CN1675410A - 耐腐蚀性铝系结构部件及其制造方法 - Google Patents
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Abstract
本发明涉及一种耐腐蚀性铝系结构部件(1),它具有密合于铝系结构部件(10)表面的底层(2)和密合于该底层(2)表面的防腐膜(3)。所述底层(2)由锌构成,所述防腐膜(3)由含三价铬的用于锌的铬酸盐被膜构成。由此,可以提供具有不含六价铬的无公害防腐膜的耐腐蚀性铝系结构部件。
Description
技术领域
本发明涉及耐腐蚀性铝系结构部件及其制造方法。在此,铝系结构部件包括由纯铝形成的结构部件和由铝合金形成的结构部件两种情况。
背景技术
以往,作为这种铝系结构部件,已公开了具有由铬酸盐被膜形成的防腐膜的结构部件(例如参照日本特公昭60-35432号公报)。
但是,由于以往的铬酸盐被膜通过使用以CrO3作为必要成分的处理液而形成,因而含有六价铬。众所周知,六价铬是对人体有害的元素,因而为了防止公害,期望防腐膜不含有六价铬。
发明内容
本发明的目的是提供具有不含六价铬的无公害防腐膜的上述耐腐蚀性铝系结构部件。
为了实现上述目的,本发明提供了如下耐腐蚀性铝系结构部件,即:具有密合于铝系结构部件表面的底层和密合于该底层表面的防腐膜,上述底层由锌构成,上述防腐膜由含三价铬的用于锌的铬酸盐被膜构成。
上述防腐膜具有优越的耐腐蚀性的同时还不含对人体有害的六价铬,因而在防止公害方面是有益的。而且,尽管含三价铬的用于锌的铬酸盐被膜没有直接地密合于铝系结构部件表面,但是对由锌构成的底层即锌底层的表面产生充分的密合性。而且,采用公知的锌酸盐处理等就可以容易地在铝系结构部件表面密合形成锌底层。
另外,本发明的目的是提供可以容易地批量生产上述结构的耐腐蚀性铝系结构部件的所述制造方法。
为了实现上述目的,本发明提供了包括如下步骤的耐腐蚀性铝系结构部件的制造方法:在铝系结构部件表面通过锌酸盐处理而形成由锌构成的底层即锌底层的步骤;以及在该锌底层的表面通过使用三价铬酸盐试剂的铬酸盐处理,形成由含三价铬的用于锌的铬酸盐被膜构成的防腐膜的步骤。
根据上述制造方法,可以容易且可靠地得到上述结构的耐腐蚀性铝系结构部件。另外,由于锌酸盐处理和铬酸盐处理均采用浸渍法,因而采用串联工艺来进行这两个处理可以实现生产率的提高。
将锌酸盐处理所需要的处理时间t1设定为例如t1≥30秒的值,该值可以增加在铝系结构部件表面的锌析出量,从而可以得到必要厚度的锌底层。另一方面,将铬酸盐处理所需要的处理时间t2设定为例如t2≤15秒的值,该值可以在所述锌底层表面可靠地形成含三价铬的用于锌的铬酸盐被膜,同时,尽管所述铬酸盐处理会引起锌底层的溶解,但也可以确保锌底层的厚度。但是,锌酸盐处理的处理时间t1如果为t1<30秒,则对于铬酸盐处理来说,锌底层的厚度是不足的;另一方面,铬酸盐处理的处理时间t2如果为t2>15秒,则会发生锌底层的溶解,于是铝系结构部件表面有可能露出。
附图说明
图1是耐腐蚀性铝合金制汽化器主体的主视图;
图2是耐腐蚀性铝合金制汽化器主体的要部放大截面图。
具体实施方式
图1表示作为耐腐蚀性铝系结构部件的由铝合金形成的耐腐蚀性汽化器主体1。如图2所示,对于该耐腐蚀性汽化器主体1,在汽化器主体10的未经防腐处理的表面上设有与其密合的底层2以及与该底层2表面密合的防腐膜3,所述汽化器主体10是使用JIS ADC12通过模铸而得到的。底层2由锌构成,另一方面,防腐膜3由含三价铬的用于锌的铬酸盐被膜形成。
由于该防腐膜3具有优越的耐腐蚀性,同时不含对人体有害的六价铬,因而在防止公害方面是有益的。另外,含三价铬的用于锌的铬酸盐被膜没有直接地密合于由铝合金形成的汽化器主体10表面,但是对由锌构成的底层即锌底层2表面表现出充分的密合性。进而,采用公知的锌酸盐处理等就可以容易地在由铝合金形成的汽化器主体10表面密合形成锌底层2。
在制造耐腐蚀性汽化器主体1时,首先对模铸后的汽化器主体10依次实施公知的预处理,即热水洗、脱脂、水洗、活化、水洗和热水洗。接着,依次进行如下步骤,即:通过锌酸盐处理在预处理后的汽化器主体10表面形成锌底层2的步骤;水洗步骤;使用三价铬酸盐试剂通过铬酸盐处理而在锌底层2表面形成防腐膜3的步骤,该防腐膜3由含三价铬的用于锌的铬酸盐被膜构成;水洗步骤;和干燥步骤。
根据上述制造方法,可以容易且可靠地得到上述结构的耐腐蚀性汽化器主体1。另外,由于锌酸盐处理和铬酸盐处理均采用浸渍法,因而采用串联工艺来进行这两个处理可以实现生产率的提高。
将锌酸盐处理所需要的处理时间t1设定为例如t1≥30秒的值,该值可以增加在汽化器主体10表面的锌析出量,从而可以得到必要厚度的锌底层2。另一方面,将铬酸盐处理所需要的处理时间t2设定为例如t2≤15秒的值,该值可以在锌底层2表面可靠地形成含三价铬的用于锌的铬酸盐被膜,同时,尽管铬酸盐处理会引起锌底层2的溶解,但也可以确保锌底层2的厚度。
[实施例]
作为锌酸盐处理液的主成分,选择锌置换液(商品名:K-102、日本カニゼン社生产)。该锌置换液含有18.6重量%的NaOH、3.1重量%的ZnO、7.8重量%的有机酸和微量的添加剂。将该溶液的浓度调制至220mL/L来作为锌酸盐处理液。
另外,作为铬酸盐处理液的主成分,选择三价铬酸盐试剂(商品名:デイツプソ一ルZT-444A,液态,デイツプソ-ル社生产)。该三价铬酸盐试剂由14重量%~16重量%的(Cr3+:4)硝酸铬[Cr(NO3)3·9H2O]、2重量%~4重量%的硝酸钴[Co(NO3)2]和余量的普通物质组成,这些物质是已知的化学物质。将该溶液的浓度调制至60mL/L来作为铬酸盐处理液。
准备多个与上述同样的铝合金制汽化器主体(JIS ADC12,模铸制品)10,对它们实施与上述同样的预处理。接着,依次进行如下处理:使用30℃的上述锌酸盐处理液,同时,对处理时间t1进行各种变更,从而形成锆底层2;水洗;使用30℃的上述铬酸盐处理液,同时,对处理时间t2进行各种变更,从而形成防腐膜3;水洗;以及干燥,从而得到各种耐腐蚀性汽化器主体1。
对这些耐腐蚀性汽化器主体1进行盐水喷雾试验,求出从试验开始到48小时后的白色生成物(因铝合金被腐蚀而产生的生成物)的面积率A,即A=(白色生成物的面积/汽化器主体的总表面积)×100(%)。表1表示有关耐腐蚀性汽化器主体1的例子1~6的锌酸盐处理的处理时间t1、铬酸盐处理的处理时间t2和白色生成物的面积率A。
表1
耐腐蚀性汽化器主体 | 锌酸盐处理的处理时间t1(秒) | 铬酸盐处理的处理时间t2(秒) | 白色生成物的面积率A(%) |
例1 | 50 | 15 | 1 |
例2 | 30 | 15 | 3 |
例3 | 15 | 15 | 10 |
例4 | 15 | 30 | 30 |
例5 | 15 | 50 | 70 |
由表1所示,例如例1和2,如果分别将锌酸盐处理的处理时间t1设定为t1≥30秒,将铬酸盐处理的处理时间t2设定为t2≤15秒,则可以得到具有优越的耐腐蚀性的铝合金制汽化器主体1。对于例3~5的情况,由于锌酸盐处理的处理时间t1为t1=15秒,所以锌底层2比较薄,但是由于铬酸盐处理的处理时间t2为t2=15秒<t2=30秒<t2=50秒,所以汽化器主体10表面的暴露量以例3、例4、例5的顺序增加,从而判定耐腐蚀性也是以该顺序恶化。
对于铝系结构部件并不限于铝合金制汽化器主体,包括由铝合金制成的节流壳体、电磁阀主体、压缩机机壳等,而且还包括由纯铝制成的结构部件。
权利要求书
(按照条约第19条的修改)
1、耐腐蚀性铝系结构部件,其特征在于,该结构部件具有密合于铝系结构部件(10)表面的底层(2)和密合于该底层(2)表面的防腐膜(3),上述底层(2)由锌构成,上述防腐膜(3)由含三价铬的用于锌的铬酸盐被膜构成。
2、耐腐蚀性铝系结构部件的制造方法,其特征在于,该方法包括如下步骤:在铝系结构部件(10)表面通过锌酸盐处理而形成由锌构成的底层(2)的步骤;以及在该底层(2)的表面通过使用三价铬酸盐试剂的铬酸盐处理,形成由含三价铬的用于锌的铬酸盐被膜构成的防腐膜(3)的步骤。
3、根据权利要求2所述的耐腐蚀性铝系结构部件的制造方法,其特征在于,将上述锌酸盐处理所需要的处理时间t1设定为以下值:该值可以增加在所述铝系结构部件(10)表面的锌析出量,从而可以得到必要厚度的由锌构成的底层(2);将上述铬酸盐处理所需要的处理时间t2设定为以下值:该值可以在所述底层(2)表面可靠地形成含三价铬的用于锌的铬酸盐被膜,同时,尽管所述铬酸盐处理会引起所述底层(2)的溶解,但也可以确保所述底层(2)的厚度。
4、根据权利要求3所述的耐腐蚀性铝系结构部件的制造方法,其特征在于,上述锌酸盐处理所需要的处理时间t1为t1≥30秒,上述铬酸盐处理所需要的处理时间t2为t2≤15秒。
5、耐腐蚀性铝系结构部件,其特征在于,该结构部件具有密合于铝系结构部件(10)表面的底层(2)和密合于该底层(2)表面的防腐膜(3),上述底层(2)由锌构成,上述防腐膜(3)由含三价铬的铬酸盐被膜构成。
6、耐腐蚀性铝系结构部件的制造方法,其特征在于,该方法包括如下步骤:在铝系结构部件(10)表面通过锌酸盐处理而形成由锌构成的底层(2)的步骤;以及在该底层(2)表面通过使用三价铬酸盐试剂的铬酸盐处理,形成由含三价铬的铬酸盐被膜构成的防腐膜(3)的步骤。
7、根据权利要求6所述的耐腐蚀性铝系结构部件的制造方法,其特征在于,将上述锌酸盐处理所需要的处理时间t1设定为以下值:该值可以增加在所述铝系结构部件(10)表面的锌析出量,从而可以得到必要厚度的由锌构成的底层(2);将上述铬酸盐处理所需要的处理时间t2设定为以下值,该值可以在所述底层(2)表面可靠地形成含三价铬的上述铬酸盐被膜,同时,尽管所述铬酸盐处理会引起所述底层(2)的溶解,但也可以确保所述底层(2)的厚度。
Claims (4)
1、耐腐蚀性铝系结构部件,其特征在于,该结构部件具有密合于铝系结构部件(10)表面的底层(2)和密合于该底层(2)表面的防腐膜(3),上述底层(2)由锌构成,上述防腐膜(3)由含三价铬的用于锌的铬酸盐被膜构成。
2、耐腐蚀性铝系结构部件的制造方法,其特征在于,该方法包括如下步骤:在铝系结构部件(10)表面通过锌酸盐处理而形成由锌构成的底层(2)的步骤;以及在该底层(2)的表面通过使用三价铬酸盐试剂的铬酸盐处理,形成由含三价铬的用于锌的铬酸盐被膜构成的防腐膜(3)的步骤。
3、根据权利要求2所述的耐腐蚀性铝系结构部件的制造方法,其特征在于,将上述锌酸盐处理所需要的处理时间t1设定为以下值:该值可以增加在所述铝系结构部件(10)表面的锌析出量,从而可以得到必要厚度的由锌构成的底层(2);将上述铬酸盐处理所需要的处理时间t2设定为以下值:该值可以在所述底层(2)表面可靠地形成含三价铬的用于锌的铬酸盐被膜,同时,尽管所述铬酸盐处理会引起所述底层(2)的溶解,但也可以确保所述底层(2)的厚度。
4、根据权利要求3所述的耐腐蚀性铝系结构部件的制造方法,其特征在于,上述锌酸盐处理所需要的处理时间t1为t1≥30秒,上述铬酸盐处理所需要的处理时间t2为t2≤15秒。
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