Method for coating a metal strip

• US 5,667,849 A
• Filed: 02/20/1996
• Issued: 09/16/1997
• Est. Priority Date: 03/27/1992
• Status: Expired due to Term

• Current Assignee: Revere Copper Products, Inc.
• Original Assignee: The Louis Berkman Company
• Inventors: Zamanzadeh, Mehrooz, Carey, Jay F. II
• Primary Examiner(s): UTECH, BENJAMIN L
• Application Number:
  US08/604,074
• Time in Patent Office: 574 Days
• Field of Search: 427/431, 427/433, 427/436, 427/443.2
• US Class Current: 427/431
• CPC Class Codes: B32B 15/18 comprising iron or steel B32B15/011, B32B15/012 and B32B15/013 take precedence
• CPC Class Codes: C23C 2/0034 Details related to elements immersed in bath
• CPC Class Codes: C23C 2/00344 Means for moving substrates, e.g. immersed rollers or immersed bearings
• CPC Class Codes: C23C 2/0035 Means for continuously moving substrate through, into or out of the bath C23C2/00344 takes precedence
• CPC Class Codes: C23C 2/0036 Crucibles
• CPC Class Codes: C23C 2/0038 characterised by the pre-treatment chambers located immediately upstream of the bath or occurring locally before the dipping process
• CPC Class Codes: C23C 2/022 by heating
• CPC Class Codes: C23C 2/024 by cleaning or etching
• CPC Class Codes: C23C 2/026 Deposition of sublayers, e.g. adhesion layers or pre-applied alloying elements or corrosion protection
• CPC Class Codes: C23C 2/08 Tin or alloys based thereon
• CPC Class Codes: C23C 28/021 including at least one metal alloy layer
• CPC Class Codes: C23C 28/025 with at least one zinc-based layer
• CPC Class Codes: Y10S 428/939 Molten or fused coating
• CPC Class Codes: Y10T 428/12708 Sn-base component
• CPC Class Codes: Y10T 428/12715 Next to Group IB metal-base component
• CPC Class Codes: Y10T 428/12722 Next to Group VIII metal-base component
• CPC Class Codes: Y10T 428/12792 Zn-base component
• CPC Class Codes: Y10T 428/12799 Next to Fe-base component [e.g., galvanized]
• CPC Class Codes: Y10T 428/12806 Refractory [Group IVB, VB, or VIB] metal-base component
• CPC Class Codes: Y10T 428/12847 Cr-base component
• CPC Class Codes: Y10T 428/12854 : Next to Co-, Fe-, or Ni-base component
• CPC Class Codes: Y10T 428/12903 : Cu-base component
• CPC Class Codes: Y10T 428/1291 : Next to Co-, Cu-, or Ni-base component
• CPC Class Codes: Y10T 428/12979 : Containing more than 10% nonferrous elements [e.g., high alloy, stainless]

Abstract

A corrosion-resistant metal strip and method for making the same which is essentially lead free and is not highly reflective. The coating on the metal strip is a metallic coating comprised of tin and a very low weight percentage of lead. The coating alloy may also include antimony, bismuth, copper, zinc to improve the coating process and/or improve the properties of the tin coating. A metal layer may also applied to the surface of the metal strip prior to applying the metallic alloy coating.

Claims

1. A method of producing a coated metal strip having a corrosive-resistant alloy comprising the steps of:

a) selecting a metal strip formed of a given metal and having an exposed surface and a thickness of less than about 0.20 inch;

b) unrolling said metal strip from a coil of said metal strip;

c) hot dip coating said metal strip with corrosion-resistant alloy by continuously passing said strip in a longitudinal direction at a speed through a molten bath of said corrosion-resistant alloy, said molten bath having a temperature of at least about 449°

F., said speed of said metal strip controlled such that said metal strip has a residence time in said molten bath is about 0.08 to about 10 minutes to deposit a substantially uninterrupted layer of said corrosion-resistant alloy having a substantially uniform thickness of about 0.001 to about 0.05 inch onto the exposed surface of said metal strip and forming an intermetallic interface comprising an interface alloy constituting a heat created mixture of said given metal and said corrosion-resistant alloy and having a thickness of about 1 to about 10 microns, said corrosion-resistant alloy comprising at least about 90 weight percent tin and up to about 0.1 weight percent lead.

2. The method as defined in claim 1, wherein said alloy includes a metal additive selected from the group consisting of a metal stabilizer, a coloring agent, a corrosion-resistant agent and mixtures thereof, said metal stabilizer including at least an effective amount of metal selected from the group consisting of antimony, bismuth, copper and mixtures thereof for inhibiting crystallization of said tin, said corrosion-resistant agent including at least an effective amount of a metal selected from the group consisting of antimony, bismuth, copper, magnesium, nickel, titanium and mixtures thereof for enhancing the corrosion-resistant properties of said corrosion-resistant alloy coating and said coloring agent including at least an effective amount of copper for reducing the reflectivity of said corrosion-resistant alloy coating.

3. The method as defined in claim 1, including the step of pre-treating said metal strip to substantially remove oxides from said exposed surface of said metal prior to passing said metal strip through said molten bath.

4. The method as defined in claim 3, wherein said pre-treating step includes pickling said exposed surface of said metal strip, said pickling including the applying of an acid solution to said exposed surface of said metal strip, said acid solution including about 5 to about 25 percent by volume hydrochloric acid and about 1 to about 15 percent by volume nitric acid, and said acid solution having a solution temperature of about 80°

to about 140°

C.

5. The method as defined in claim 3, wherein pre-treating step includes chemically activating said metal strip with an oxidizing agent, said deoxidizing solution including about 5 to about 50 percent by volume zinc chloride and about 1 to about 15 percent by volume hydrochloric acid.

6. The method as defined in claim 3, wherein said pre-treatment step includes the minimizing of oxygen contact with said exposed surface of said metal strip until said metal strip is passed into said molten bath.

7. The method as defined in claim 1, wherein said given material is stainless steel.

8. The method as defined in claim 1, wherein said given material is copper.

9. The method as defined in claim 1, wherein said alloy comprises:

space="preserve" listing-type="tabular">______________________________________ Tin at least about 90% Aluminum 0.0-5% Antimony 0.0-7.5% Bismuth 0.0-1.7% Copper 0.0-5% Lead 0.0-0.5% Magnesium 0.0-5% Nickel 0.0-5% Titanium 0.0-1% Zinc 0.0-7% ______________________________________

10. The method as defined in claim 1, including the step of applying an intermediate metal layer to said exposed surface of said metal strip prior to passing said metal strip through said molten bath.

11. The method as defined in claim 10, wherein said intermediate layer is selected from the group consisting of tin, chromium, nickel or copper.

12. The method as defined in claim 10, including the step of pre-heating said intermediate metal layer prior to passing said strip through said molten alloy.

13. The method as defined in claim 1, including the step of controlling the coating thickness on said metal strip to about 0.0003 to about 0.2 inch as said metal strip exits said molten bath.

14. The method as defined in claim 1, including the step of exposing said intermetallic interface by removing said corrosion-resistant alloy coating.

15. The method as defined in claim 14, wherein said step of exposing includes the subjecting of said coated metal strip to an oxidizing solution.

16. The method as defined in claim 15, wherein said oxidizing solution includes about 5 to about 60 percent by volume nitric acid.

17. The method as defined in claim 16, wherein said oxidizing solution includes up to about 10 percent by volume copper sulfate.

18. The method as defined in claim 17, wherein said oxidizing solution has a temperature of at least about 30°

C. and said coated metal strip subjected to said oxidizing solution for a time passed of up to about 2 minutes.

19. A method of producing a coated metal strip with a corrosive-resistant alloy comprising the steps of:

a) selecting a strip formed of a given metal and having an exposed surface; and

,

b) coating said strip with a corrosion-resistant coating by passing said strip through a molten bath of said corrosion-resistant alloy such that the residence time of said strip is sufficient to deposit a layer of said corrosion-resistant alloy onto the exposed surface of said metal strip and forming an intermetallic interface comprising an interface alloy constituting a heat created mixture of said given metal and said corrosion-resistant alloy, said corrosion-resistant alloy comprising a majority of tin and a metal additive, said metal additive selected from the group consisting of a metal stabilizer, a coloring agent, a corrosion-resistant agent and mixtures thereof.

20. The method as defined in claim 19, wherein said metal stabilizer includes at least an effective amount of metal selected from the group consisting of antimony, bismuth, copper and mixtures thereof for inhibiting crystallization of said tin.

21. The method as defined in claim 20, wherein said corrosion-resistant agent includes at least an effective amount of a metal selected from the group consisting of antimony, bismuth, copper, magnesium, nickel, titanium and mixtures thereof for enhancing the corrosion-resistant properties of said corrosion-resistant coating.

22. The method as defined in claim 21, wherein said coloring agent includes at least an effective amount of copper for reducing the reflectivity of said corrosion-resistant coating.

23. The method as defined in claim 20, wherein said coloring agent includes at least an effective amount of copper for reducing the reflectivity of said corrosion-resistant coating.

24. The method as defined in claim 19, wherein said corrosion-resistant agent includes at least an effective amount of a metal selected from the group consisting of antimony, bismuth, copper, magnesium, nickel, titanium and mixtures thereof for enhancing the corrosion-resistant properties of said corrosion-resistant coating.

25. The method as defined in claim 24, wherein said coloring agent includes at least an effective amount of copper for reducing the reflectivity of said corrosion-resistant coating.

26. The method as defined in claim 19, wherein said coloring agent includes at least an effective amount of copper for reducing the reflectivity of said corrosion-resistant coating.

27. The method as defined in claim 19, including the step of pre-treating said metal strip to substantially remove oxides from said exposed surface said metal strip prior to passing said metal strip through said molten bath.

28. The method as defined in claim 19, wherein said given material is stainless steel.

29. The method as defined in claim 19, wherein said given material is copper.

30. The method as defined in claim 19, wherein said tin is at least about 75 weight percent of said alloy.

31. The method as defined in claim 30, wherein said corrosion-resistant alloy comprises:

space="preserve" listing-type="tabular">______________________________________ Tin at least about 90% Aluminum 0.0-5% Antimony 0.0-7.5% Bismuth 0.0-1.7% Copper 0.0-5% Lead 0.0-0.5% Magnesium 0.0-5% Nickel 0.0-5% Titanium 0.0-1% Zinc 0.0-7% ______________________________________

32. The method as defined in claim 30, wherein said corrosion-resistant alloy comprises:

space="preserve" listing-type="tabular">______________________________________ Tin 90-99.95% Aluminum 0.0-5% Antimony and/or Bismuth 0.0-0.5% Copper 0.0-1% Iron 0.0-1% Lead 0.0-0.05% Magnesium 0.0-5% Nickel 0.0-5% Titanium 0.0-1% Zinc 0.0-1.5% ______________________________________

33. The method as defined in claim 30, wherein said corrosion-resistant alloy comprises:

space="preserve" listing-type="tabular">______________________________________ Tin 90-99.95% Aluminum 0.0-5% Antimony, Bismuth and/or Copper 0.005-0.5% Lead 0.0-0.01% Magnesium 0.0-5% Nickel 0.0-5% Titanium 0.0-1% Zinc 0.0-0.5% Iron 0.0-1% ______________________________________

34. The method as defined in claim 19, wherein said corrosion-resistant alloy includes about 0.01 to about 2.7 weight percent copper.

35. The method as defined in claim 34, wherein said corrosion-resistant alloy includes about 0.1 to about 1.6 weight percent copper.

36. The method as defined in claim 35, wherein said corrosion-resistant alloy includes about 1.0 to about 1.5 weight percent copper.

37. The method as defined in claim 19, wherein said corrosion-resistant alloy includes about 0.3 to about 1.0 weight percent nickel.

38. The method as defined in claim 37, wherein said corrosion-resistant alloy includes about 0.7 weight percent nickel.

39. The method as defined in claim 19, wherein said corrosion-resistant alloy includes about 0.1 to about 1.0 weight percent magnesium.

40. The method as defined in claim 30, wherein said corrosion-resistant alloy includes about 0.1 to about 0.4 weight percent magnesium.

41. The method as defined in claim 19, wherein said corrosion-resistant alloy includes about 0.01 to about 1.0 weight percent titanium.

42. The method as defined in claim 41, wherein said corrosion-resistant alloy includes about 0.01 to about 0.5 weight percent titanium.

43. The method as defined in claim 42, wherein said alloy includes about 0.01 to about 0.15 weight percent titanium.

44. The method as defined in claim 19, wherein said alloy includes about 0.01 to about 1.0 weight percent aluminum.

45. The method as defined in claim 44, wherein said alloy includes about 0.01 to about 0.5 weight percent aluminum.

46. The method as defined in claim 45, wherein said alloy includes 0.01 to about 0.3 weight percent aluminum.

47. The method as defined in claim 19, including the step of applying an intermediate metal layer to said exposed surface of said metal strip prior to passing said metal strip through said molten bath.

48. The method as defined in claim 47, wherein said intermediate layer is selected from the group consisting of tin, chromium, nickel or copper.

49. The method as defined in claim 47, including the step of pre-heating said intermediate metal layer prior to passing said strip through said molten alloy.

50. The method as defined in claim 19, including the step of controlling the coating thickness on said metal strip to about 0.0003 to about 0.2 inch as said metal strip exits said molten bath.

51. A method of producing a coated metal strip having a corrosive-resistant alloy comprising the steps of:

a) selecting a metal strip formed of stainless steel and having a thickness of up to about 0.20 inch;

b) unrolling said stainless steel strip from a coil of said stainless steel strip;

c) hot dip coating said stainless steel strip with a corrosive-resistant alloy by continuously passing said stainless steel strip in a longitudinal direction at a speed through a molten bath having a temperature of at least about 449°

F., said speed of said stainless steel strip controlled such that said stainless steel strip has a residence time in said molten bath is about 0.08 to about 10 minutes to deposit a substantially uninterrupted layer of said corrosion-resistant alloy having a substantially uniform thickness of about 0.001 to about 0.05 inch onto the exposed surface of said stainless steel strip and forming an intermetallic interface comprising an interface alloy constituting a heat created mixture of said stainless steel strip and said corrosion-resistant alloy and having a thickness of about 1 to about 10 microns, said corrosion-resistant alloy comprising over 90 weight percent tin.

52. The method as defined in claim 51, wherein said corrosion-resistant alloy comprises over 95 weight percent tin.

53. The method as defined in claim 52, wherein said corrosion-resistant alloy includes a metal additive selected from the group consisting of at least an effective amount of metal stabilizer for inhibiting crystallization of said tin, at least an effective amount of corrosion-resistant agent for enhancing the corrosion-resistant properties of said corrosion-resistant alloy, at least an effective amount of coloring agent for reducing the reflectivity of said corrosion-resistant coating and mixtures thereof.

54. The method as defined in claim 53, wherein said metal stabilizer includes a metal selected from the group consisting of antimony, bismuth, copper and mixtures thereof.

55. The method as defined in claim 53, wherein said corrosion-resistant agent includes a metal selected from the group consisting of antimony, bismuth, copper, magnesium, nickel, titanium and mixtures thereof.

56. The method as defined in claim 53, wherein said coloring agent includes copper.

57. The method as defined in claim 52, including the step of applying an intermediate metal layer to the surface of said stainless steel strip prior to passing said stainless steel strip through said molten bath of said corrosion-resistant alloy.

58. The method as defined in claim 51, wherein said corrosion-resistant alloy includes a metal additive selected from the group consisting of at least an effective amount of metal stabilizer for inhibiting crystallization of said tin, at least an effective amount of corrosion-resistant agent for enhancing the corrosion-resistant properties of said corrosion-resistant alloy, at least an effective amount of coloring agent for reducing the reflectivity of said corrosion-resistant coating and mixtures thereof.

59. The method as defined in claim 58, wherein said metal stabilizer includes a metal selected from the group consisting of antimony, bismuth, copper and mixtures thereof.

60. The method as defined in claim 58, wherein said corrosion-resistant agent includes a metal selected from the group consisting of antimony, bismuth, copper, magnesium, nickel, titanium and mixtures thereof.

61. The method as defined in claim 58, wherein said coloring agent includes copper.

62. The method as defined in claim 51, including the step of applying an intermediate metal layer to the surface of said stainless steel strip prior to passing said stainless steel strip through said molten bath of said corrosion-resistant alloy.

63. A method of producing a coated metal strip having a corrosion-resistant alloy comprising the steps of:

a) selecting a metal strip formed of stainless steel and having a thickness of up to about 0.2 inch;

b) unrolling said stainless steel strip from a coil of said stainless steel strip at a speed rate of up to 400 ft/min.;

c) coating said stainless steel strip with a corrosion-resistant alloy to deposit a substantially uninterrupted layer of said corrosion-resistant alloy having a substantially uniform thickness of up to about 0.05 inch and forming a heat created intermetallic interface comprising an interface alloy which includes iron, chromium and tin and has a thickness of up to about 10 microns, said corrosion-resistant alloy comprising over 90 weight percent tin and a metal additive selected from the group consisting of at least an effective amount of metal stabilizer for inhibiting crystallization of said tin, at least an effective amount of corrosion-resistant agent for enhancing the corrosion-resistant properties of said corrosion-resistant alloy, at least an effective amount of coloring agent for reducing the reflectivity of said corrosion-resistant coating and mixtures thereof.

64. The method as defined in claim 63, wherein said metal stabilizer includes a metal selected from the group consisting of antimony, bismuth, copper and mixtures thereof.

65. The method as defined in claim 63, wherein said corrosion-resistant agent includes a metal selected from the group consisting of antimony, bismuth, copper, magnesium, nickel, titanium and mixtures thereof.

66. The method as defined in claim 63, wherein said coloring agent includes copper.

67. The method as defined in claim 63, including the step of applying an intermediate metal layer to the surface of said stainless steel strip prior to passing said stainless steel strip through said molten bath of said corrosion-resistant alloy.

68. The method as defined in claim 63, wherein said stainless steel strip is coated by passing said stainless steel strip through a molten bath of said corrosion-resistant alloy having a temperature of at least about 449°

F., said speed rate of said stainless steel strip selected such that said stainless steel strip has a residence time in said molten bath of about 0.08 to about 10 minutes.

69. The method as defined in claim 63, wherein said stainless steel strip is coated by passing said stainless steel strip through a solution of corrosion-resistant alloy and plating said corrosion-resistant alloy onto the surface of said stainless steel strip, said plated stainless steel strip being subsequently heated for a sufficient time period to form said heat created intermetallic interface.