JP2006233311A - Method for producing spray-coated steel sheet having excellent corrosion resistance and equipment line for steel sheet - Google Patents
Method for producing spray-coated steel sheet having excellent corrosion resistance and equipment line for steel sheet Download PDFInfo
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本発明は、土木、建築、造船、建産機、エネルギー関連機器、化学工業など耐食性が要求される分野に用いられる大面積の溶射被覆鋼板を大量に製造する方法及び設備列に関する。 The present invention relates to a method and an equipment row for manufacturing a large amount of a spray-coated steel sheet having a large area used in a field where corrosion resistance is required, such as civil engineering, construction, shipbuilding, construction machinery, energy-related equipment, and chemical industry.
金属溶射技術は、構造物の表層部分に耐食性や耐摩耗性を付与する技術として一般的に広く用いられている。しかし、溶射により形成された皮膜は、そのままでは気孔を有するため、長期間の使用においては、その気孔を通じての腐食因子の浸透により、耐食性が十分に発揮されない場合がある。 The metal spraying technique is generally widely used as a technique for imparting corrosion resistance and wear resistance to a surface layer portion of a structure. However, since the coating formed by thermal spraying has pores as it is, the corrosion resistance may not be sufficiently exhibited due to the penetration of the corrosion factor through the pores when used for a long period of time.
また、皮膜と基材鋼板の密着性については、完全な拡散接合が達成されているわけではなく、加工や長期間の使用中に剥離を生じる場合がある。また、皮膜が何らかの原因で損傷し、接合界面が腐食環境にさらされた場合、接合が不完全であると界面に沿って腐食が進行する場合がある。 Moreover, about the adhesiveness of a membrane | film | coat and a base-material steel plate, perfect diffusion bonding is not achieved, and peeling may arise during a process and long-term use. Further, when the film is damaged for some reason and the bonding interface is exposed to a corrosive environment, if the bonding is incomplete, corrosion may proceed along the interface.
このような問題に対して、従来からいろいろな対策が提案されている。古典的にはフュージングと呼ばれる技術があり、１０００℃程度の炉中で素材ごと加熱し、皮膜および界面を溶融することにより、皮膜の緻密性と接合強度を高める技術がある。 Various countermeasures have been proposed for such problems. Classically, there is a technique called fusing, and there is a technique for increasing the denseness and bonding strength of a film by heating the whole material in a furnace at about 1000 ° C. and melting the film and the interface.
しかし、この技術は、皮膜材料が融点の低い自溶性合金に限られること、素材が熱影響を受けること、さらに生産性が低い等の課題があった。 However, this technique has problems such as that the coating material is limited to a self-fluxing alloy having a low melting point, the material is affected by heat, and the productivity is low.
これらの課題を解決するために、例えば、特許文献１には、ＡｌとＺｎの低融点金属溶射において、基板を予め７０〜３５０℃に加熱し、密着性を高め、同時に大量生産を可能とする技術が開示されている。 In order to solve these problems, for example, Patent Document 1 discloses that in low-melting-point metal spraying of Al and Zn, the substrate is heated to 70 to 350 ° C. in advance to improve adhesion, and mass production is possible at the same time. Technology is disclosed.
特許文献２には、基板と皮膜の界面のみを高周波誘導電流により加熱し、同時に加熱部分の皮膜を加圧体により加圧する方法により、皮膜の緻密性と密着性を向上させる技術が開示されている。特許文献３には電子ビームにより溶射皮膜を再溶融し、緻密性と密着性を高める技術が開示されている。 Patent Document 2 discloses a technique for improving the denseness and adhesion of a film by a method in which only the interface between the substrate and the film is heated by a high-frequency induced current and at the same time the film in the heated portion is pressed by a pressurizing body. Yes. Patent Document 3 discloses a technique for remelting a thermal spray coating with an electron beam to improve the denseness and adhesion.
また、高周波誘導加熱により溶射後の鋼板を加熱して、溶射被膜の緻密性と密着性を高める技術が種々提案されている。 Various techniques have been proposed in which the steel sheet after thermal spraying is heated by high-frequency induction heating to improve the denseness and adhesion of the thermal spray coating.
特許文献４には、高周波誘導加熱により、溶射後の鋼板の最表面だけを１２５０℃〜１５５０℃に加熱し、耐食性金属を拡散させ耐食性を高める技術が開示されている。
特許文献５には、高周波誘導加熱により、金属母材と溶射皮膜との境界層に拡散層を形成する温度で熱処理し、溶射皮膜の密着強度を高める技術が開示されている。
Patent Document 4 discloses a technique in which only the outermost surface of a steel plate after thermal spraying is heated to 1250 ° C. to 1550 ° C. by high-frequency induction heating, thereby diffusing the corrosion-resistant metal and improving the corrosion resistance.
Patent Document 5 discloses a technique for increasing the adhesion strength of the thermal spray coating by performing heat treatment at a temperature at which a diffusion layer is formed in the boundary layer between the metal base material and the thermal spray coating by high-frequency induction heating.
特許文献６には、高周波誘導加熱と溶射を連動させることにより、表面が溶融状態の金属母材に溶射を行い、密着性の高い皮膜を形成する技術が開示されている。
しかしながら、特許文献１記載の技術は皮膜材料として低融点金属に関するもので、高耐食性のステンレス鋼やＮｉ合金のような比較的高融点の被膜材料に対して適用することは困難である。 However, the technique described in Patent Document 1 relates to a low-melting-point metal as a coating material, and is difficult to apply to a relatively high-melting-point coating material such as highly corrosion-resistant stainless steel or Ni alloy.
特許文献２記載の技術は、完成した構造体に対する後処理としての技術であり、装置自体の大型化が難しいことと、十分な特性を得るためには比較的長時間の加圧処理が必要と考えられることから、生産性を高めることは容易でない。特許文献３記載の技術も、電子ビームによる加熱のため、局所的な加熱となり、大量生産に適した技術とは言い難い。 The technique described in Patent Document 2 is a technique as post-processing for a completed structure, and it is difficult to increase the size of the apparatus itself, and a relatively long pressurizing process is required to obtain sufficient characteristics. Because of this, it is not easy to increase productivity. The technique described in Patent Document 3 is also a local heating due to the heating by the electron beam, and is not a technique suitable for mass production.
また、特許文献４〜６記載の高周波誘導加熱装置による加熱は、加熱面積が大きい鋼板を大量に製造する場合、その適用が困難と考えられる。 Moreover, it is thought that the application by the high frequency induction heating apparatus of patent documents 4-6 is difficult when manufacturing a steel plate with a large heating area in large quantities.
特許文献４記載の技術は、高周波誘導加熱を用いて鋼板表面のみを高温に加熱することにより短時間で耐食性金属の拡散を達成する技術であるが、鋼板表面のみであっても１２５０〜１５５０℃の高温に加熱するためには多大の電力が必要で、例えば幅４ｍ長さ４０ｍの厚鋼板等の大量生産に適用することは困難である。 The technique described in Patent Document 4 is a technique for achieving diffusion of a corrosion-resistant metal in a short time by heating only the steel sheet surface to a high temperature using high-frequency induction heating. In order to heat to a high temperature, a large amount of electric power is required. For example, it is difficult to apply to mass production of a steel plate having a width of 4 m and a length of 40 m.
特許文献５記載の技術は、高周波誘導加熱により金属母材と溶射皮膜の拡散を促進する技術であり、その加熱温度は７００℃程度であり、電力供給能力的には厚鋼板にも適用可能な水準であるが、十分な拡散を得るためには熱処理時間が数十分から数時間を要してしまい、数分に１枚程度の厚板圧延を考慮すると、生産能力という観点からは不十分である。
特許文献６記載の技術は、高周波誘導加熱により鋼板表面を溶融状態としたところに溶射を行い皮膜の密着性を高めるもので、金属板成形金型等の小型部材への適用には向いていると考えられるが、厚板等の大型製品へ適用するにあたっては、やはり投入電力が非現実的に膨大であることや溶融した母材金属が飛散する等のエンジニアリング的な問題がある。
The technique described in Patent Document 5 is a technique that promotes diffusion of a metal base material and a thermal spray coating by high-frequency induction heating. The heating temperature is about 700 ° C., and the power supply capability can be applied to a thick steel plate. Although it is a standard, it takes several tens of minutes to several hours to obtain sufficient diffusion, and considering the rolling of about 1 sheet per minute, it is insufficient from the viewpoint of production capacity It is.
The technique described in Patent Document 6 is intended to increase the adhesion of the coating by spraying the surface of the steel sheet in a molten state by high-frequency induction heating, and is suitable for application to a small member such as a metal plate molding die. However, when applied to large products such as thick plates, there are still engineering problems such as unrealistically large input power and scattering of molten base metal.
また、溶射を行うための前提条件として、一般に、基材鋼板表面に酸化スケールがある場合にはそれを予め除去することが必要であり、溶射工程の前にショットブラスト等のデスケーリングの工程が必須である。 In addition, as a precondition for performing thermal spraying, it is generally necessary to remove oxide scale on the surface of the base steel sheet in advance, and a descaling process such as shot blasting is required before the thermal spraying process. It is essential.
この工程は生産性を阻害するため、何らかの方法により簡略化、望ましくは省略することが切望されているが、今のところ有効な技術は開示されていない。 Since this process hinders productivity, it is desired to be simplified or preferably omitted by some method, but no effective technique has been disclosed so far.
本発明は、被溶射面積が大きく、且つ溶射皮膜の緻密性と密着性を高め、耐食性に優れる溶射被覆鋼板を高い生産性で製造する技術を提供することを目的とする。 It is an object of the present invention to provide a technique for manufacturing a spray-coated steel sheet having a large area to be sprayed, improving the denseness and adhesion of the sprayed coating, and excellent in corrosion resistance with high productivity.
本発明者らは、前記課題を解決するため、皮膜の緻密性と密着性を向上させる、原子の拡散現象と熱履歴の関係に着目し、溶射前後の温度を適正に制御した場合、比較的低温でかつ短時間の熱処理で十分な効果が得られることを知見した。 In order to solve the above problems, the inventors have focused on the relationship between the diffusion phenomenon of atoms and the thermal history, which improves the denseness and adhesion of the film, and when the temperature before and after spraying is appropriately controlled, It was found that a sufficient effect can be obtained by a heat treatment at a low temperature for a short time.
また、高温プロセスで問題になる鋼板表面や皮膜表面の酸化現象についても、熱履歴を適正に制御すれば解決できることを見出した。さらに、その熱履歴が、厚板製造ラインにおける各工程を適正に配置すれば実現可能で、一貫したプロセスにより生産性を高められること、さらには熱エネルギーを有効に活用できることを見出した。 In addition, it has been found that the oxidation phenomenon of the steel sheet surface and the film surface, which is a problem in the high temperature process, can be solved by appropriately controlling the thermal history. Furthermore, it was found that the heat history can be realized if each process in the thick plate production line is properly arranged, productivity can be improved by a consistent process, and heat energy can be effectively utilized.
本発明は得られた知見を基に、更に検討を加えてなされたもので、すなわち、本発明は、
１高周波誘導加熱装置により鋼板表面を５７０Ｋ以上、１１３０K以下に加熱後、溶射装置により溶射被膜を形成し、その後、前記高周波誘導加熱装置により、鋼板表面部分を溶射金属の融点の０．５倍以上、１１３０Ｋ以下に加熱することを特徴とする耐食性に優れた溶射被覆鋼板の製造方法。
２溶射材料が鉄基またはニッケル基の耐食合金であることを特徴とする１に記載の溶射被覆鋼板の製造方法。
３熱処理用冷却装置の下流側の搬送ライン上に、搬送方向に沿って順次配置した熱間矯正機、高周波誘導加熱装置、および溶射装置と、前記熱間矯正機、前記高周波誘導加熱装置および前記溶射装置間で鋼板の搬送方向を順逆可能とする搬送機構を備えたことを特徴とする鋼板の製造設備列。
４溶射装置が、高速フレーム溶射装置であることを特徴とする３記載の鋼板の製造設備列。
The present invention has been made based on the obtained knowledge and further studies, that is, the present invention,
1 After heating the steel plate surface to 570K or higher and 1130K or lower with a high frequency induction heating device, a thermal spray coating is formed with a thermal spraying device, and then the steel plate surface portion is 0.5 times or more of the melting point of the thermal spray metal with the high frequency induction heating device. A method for producing a spray-coated steel sheet excellent in corrosion resistance, characterized by heating to 1130 K or less.
2. The method for producing a spray-coated steel sheet according to 1, wherein the thermal spray material is an iron-based or nickel-based corrosion resistant alloy.
3 Hot straightening machine, high-frequency induction heating apparatus, and thermal spraying apparatus, which are sequentially arranged along the conveyance direction, on the conveyance line on the downstream side of the cooling device for heat treatment, the hot straightening machine, the high-frequency induction heating apparatus, and the A steel plate manufacturing facility row comprising a transport mechanism that enables a steel plate transport direction to be reversed between spraying apparatuses.
4. The steel plate manufacturing equipment row according to 3, wherein the 4 thermal spraying apparatus is a high-speed flame spraying apparatus.
本発明によれば、連続プロセスにより、高耐食性を得るための皮膜の緻密化と密着化が達成でき、従来の方法に比べて、格段に生産性を高めることができ、大面積で、高性能の製品を安価にかつ大量に生産でき、産業上極めて有用である。 According to the present invention, it is possible to achieve densification and adhesion of a film for obtaining high corrosion resistance by a continuous process, and it is possible to remarkably increase productivity compared to conventional methods, with a large area and high performance. Can be produced at low cost and in large quantities, and is extremely useful in industry.
本発明は、基材鋼板に、緻密で密着性に優れる溶射被膜を形成し、その溶射工程を、厚板などの鋼板製造ラインを利用して、連続プロセスとして実現することを特徴とする。 The present invention is characterized in that a thermal spray coating having a dense and excellent adhesion is formed on a base steel sheet, and the thermal spraying process is realized as a continuous process using a steel plate production line such as a thick plate.
［溶射条件］
高周波誘導加熱装置により鋼板を５７０Ｋ以上、１１３０K以下に加熱後、溶射装置により溶射被膜を形成する。
溶射前の基材鋼板の温度を５７０Ｋ以上とすることにより、溶射時の溶射金属の密着性が良くなることと、溶射後の皮膜内の原子拡散現象が活発になることにより、引き続く高周波誘導加熱による熱処理で、皮膜内の空隙や基材鋼板との接合界面の空隙が短時間で消滅するようになる。ここで、基材鋼板とは、溶射前の鋼板又は溶射後の溶射被覆鋼板の下地鋼板を示す。また、温度を倍数表現している場合は絶対温度（Ｋ）を基準としている。
また、加熱方法として高周波誘導加熱を用いることにより、基材鋼板の表面のみ加熱され鋼板内部との温度差に起因する板厚方向応力のため、基材鋼板の表面酸化スケールが後の溶射工程で剥離し易くなる。
一方、１１３０Ｋを超えると、溶射前の鋼板表面の酸化スケール厚みが急激に大きくなり、溶射工程における溶射材料の衝突だけでは酸化皮膜を除去することが難しくなる。しかし、酸化スケールの厚みが１１３０Ｋで形成されるときの厚みを超えなければ、溶射時の溶射材料の衝突エネルギーにより、酸化スケールは破壊、飛散してしまい、基材鋼板と溶射金属の直接の接触が達成される。
このため、溶射前の基材鋼板の温度を５７０Ｋ以上１１３０Ｋ以下とし、かつ加熱方法として高周波誘導加熱を用いることが必要である。
[Spraying conditions]
After the steel sheet is heated to 570K or higher and 1130K or lower with a high frequency induction heating device, a thermal spray coating is formed with a thermal spraying device.
By setting the temperature of the base steel plate before spraying to 570 K or higher, the adhesion of the sprayed metal during spraying is improved, and the atomic diffusion phenomenon in the coating after spraying is activated, thereby continuing high frequency induction heating. By the heat treatment, the voids in the film and the voids at the bonding interface with the base steel plate disappear in a short time. Here, the base steel plate refers to a base steel plate of a steel plate before spraying or a spray-coated steel plate after spraying. Further, when the temperature is expressed as a multiple, the absolute temperature (K) is used as a reference.
In addition, by using high-frequency induction heating as the heating method, only the surface of the base steel sheet is heated, and due to the plate thickness direction stress due to the temperature difference with the inside of the steel sheet, the surface oxide scale of the base steel sheet is in the subsequent spraying process It becomes easy to peel.
On the other hand, if it exceeds 1130K, the oxide scale thickness on the surface of the steel plate before thermal spraying increases rapidly, and it becomes difficult to remove the oxide film only by the collision of the thermal spray material in the thermal spraying process. However, if the thickness of the oxide scale does not exceed the thickness when it is formed at 1130K, the oxide scale breaks and scatters due to the collision energy of the sprayed material during spraying, and the base steel plate and the spray metal are in direct contact. Is achieved.
For this reason, it is necessary to set the temperature of the base steel sheet before thermal spraying to 570 K or more and 1130 K or less and to use high frequency induction heating as a heating method.
溶射皮膜の厚さとして、１０μｍ以上とすることにより、安定した耐食性を発揮できるようになる。一方、５００μｍを超えて皮膜を形成しようとすると、溶射に長時間を要するようになり、生産性を損ねるようになる。このため、皮膜厚さは１０〜５００μｍとすることが好ましい。
なお、特に優れて安定した耐食性と、高い生産性を両立するためには、皮膜厚さを２０〜２００μｍとすることがより好ましい。
By setting the thickness of the thermal spray coating to 10 μm or more, stable corrosion resistance can be exhibited. On the other hand, when it is going to form a film | membrane exceeding 500 micrometers, a long time will be required for thermal spraying, and productivity will be impaired. For this reason, it is preferable that the film thickness is 10 to 500 μm.
In order to achieve both excellent and stable corrosion resistance and high productivity, the film thickness is more preferably 20 to 200 μm.
溶射装置により溶射被膜を形成後、前記高周波誘導加熱装置により、表面部分を溶射金属の融点の０．５倍以上、１１３０Ｋ以下に加熱する。溶射後の高周波誘導加熱は、鋼板の表面部分を溶射金属の融点の０．５倍以上に加熱すると、皮膜内の拡散現象を著しく高めることができ好ましい。 After the thermal spray coating is formed by the thermal spraying device, the surface portion is heated to 0.5 times or more and 1130K or lower of the melting point of the thermal spray metal by the high frequency induction heating device. The high frequency induction heating after thermal spraying is preferable because the diffusion phenomenon in the coating can be remarkably enhanced if the surface portion of the steel sheet is heated to 0.5 times or more of the melting point of the thermal spray metal.
一方、１１３０Ｋを超えて加熱すると、溶射皮膜表面において酸化スケールの成長が顕著になり、この酸化スケールに起因する溶射皮膜のすき間腐食が発生し易くなるため、溶射金属の融点の０．５倍以上１１３０Ｋ以下とすることが好ましい。 On the other hand, when heated above 1130K, the growth of the oxide scale becomes remarkable on the surface of the sprayed coating, and crevice corrosion of the sprayed coating due to this oxide scale is likely to occur, so that the melting point of the sprayed metal is 0.5 times or more. It is preferable to set it to 1130K or less.
尚、好ましくは基材鋼板の融点の０．５倍以上である８７０Ｋ以上に数秒以上保持することが好ましい。また、基材鋼板の平均温度の上限を、材質変化を抑制する観点から、１０００K以下とすることが好ましい。 In addition, it is preferable to hold at 870 K or more, which is 0.5 times or more of the melting point of the base steel plate, for several seconds or more. Moreover, it is preferable that the upper limit of the average temperature of a base-material steel plate shall be 1000K or less from a viewpoint of suppressing a material change.
尚、本プロセスは、溶射時の基板鋼板の温度が５７０Ｋ以上のときにこのプロセスが有効であり、もし溶射時の温度が十分でない場合には、従来のフュージングと同じになり、さらに高い温度で長時間の熱処理が必要となるため生産性を著しく阻害する。温度の保持については時間を長くしても効果が飽和するため、数分以内で十分である。 This process is effective when the temperature of the substrate steel plate during thermal spraying is 570 K or higher. If the temperature during thermal spraying is not sufficient, it becomes the same as conventional fusing, and at a higher temperature. Productivity is significantly hindered because long heat treatment is required. For maintaining the temperature, even if the time is extended, the effect is saturated, so that it is sufficient within a few minutes.
溶射材料としては、鉄基またはニッケル基の耐食合金が好ましい。鉄基またはニッケル基合金は、基材鋼板との間で脆性相を作ったり、液相を生成したりして接合性を阻害することが少ない。また、鉄基合金やニッケル基合金は、溶射時に適度の硬さを有していることから、基材鋼板表面にある酸化スケールを溶射時の衝突の際に破壊、飛散させることができるため、基材鋼板との密着性を確保することが比較的容易である。 As the thermal spray material, an iron-based or nickel-based corrosion resistant alloy is preferable. An iron-base or nickel-base alloy rarely inhibits bondability by forming a brittle phase with a base steel plate or generating a liquid phase. In addition, since the iron-base alloy and nickel-base alloy have an appropriate hardness at the time of thermal spraying, the oxide scale on the base steel sheet surface can be destroyed and scattered at the time of collision during thermal spraying, It is relatively easy to ensure adhesion with the base steel plate.
上述した溶射方法を用いて、溶射被覆を形成した厚鋼板の製造に、好適な製造設備列について説明する。 A manufacturing equipment row suitable for manufacturing a thick steel plate having a thermal spray coating using the above-described thermal spraying method will be described.
［製造設備列］
図１は、本発明に係る溶射被覆鋼板の製造設備列の一実施例を模式的に示し、図において、１は圧延用加熱炉、２は熱間圧延機、３は熱処理用冷却装置である加速冷却装置、４は熱間矯正機、５は高周波誘導加熱装置、６は溶射装置を示す。
[Manufacturing equipment column]
FIG. 1 schematically shows an embodiment of a production equipment row of thermal spray coated steel sheets according to the present invention, in which 1 is a heating furnace for rolling, 2 is a hot rolling mill, and 3 is a cooling device for heat treatment. An acceleration cooling device, 4 is a hot straightening machine, 5 is a high frequency induction heating device, and 6 is a thermal spraying device.
図示した製造設備列では、鋼板の熱間圧延機２の下流側に、熱間矯正機４、高周波誘導加熱装置５、溶射装置６を順次、配置し、鋼板の搬送機構は、熱間矯正機４、高周波誘導加熱装置５、溶射装置６間で鋼板の搬送が順逆送可能に構成する。 In the illustrated manufacturing equipment row, a hot straightening machine 4, a high-frequency induction heating device 5, and a thermal spraying device 6 are sequentially arranged on the downstream side of the steel sheet hot rolling mill 2, and the steel sheet transport mechanism is a hot straightening machine. 4. It is configured that the conveyance of the steel sheet can be forward-reversely transferred between the high frequency induction heating device 5 and the thermal spraying device 6.
なお、順送とは製造ライン上を通板方向に対し圧延用加熱炉１から熱間圧延機２側に搬送することを意味し、逆送とは順送とは逆向きに搬送することを意味する。また、上流側とは製造ライン上の各設備の位置関係を示し、通板方向の順送に対し手前側を意味し、下流側とは後ろ側を意味する。 In addition, the forward feed means that the production line is transported from the rolling heating furnace 1 to the hot rolling mill 2 side with respect to the plate direction, and the reverse feed is transported in the opposite direction to the forward feed. means. Further, the upstream side indicates the positional relationship of each facility on the production line, and means the front side with respect to the forward feeding in the sheet passing direction, and the downstream side means the rear side.
基材鋼板（図示しない）は、圧延用加熱炉１で所定の温度に加熱された後、熱間圧延機２により所望の板厚に熱間圧延され、必要に応じて加速冷却装置３により冷却された後、高周波誘導加熱装置５内に搬入できるように熱間矯正機４により、鋼板の反りや歪が除去される。なお、基材鋼板の特性によって加速冷却装置の使用の有無は選択可能である。 A base steel plate (not shown) is heated to a predetermined temperature in a heating furnace 1 for rolling, and then hot-rolled to a desired plate thickness by a hot rolling mill 2, and cooled by an accelerated cooling device 3 as necessary. Then, the warp or distortion of the steel sheet is removed by the hot straightening machine 4 so that it can be carried into the high frequency induction heating device 5. Whether or not the accelerated cooling device is used can be selected depending on the characteristics of the base steel plate.
その後、高周波誘導加熱装置５により予熱した後、溶射装置６により溶射被膜を形成する。高周波誘導加熱を用いることにより、基材鋼板の表面のみ加熱され鋼板内部との温度差に起因する板厚方向応力のため、溶射工程における基材鋼板の表面酸化スケールの剥離が容易となる。 Then, after preheating with the high frequency induction heating apparatus 5, a thermal spraying film is formed with the thermal spraying apparatus 6. FIG. By using high-frequency induction heating, only the surface of the base steel sheet is heated, and stress in the thickness direction due to a temperature difference from the inside of the steel sheet makes it easy to peel the surface oxide scale of the base steel sheet in the thermal spraying process.
鋼板の搬送機構が、高周波誘導加熱装置５、溶射装置６の間で鋼板が逆送可能に構成されているので、溶射皮膜の温度が高い溶射直後で、拡散が活発である状態において、高周波誘導加熱装置５により溶射被膜を後熱し、皮膜の緻密性と密着性を向上させることが可能となる。 Since the steel plate transport mechanism is configured such that the steel plate can be fed back between the high frequency induction heating device 5 and the thermal spraying device 6, the high frequency induction is performed in a state where diffusion is active immediately after the thermal spray coating having a high temperature. It is possible to post-heat the sprayed coating by the heating device 5 and improve the denseness and adhesion of the coating.
また、熱間矯正機４の搬送機構も逆送可能に構成されているので、溶射皮膜の温度が高い溶射直後で、変形抵抗が低く拡散が活発である状態において熱間矯正機４により溶射皮膜に圧縮応力を加え、溶射時に皮膜内や接合界面にできる空隙を機械的に潰すことにより、皮膜の緻密性と密着性を向上させることが可能となる。 In addition, since the transport mechanism of the hot straightening machine 4 is also configured to be able to reversely feed, the hot spraying machine 4 directly sprays the thermal spray coating in a state where the deformation resistance is low and the diffusion is active immediately after the thermal spray coating has a high temperature. It is possible to improve the denseness and adhesiveness of the film by applying compressive stress to the film and mechanically crushing voids formed in the film or at the bonding interface during thermal spraying.
熱間矯正機４による曲げ、圧縮応力の付加は高周波誘導加熱装置５による加熱の前または後に行う。高周波誘導加熱装置５により加熱後、熱間矯正機４により曲げ、圧縮応力を付加する場合は、溶射後の鋼板を、高周波誘導加熱装置５へ逆送して加熱した後、熱間矯正機４へ逆送して曲げ、圧縮応力を付加する。 Bending by the hot straightening machine 4 and application of compressive stress are performed before or after heating by the high frequency induction heating device 5. When heated by the high frequency induction heating device 5, bent by the hot straightening machine 4, and applied with compressive stress, the sprayed steel sheet is fed back to the high frequency induction heating device 5 and heated, and then the hot straightening machine 4 Backward to bend and apply compressive stress.
熱間矯正機４により曲げ、圧縮応力の付加後、高周波誘導加熱装置５により加熱する場合は、溶射後の鋼板を、高周波誘導加熱装置５へ逆送して加熱することなく通過させ、熱間矯正機４により曲げ、圧縮応力の付加後、高周波誘導加熱装置５に順送して加熱する。 When heated by the high-frequency induction heating device 5 after being bent by the hot straightening machine 4 and applying compressive stress, the thermally sprayed steel plate is fed back to the high-frequency induction heating device 5 without being heated, After bending by the straightening machine 4 and applying compressive stress, it is fed to the high frequency induction heating device 5 and heated.
いずれの搬送方法でも、高周波誘導加熱装置５と熱間矯正機４による曲げ、圧縮応力の付加を複数回に分けて行い、加熱と曲げ、圧縮応力の付与を交互に行うことが好ましい。 In any conveyance method, it is preferable to perform bending and compressive stress application by the high-frequency induction heating device 5 and the hot straightening machine 4 in a plurality of times, and alternately apply heating, bending and compressive stress.
上述した製造設備列は、溶射装置６を除くと、厚板製造ラインとして、幅４０００ｍｍ、長さ４０ｍの大面積の鋼板を製造することも可能で、焼入れ後、高周波誘導加熱装置５による焼戻し処理を行う、インライン焼戻し設備としても使用可能である。 The above-described manufacturing equipment row can produce a steel plate having a width of 4000 mm and a length of 40 m as a thick plate production line, excluding the thermal spraying device 6, and is tempered by the high-frequency induction heating device 5 after quenching. It can also be used as an in-line tempering facility.
焼戻し処理後において、溶射被膜の形成を行うと、靭性に優れた焼入れ焼戻し鋼板を高生産性を損なわず、製造することが可能となるなど、多様な基材鋼板特性の溶射被覆鋼板を製造可能である。 After the tempering process, forming a sprayed coating makes it possible to manufacture a hardened and tempered steel sheet with excellent toughness without sacrificing high productivity. It is.
溶射方法としては、プラズマ溶射、アーク溶射、フレーム溶射等いずれの方法でも可能であるが、より緻密な皮膜を、厚板製造ラインの他工程に同期して高速で形成することが可能な高速フレーム溶射（ＨＶＯＦ：High Velocity Oxyfuel Thermal Spraying）が適している。 As the thermal spraying method, any method such as plasma spraying, arc spraying, flame spraying, etc. can be used, but a high-speed flame capable of forming a denser film at high speed in synchronization with other processes of the thick plate production line. Thermal spraying (HVOF: High Velocity Oxyfuel Thermal Spraying) is suitable.
また、生産性向上のためには、溶射ガンをライン上に複数台配置し、鋼板の幅方向、すなわちラインと直角方向に走査する方法が考えられる。なお、基本的には鋼板の上面からの溶射となる。 In order to improve productivity, a method of arranging a plurality of spray guns on a line and scanning in the width direction of the steel sheet, that is, in a direction perpendicular to the line can be considered. Basically, thermal spraying is performed from the upper surface of the steel sheet.
本発明の実施例として実験を行った結果について述べる。実験条件を表１に示す。スラブから実験室サイズの小型の鋼塊を準備し、１４３０Ｋに加熱後、所定の規格の機械的性質が得られるように圧延を行い、必要に応じて圧延後に加速冷却を行って、板厚１６ｍｍの鋼板を得た。 Results of experiments conducted as examples of the present invention will be described. Table 1 shows the experimental conditions. A laboratory-sized small steel ingot is prepared from the slab, heated to 1430 K, rolled to obtain the mechanical properties of the specified standard, accelerated cooling after rolling as necessary, and a plate thickness of 16 mm Steel plate was obtained.
その後、鋼板表面温度が表１に示す溶射前鋼板温度になるように、高周波誘導加熱により加熱を行った。所定の温度に到達後、酸化スケールが付いたまま、デスケーリング無で、上面から溶射を行った。なお、温度は鋼板表面温度を放射温度計により測定したものである。 Then, it heated by high frequency induction heating so that the steel plate surface temperature might become the steel plate temperature before thermal spraying shown in Table 1. After reaching a predetermined temperature, thermal spraying was performed from the top surface without descaling with an oxide scale attached. In addition, temperature is a steel plate surface temperature measured with a radiation thermometer.
溶射終了後、再び高周波誘導加熱用のコイルの中に鋼板を導き、表面温度を放射温度計で測定しながら、所定の温度になるまでコイルの中に鋼板を出し入れしながら加熱を行った。圧縮と曲げ応力を加えるものは、加熱前後に熱間矯正機により応力を付加した。なお、鋼板平均温度は、シミュレーション計算により得られた値である。 After the thermal spraying, the steel plate was again guided into the high frequency induction heating coil, and the surface temperature was measured with a radiation thermometer, and heating was performed while taking the steel plate into and out of the coil until a predetermined temperature was reached. In the case of applying compression and bending stress, the stress was applied by a hot straightener before and after heating. In addition, the steel plate average temperature is a value obtained by simulation calculation.
特性評価方法としては、まず、２４時間連続の塩水噴霧試験により耐食性の評価を行った。試験片表面にはクロスカットを施し、接合界面での皮膜の密着性も同時に評価できるようにした。 As a characteristic evaluation method, first, corrosion resistance was evaluated by a salt spray test for 24 hours. The test piece surface was cross-cut so that the adhesion of the film at the joint interface could be evaluated at the same time.
表２に結果を示す。表２中の○印は、接合界面に沿った腐食に起因する皮膜のふくれや、皮膜表面の発錆等が無かったことを表す。 Table 2 shows the results. The circles in Table 2 indicate that there was no blistering of the film due to corrosion along the bonding interface, and no rusting on the film surface.
皮膜の密着性、健全性の評価として、曲げ試験を行った。曲げ試験は、皮膜を外側にして、曲げ半径として板厚の２倍、すなわち曲げ半径４０ｍｍの１８０°ローラー曲げ試験を行った。 A bending test was performed as an evaluation of the adhesion and soundness of the film. In the bending test, a 180 ° roller bending test was performed with the coating on the outside and a bending radius of twice the plate thickness, that is, a bending radius of 40 mm.
また、鋼板の機械的性質に及ぼす加熱の影響を評価するために、溶射被覆した鋼板の引張試験を行い、比較材として加熱を行わなかった場合を想定して準備した鋼板の引張強度の比較を行った。表２には比較材に対する強度の変化を記した。 In addition, in order to evaluate the effect of heating on the mechanical properties of the steel sheet, a thermal test was performed on the steel sheet coated with thermal spray, and a comparison was made of the tensile strength of the steel sheets prepared assuming that no heating was performed as a comparative material. went. Table 2 shows the change in strength relative to the comparative material.
本発明例であるNo.1からNo.8は、いずれも溶射皮膜の性能に優れ、基材鋼板の強度にも変化は見られなかった。 Examples No. 1 to No. 8 as examples of the present invention were all excellent in the performance of the sprayed coating, and no change was observed in the strength of the base steel sheet.
一方、比較条件のNo.9とNo.12においては、溶射時の鋼板温度が低かったため、溶射後に溶射金属の融点の０．５倍以上の温度まで加熱したが、溶射皮膜の耐食性が劣っていた。 On the other hand, in comparison conditions No. 9 and No. 12, since the steel plate temperature at the time of thermal spraying was low, it was heated to a temperature of 0.5 times the melting point of the thermal spray metal after spraying, but the corrosion resistance of the thermal spray coating was inferior. It was.
また、基材鋼板と皮膜の間に酸化スケールが多く残存していたため、曲げ試験で皮膜の剥離が発生した。No.10は、溶射材料がＡｌであったため、溶射時の鋼板温度は十分高かったものの、酸化スケールを破壊、飛散させることができず、残存した酸化スケールのため、皮膜の密着性に劣り、塩水噴霧試験での皮膜のふくれや曲げ試験での剥離が起こる結果となった。 Further, since a large amount of oxide scale remained between the base steel plate and the coating, peeling of the coating occurred in the bending test. No.10, because the thermal spray material was Al, the steel plate temperature at the time of thermal spraying was sufficiently high, but the oxide scale could not be destroyed and scattered, and because of the remaining oxide scale, the film adhesion was poor, As a result, swelling of the film in the salt spray test and peeling in the bending test occurred.
No.11は、溶射時の鋼板温度が高すぎたため、酸化スケールが厚く成長し、溶射時に多くが残存し、皮膜の密着性に劣る結果となった。No.13は、溶射時の鋼板温度は十分高かったものの、溶射後の加熱温度が低かったため、溶射皮膜の性能が劣っていた。 In No. 11, the steel plate temperature at the time of thermal spraying was too high, so that the oxide scale grew thick, and much remained at the time of thermal spraying, resulting in poor film adhesion. In No. 13, although the steel plate temperature at the time of thermal spraying was sufficiently high, since the heating temperature after thermal spraying was low, the performance of the thermal spray coating was inferior.
No.14は、溶射後の加熱温度が高すぎたため、溶射材料の表面に酸化スケールが厚く生成してしまい、耐食性が劣化し、また、鋼板の平均温度も高かったため、基材鋼板の強度が著しく低下した。 In No.14, the heating temperature after thermal spraying was too high, so a thick oxide scale was formed on the surface of the thermal spray material, the corrosion resistance deteriorated, and the average temperature of the steel plate was high, so the strength of the base steel plate was high. Remarkably reduced.
１ 圧延用加熱炉
２ 熱間圧延機
３ 加速冷却装置
４ 熱間矯正機
５ 高周波誘導加熱装置
６ 溶射装置
DESCRIPTION OF SYMBOLS 1 Heating furnace for rolling 2 Hot rolling mill 3 Accelerated cooling apparatus 4 Hot straightening machine 5 High frequency induction heating apparatus 6 Thermal spraying apparatus
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| DE102008044973A1 (en) * | 2008-08-29 | 2010-03-04 | Daimler Ag | Metal spray process to apply a coating to e.g. the bearing of an automotive engine connecting rod in presence of induction heat coil |
| JP2011516725A (en) * | 2008-03-31 | 2011-05-26 | ヴィティーティー テクニカル リサーチ センター オブ フィンランド | Precision spray molding / lamination rolling repair and manufacturing equipment |
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| JP2011516725A (en) * | 2008-03-31 | 2011-05-26 | ヴィティーティー テクニカル リサーチ センター オブ フィンランド | Precision spray molding / lamination rolling repair and manufacturing equipment |
| DE102008044973A1 (en) * | 2008-08-29 | 2010-03-04 | Daimler Ag | Metal spray process to apply a coating to e.g. the bearing of an automotive engine connecting rod in presence of induction heat coil |
| JP2014119440A (en) * | 2012-12-19 | 2014-06-30 | Nippon Thermonics Co Ltd | Alloy re-molten state detection method, alloy re-molten state detection device, and self-fluxing alloy re-melting device |
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| JP7312583B2 (en) | 2019-03-22 | 2023-07-21 | 株式会社栗本鐵工所 | Cast iron pipe and its manufacturing method |
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