗δ相生成的致密ζ相;致密的ζ相层阻止液相和δ相的直接接触;富钴ζ相可容纳大约0.25% Si,避免在固-液界面产生硅的富集,液相通道消失,从而抑制含硅钢热浸镀锌过程中硅反应性的产生.     

低碳钢表面热浸镀锌层的组织

利用传统的溶剂工艺在低碳钢表面热浸镀锌。采用X射线衍射仪和扫描电镜研究了低碳钢热浸镀锌层的显微组织及相组成。结果表明,热浸镀锌层的组织由基体向表面依次为Γ(Fe5Zn21)相、1δ(FeZn7)相、ζ(FeZn13)相和η(Zn)相;镀层最表层出现异常的Γ相,而1δ相合金层存在η相;与基体结合处的Γ相呈白亮的线状,靠近表面则呈齿状;镀层不同部位的块状1δ相的致密度不同,远离基体处比较疏松;棒状ζ相分散在η相中。     

低碳钢在锌液中的界面反应动力学及机理研究

研究了低碳钢短时间浸入锌液后铁、锌之间的反应过程。结果表明,低碳钢与锌液的反应层产物主要包括靠近内侧呈柱状晶生长的紧凑、致密δ-Fe Zn10相和外侧较为疏松的ζ-Fe Zn13相,稳定生长阶段疏松的ζ-Fe Zn13相生长占据主导地位。铁、锌的反应产物生长过程符合抛物线生长规律,生长初期主要受界面反应控制,而在稳定生长阶段,主要受液锌原子扩散控制。铁、锌产物层从钢基体到表面依次为过饱和α-Fe、Γ1-Fe5Zn21、δ-Fe Zn10、ζ-Fe Zn13和表层的η-Zn。     

扩散处理工艺对镀锌层组织和性能的影响

研究了扩散处理工艺对要进行热冲压成形的钢板含0.17%Al(质量分数)的镀锌层组织和性能的影响。结果表明,随着扩散处理温度的提高和保温时间的延长,镀锌层组织和性能发生了明显的变化,在520℃扩散处理20 s后镀锌层表面的ζ相消失。随着扩散处理温度的升高,镀锌层与钢基体界面处的Γ相增厚,在500~520℃时增厚尤为明显。当镀层由ζ相和疏松的δ相或者由疏松的δ相和Γ相构成时,镀层塑性较好。而致密的δ相会明显降低镀层的塑性。     

对锌淬高强度螺栓镀锌层组织形成的探讨

探讨了锌淬时镀锌层组织形成的过程,结果表明:在锌淬过程中依次形成Fe-Al相、δ_1相、ζ相和η相。由于锌淬时较一般热镀锌时钢件入锌浴的温度高,有利于形成Fe-Al化合物,增加合金层的铝含量,因而提高了镀锌层的粘附力。     

铁锰二元合金耐液锌腐蚀机理

研究了四种不同Mn含量的铁锰二元合金在450℃液锌中的腐蚀行为,探讨了Mn对铁锌反应的影响规律。结果表明,铁锰二元合金在液锌中的腐蚀属于溶解性腐蚀。随着锰含量的增加,腐蚀速率有较大变化。含锰量为10wt%的合金,其腐蚀速率为5.79×10-3g.cm-2.h-1,含锰量为15wt%的合金,其腐蚀速率为3.64×10-2.gcm-2.h-1。锰含量为10wt%时,腐蚀产物由致密的δ相层和块状的ζ相层组成,致密的较厚的δ相层的存在,降低了铁锌反应速率,合金表现出较好的耐液锌腐蚀能力,而锰含量为15wt%时,腐蚀产物由大量疏松的颗粒状ζ相分布在液锌相中组成,疏松的组织恶化了合金的耐液锌腐蚀能力。     

合金化时间对热镀锌IF钢板镀层相结构的影响

通过模拟合金化镀锌试验,研究了IF钢合金化镀层结构随着合金化时间的演变规律。结果表明:在520℃合金化时,随着合金化时间的延长,镀层中铁含量快速增加,而当铁含量超过12%时,增长缓慢。合金化7 s时,镀层从表面到基板依次是纯锌η相、柱状ζ相(Fe Zn13)以及栅状δ1P相;随着时间增加,基体Fe继续向镀层扩散,纯锌η相、柱状ζ相消失,栅状δ1P相逐渐转变为致密的δ1k相,同时在基板处生产了齿状的Γ相,在合金化17 s后,镀层相结构最终稳定为δ1k相和基板处少量的Γ相。     

组织及相结构对GA板镀层成形性的影响

采用扫描电镜、X射线衍射法,辉光放电光谱法(GDOES)及60°V弯试验研究了工业大生产条件下的铝镇静钢(AK)、IF钢及高强IF钢(HSIF)合金化镀锌(GA)板镀层微观组织、相结构及其成形性能。结果表明,三种GA板镀层中均主要含δ相,占90%以上;AK和IF钢镀层表面相似,均为致密的δ相及少量ζ相,而HSIF钢镀层表面为致密的δ相,不含ζ相;AK和IF钢镀层中Fe含量基本相当,HSIF钢镀层中Fe含量最高;当镀层表面为δ相和少量的ζ相时其抗粉化性能较好,而只含有δ相时其抗粉化性能较差。     

电脉冲处理对热镀锌镀层组织和生长的影响

研究了电脉冲处理对热镀锌镀层组织和生长影响。采用冷轧钢板在460℃条件下得到不同电脉冲处理参数不同浸镀时间的镀层组织,结果表明,未经电脉冲处理试样铁锌互扩散较快,δ相和ζ相同时生长,且随时间延长ζ相呈起伏式生长,合金层的组织变得不连续且存在疏松。电脉冲处理后试样合金层的生长均受到抑制,生长比较稳定。在180 s浸镀时间内,δ相层的组织晶粒度均匀致密,ζ相的连绵式生长消失,与δ相和η相相界面变得非常连续,厚度明显减薄,由83.5μm减薄到70μm以内。经电脉冲处理后,合金层的生长由扩散和界面反应联合控制转变为仅受扩散控制。     

渗碳时间对TC4钛合金显微组织和强化效果的影响

研究了渗碳工艺对TC4钛合金表面渗碳层组织、组成相及强化效果的影响,特别对不同的渗碳时间对渗碳层厚度、微观组织、相组成及其形成机理进行了深入的探究。结果表明:钛合金表面经渗碳后均形成Ti C陶瓷层+扩散层。表面呈众多胞状结构、小沟槽及纳米微孔的形貌特征,微观组织为众多取向各异、亚微米级的Ti C相晶粒。随着渗碳时间的延长,渗碳层厚度明显增加,经3h渗碳后能获得均匀且致密的Ti C陶瓷层。Ti C陶瓷层硬度高达1195 HV0.2,可有效提高钛合金的表面硬度和耐磨性。     

Mathematical modeling and numerical simulation of layer growth and phase transformation during galvannealing process

In the galvannealing process, a galvanized sheet is given an annealing treatment to transform the zinc coating to the Zn–Fe intermetallic coating through diffusional reactions. In the present work, a mathematical model for predicting the growth of ζ (zeta), δ (delta), and Γ (gamma) during the galvannealing process has been developed by using fundamental diffusion data. The primary diffusion mechanism is the movement of zinc through the multiphase of the Zn–Fe intermetallics. The values of iron content in the coating were predicted and compared to the data obtained from experimental studies. With the increase of galvannealing temperature, the growth rate of the δ phase increases, while the growth rate of the ζ phase decreases. At the same iron content in the coating, the thickness of the Γ phase layer is thicker at a higher temperature. The new type of galvannealing process of first high annealing temperature and then low annealing temperature is validated as a better galvannealing process, which should be a range of practical application. The simulated results agree well with experimental observations, and the model can be utilized to optimize the galvannealing parameters.     

Effects of zinc bath temperature on the coatings of hot-dip galvanizing

The purpose of this work is to identify the influence of zinc bath temperature on the morphology and the thickness of hot-dip galvanizing coating. Hot-dip galvanizing samples were prepared at temperatures in the range of 450-530 °C in steps of 10 °C and at different immersing time. The samples were characterized by using scanning electron microscopy/energy dispersive X-ray analysis. When the galvanizing temperature ranges from 450 to 470 °C, the coating has a coherent and compact ζ layer on the top of a δ layer. ζ phase coexists with liquid zinc pocket around 480 °C. It was found that the coating thickness reaches maximum at 480 °C. When the temperature is above 500 °C, the coating changes to be primarily δ phase.     

Crack initiation and propagation of galvanized coatings hot-dipped at 450 °C under bending loads

Crack initiation and propagation behaviors in the intermetallic layers of galvanized coatings subjected to bending loads are characterized and numerically simulated. Coating structure of galvanized steel prepared by hot dipping at 450 °C is a laminate composite consisting of δ, ζ, and η phases, with an infinitesimal layer between the coating and steel article speculatively representing a Γ phase. The specimens were deformed in a four-point bending configuration, and the evolution of cracks was investigated as a function of bending angles. Through-cracks were found to develop in the δ layer of the coatings after thermal cooling due to thermal stresses and propagate toward the outer surface under increments of bending loads. Finite element simulations of galvanized steels were subsequently developed with an initial crack tip located in the δ layer to determine the controlling parameters of the crack propagation and to assess the coatings' fracture parameter, critical far field stress, and stress distributions. The analysis highlights the enhancement of fracture resistance of the galvanized coatings owing to the presence of the ζ layer.     

INFLUENCE OF SILICON IN STEELS ON GALVANIZED COATINGS

After steel sheets （0.37wt%Si） pre-electroplated with a thin layer of pure Fe were immersed in molten zinc for various time, the change in the microstructure of the galvanized coating on the steel and the change of α-Fe/Г interface were studied. The EDS （energy dispersive sepectroscopy） resuits show that excessive silicon accumulates on the surface of the steel substrate due to the low solubility of silicon in the Г layer after the Fe layer is depleted by the increasing growth of the compound layers. With the movement of α-Fe/Г interface towards the substrate by the Fe/Zn reaction, silicon-rich α-Fe peels off from the substrate and breaks into particles. The particles, much like an inert marker in a Kirkendall effect experiment, move towards the δ layer through the Г layer because silicon-rich α-Fe can not be adsorbed in the Г layer. On reaching the 8/F interface, the particles quickly dissolve in the δ layer, and accelerate its growth, resulting in the gradual disappearance of the Г layer. At the same time, the normal coating is quickly changed into coatings typical of reactive steels as silicon dissolved in the δ layer soon diffuses toward the ζ layer. A similar process may happen in the initial stage of galvanizing reactive steels on a small scale, although it is hard to be observed.     

GH738合金表面Al-Si渗层的制备及其抗氧化行为

采用热扩散法在GH738合金表面制备出Al-Si渗层。通过X射线衍射仪(XRD),扫描电镜(SEM),能谱仪(EDS)分析了Al-Si渗层形貌、厚度、物相组成和元素分布;采用显微维氏硬度计测定了渗层的硬度;采用静态增量试验方法,在1200℃,对Al-Si渗层试样和GH738镍基合金基体进行了100 h的恒温抗氧化性能测试。结果表明,Al-Si渗层厚度可达120μm,渗层为明显的双层结构,外层为Al-Si层,内层为互扩散层;渗层物相组成主要为NiAl和Ni₂Al₃以及少量Cr₃Si;渗层表面硬度达到900 HV0.1左右,约为基体的3.5倍;Al-Si渗层氧化动力学曲线满足抛物线规律,氧化速率常数为0.0987 mg²·cm^-4·h^-1,表面形成比较致密的Al₂O₃保护膜,其高温抗氧化性能较基体提高了约5倍。     

Mg含量对热浸镀Al-Zn-Mg-Si镀层组织及性能的影响

为了提高冷轧镀铝锌钢板表面晶花质量,在连续热浸镀生产线制备了4种不同成分的Al-Zn-Mg-Si镀层样板,采用体视显微镜、扫描电镜、电子探针、X射线衍射仪和电子背散射衍射等方法,研究了Mg含量对镀层凝固组织和耐腐蚀性能的影响。结果表明:随Mg含量的增加,镀层晶花尺寸先减小后增大,耐腐蚀性先降低后增高;在Mg质量分数为1.0%时,镀层质量最佳,晶花细小均匀,平均晶粒尺寸为1.2 mm,镀层截面组织中含质量分数为68.3%的富铝相、质量分数为26.1%的富锌相、少量富硅相和富镁相,在60 d内的平均失重速率为0.05 g/(m²·d)。     

镀锌钢在红沿河大气环境中的腐蚀行为

目的研究镀锌钢在红沿河地区SO2和Cl-含量较高的大气环境中的腐蚀行为与机理。方法根据GB/T 6464—1997将制备好的试样在红沿河核电厂进行现场暴晒试验,分别暴晒4、12、18、24个月后取回试样。利用失重分析、X射线衍射(XRD)和扫描电镜(SEM)等技术,观察与分析试样暴晒后的腐蚀产物。结果镀锌钢腐蚀失重随暴晒时间的延长而线性增加;随着暴晒时间的延长,锌镀层表面形成的腐蚀产物成分变化不大,以Zn12(SO4)3Cl3(OH)15·5H2O和6Zn(OH)2·Zn SO4·4H2O为主;腐蚀产物随暴晒时间的延长逐渐增加,产物形貌略有变化,以球状和针状为主。暴晒18个月后,腐蚀产物分为双两层,内层致密,外层疏松;暴晒24个月后,腐蚀产物厚度稍有增加,疏松层向致密层转变。结论 SO2与Cl-是镀锌钢在红沿河地区的大气腐蚀过程的主要影响因子。镀锌钢表面形成的腐蚀产物对锌镀层的保护作用较差。     

CLAM钢表面铝化物涂层的制备与铅液相容性研究

目的探索铝化物涂层的制备工艺,研究其是否能有效抑制铅液对CLAM钢的腐蚀。方法用配制的渗剂对CLAM钢进行包埋渗铝,并通过随后的热扩散和原位氧化处理,在CLAM钢表面制备铝化物涂层,研究不同渗铝时间和热扩散时间对涂层厚度的影响。通过静态氧化试验和铅液腐蚀试验,分别评价铝化物涂层的抗氧化性能及其与铅液的相容性,采用XRD、SEM和EPMA分析涂层的相组成以及铅液腐蚀前后的微观形貌和元素分布。结果包埋渗铝+热扩散+原位氧化处理制备的铝化物涂层主要由约30μm的FeAl相层和约70μm的α-Fe(Al)固溶体层组成。在热处理过程中,由于Al和Fe的互扩散现象,涂层中的Fe-Al相依次经过了Fe₂Al₅、FeAl₂、FeAl、Fe₃Al和α-Fe(Al)的转变。在600℃空气中静态氧化120 h后,铝化物涂层试样氧化质量增量为0.028 mg/cm²,比CLAM钢的氧化质量增量降低了1个数量级,铝化物涂层使CLAM钢的氧化动力学曲线由直线规律转变为抛物线规律。经550℃铅液腐蚀600、1800 h后,铝化物涂层的腐蚀质量增量分别为0.058、0.077 mg/cm²,仅约为CLAM钢的1/120。CLAM钢表面产生了疏松多孔的铁氧化物层,而铝化物涂层没有发生明显的腐蚀,但是腐蚀1800 h后,随着表面铝含量的不断消耗,Al₂O₃层厚度逐渐减小。结论铝化物涂层具有良好的抗氧化性能及与铅液的相容性,能够有效抑制铅液对CLAM钢的腐蚀。