Surface Coating Alloys

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Why surface coating?

Annual loss due to corrosion is estimated to be 3-5 % of GNP, about 80,000 Cr `/ year Direct Loss: material cost, over design, use of costly material Indirect losses: loss of production, contamination of product, liability in 6/18/12 accidents

Corrosion in India

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Coated Steels
Most common metallic coating for corrosion protection of steel is a zinc
(sacrificial coating)

Offers Barrier and Galvanic protection

Zinc and Steel Scrat ch

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Electroly te Zinc Coating Steel Substrate

forms of alloy used Zinc, Pure Al, Al-Zn and Zn-Al-Si alloy

Surface Coating Alloy

worldwide
Chemical Composition(%) Zn 43 12-24 12-24 Si ---Up to 4 0.3-4 Fe -0.25 0.3-3.5

composition used

Al 55 Balance Balance

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AlZnSi Alloy (Galvalume)

Minex manufactures Pre-mixed AlZnSi alloy and Aluminum Silicon master alloys AlZnSi Alloy - assures consistent alloy chemistry - ease of addition and control -6/18/12 control on coating bath close

Minex Manufacturing Facilities

Coating alloys manufactured at Nimji 2 set of 1MT Induction Furnace 1MT Uni Directional Stirring Furnace
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Minex Manufacturing Facilities

ISO 9001:2008 and NABL accredited lab facilities Adherence to strict quality control during production and process

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Minex Manufacturing Facilities

Alloys manufactured with ASTM standards and specifications 500 Kgs to 1MT cast size or Custom sows for large capacity Use of AlSi 50% alloy for close control of 6/18/12

Production Process
RM used
Si

Raw Material Aluminum Melt + AlSi50 & Zinc Metal

RM Inspection by Lab Weighing as per requirement

EC grade Al
Element Al % Fe 0.20 Max Others traces 99.70 0.10 Max

Transfer Aluminum Melt from Skelner Furnace to UDS (temp. 70015C) Dissolve AlSi50 alloy in Aluminum Melt After dissolution clean dross (temp. 76015C)

Zn Metal added in AlSi melt Till homogenization

AlSi 50
Element Al % 50.0

Sample token is withdrawn for Chemical Analysis

Si 50.0 Max

Fe 0.20 Max

Ca 0.10 Max
Dilution or addition of material depends upon sample analysis

Results Analyzed with ED-XRF

Element Zn Si Fe Zn metal??? % 99.0

Alloy Casting in C I mould (temp. 68515C)

Mould:Mass ratio >1.5 is for better heat dissipation Cleaning of C.I. mould, maintain mould temp in range 150C max, with mould wash coating

others 0.10 Max

Ingot Surface Finish Analyzed for packing & dispatch

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0.20 Max

0.20 Max

Minex Alloy for Surface Coating

Alloy Composition Alloy
Grade Al Zn Al-Zn-Si 55 Alloy 58 -4143 Si Chemical Composition (%) Cd Pub Sn Fe Cu (max) (max) (max) (max) (max)
Ni (max) Ti +Ba+Cr (max)

1.5-2 0.25 0.03 0.05 0.01 0.05 0.05

0.05

AlSi 3% Finished Alloy Element Si % 2.8-3.2

Fe 0.20 max

Others Trace

Al Balance

Ingot Forms

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Advantage
AlZnSi coating alloy v/s AlSi master alloy

Coating alloy directly melted in coating tank Consistent alloy chemistry restricts charge balance for each alloy addition Alloy chemistry designed with close tolerance over tramp and impurities High degree of homogeneity with UDS 6/18/12 furnace

Advantage and Effects

Corrosion performance is mostly related to Al Zn alloy, Silicon addition minimize the growth of brittle intermetallic layer of steel and zinc during Hot DipProcess. 6/18/12

Al-Zn-Si alloy microstructure

2 layers i.e.an AlZn overlay coating and Fe containing intermetallic/alloy layer. Alloy layer forms at the interface between the coating and steel substrate. Due to this, AlZnSi Alloy combines the Galvanic corrosion protection of Zn with the barrier protection of Aluminum

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thank
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you!