Flat Products Coated Steel Sheets Hot-dip Galvanized Sheets, Electrogalvanized Sheets and Precoated Sheets http://www.nssmc.com/ 2-6-1 Marunouchi, Chiyoda-ku,Tokyo 100-8071 Japan Tel: +81-3-6867-4111 Coated Steel Sheets U008en_01_201211f © 2012 NIPPON STEEL & SUMITOMO METAL CORPORATION Coated Steel Sheets of Nippon Steel & Sumitomo Metal Corporation Steel sheets are applied throughout a broad spectrum of life and industry—including automobiles, home electric appliances, building materials, housing, beverage cans, and transformers. Economic growth in the emerging countries and other parts of the world has spurred an expansion in steel sheet use. By its speedy response to a wide range of needs and its rich line-up of products, Nippon Steel & Sumitomo Metal Corporation is renowned for its coated steel sheets. Nippon Steel & Sumitomo Metal develops and markets high-performance steel materials capable of responding to increasingly stringent needs, such as growing concern for the environment and energy conservation. Coated steel sheets, in particular, are required to possess not only rust resistance but press formability, weldability, paintability, and various other properties as well. In addition to metallurgy, a growing diversity of other technologies is indispensable for meeting these needs. They include electro-chemistry, thin-film engineering, paint engineering, interface engineering, corrosion science, thermal technology, and alloying control (dif fusion) technology. In the case of coated steel sheets, if any of these technologies is lacking, customer needs cannot be fulfilled. Nippon Steel & Sumitomo Metal has outstanding command of these various elemental technologies and continues to develop products that precisely meet the performance requirements of its customers. Civil engineering structure Building structural member Hot-dip galvanizing line Heater Road fence Electrogalvanizing line Microwave oven Kitchen stove DURGRIPTM Hot-dip galvannealed steel sheet and strip DURGRIPTM Roof, wall Hot-dip galvanized steel sheet and strip Housing structural member Duct Air conditioner (outdoor unit) Washing machine Refrigerator SuperDymaTM Hot-dip zinc-aluminum-magnesium-silicon alloy coated steel sheet and strip Hot-dip galvanized steel sheets ● Advanced control over the coating atmosphere secures adhesion of the zinc to the base metal, thereby ensuring good workability. These products are used mainly in home electric appliances and building materials. GALVALUME STEEL SHEETTM Hot-dip 55% aluminum-zinc alloy-coated steel sheet and strip ALSHEETTM Automatic vending machine Hot-dip aluminum-coated steel sheet and strip Automobile ECOKOTETM-S Deck plate Greenhouse Steel furniture Sn-Zn coated steel sheet and strip Washing machine Tank roof Building Air conditioner structural (outdoor unit) member Refrigerator Housing structural member ZINKOTETM COLOR Precoated Sheets Pre-Coating Steel Sheet and Strip VIEWKOTETM Pre-Coating Steel Sheet and Strip ZINKOTETM Electrolytic zinc-coated steel sheet and strip DURZINKLITETM Electrolytic zinc-nickel alloy-coated steel sheet and strip Electrogalvanized steel sheets AV equipment Office equipment Precision machine AV equipment Copying machine Steel furniture ECOTRIOTM Zn-Si-Ni alloy coated steel sheet and strip ● The surface texture is uniform and beautiful. The lack of heat treatment during the coating process helps to retain the properties of the base metal. These products are used mainly in home electric appliances for indoor use. Notice: While ever y ef for t has been made to ensure the accuracy of the information contained within this publication, the use of the information is at the reader´s risk and no warranty is implied or expressed by Nippon Steel & Sumitomo Metal Corporation with respect to the use of the information contained herein. The information in this publication is subject to change or modification without notice. Please contact the Nippon Steel & Sumitomo Metal Corporation office for the latest information. SUPERNICKELTM Nickel Coated Steel Sheet and strip Please refrain from unauthorized reproduction or copying of the contents of this publication. The names of our products and services shown in this publication are trademarks or registered trademarks of Nippon Steel & Sumitomo Metal Corporation, affiliated companies, or third parties granting rights to Nippon Steel & Sumitomo Metal Corporation or affiliated companies. Other product or service names shown may be trademarks or registered trademarks of their respective owners. Copying machine Office equipment Battery cell Washing machine Heater Refrigerator Kitchen stove Air conditioner (outdoor unit) Automobile 1 Lineup of Coated Steel Sheets of Nippon Steel & Sumitomo Metal Available sizes Type Brand name Electrogalvanized sheet 0.3 610 50 2.0 1,250 10 0.4 600 40 3.2 1,650 10 0.4 600 40 2.3 1,650 4 0.15 580 15 1.0 1,024 1 0.15 25 〜 4(μm) 0.8 1,000 10 0.4 600 〜 40 0.8 1,650 0.3 25 EG type 10 〜 40 CG type 60 〜 150 〜 Precoated sheet 30 〜 Zn 1,250 〜 Base metal 2.5 〜 VIEWKOTETM 20g/m2(2.8μm) Polyester, etc. (25μm) 160 〜 Zn 610 〜 Topcoat 0.3 〜 COLOR Base metal 40 〜 ZINKOTE Base metal 1,230 〜 TM Fe-Ni alloy Ni layer 1.6 〜 SUPERNICKEL TM Base metal 170 〜 Nickel Coated Steel Sheet and strip Zn-Sn-Ni alloy Special film 610 〜 ECOTRIOTM Base metal 0.25 〜 Zn-Si-Ni alloy coated steel sheet and strip Zn-Ni alloy 20g/m2 (2.8μm) 90 〜 DURZINKLITETM 1,700 〜 Electrolytic zinc-nickel alloy-coated steel sheet and strip Base metal 9.0 〜 ZINKOTE TM 275 〜 Zn 20g/m2 (2.8μm) Electrolytic zinc-coated steel sheet and strip 580 〜 Special film 0.27 〜 Base metal Sn-Zn layer 60 〜 ECOKOTETM-S Base metal 1,840 〜 Sn-Zn coated steel sheet and strip Al-Si alloy 50g/m2 (18.5μm) 6.0 〜 ALSHEETTM Base metal 600 〜 Hot-dip aluminum-coated steel sheet and strip Zn-55%Al alloy 78g/m2 (21μm) 580 〜 GALVALUME STEEL SHEETTM 0.23 〜 Hot-dip 55% aluminum-zinc alloy-coated steel sheet and strip Base metal 60 〜 SuperDymaTM Zn-Al (11%) -Mg (3%) -Si (0.2%) 1,850 〜 Hot-dip zinc-aluminummagnesium-silicon alloy coated steel sheet and strip 4.5 〜 DURGRIP Base metal 120 〜 Zn 120g/m2(17μm) TM 610 〜 Hot-dip galvanized steel sheet and strip Base metal 0.5 〜 DURGRIPTM 30 Width(mm) 〜 Zn-Fe alloyed 45g/m2(6μm) Coating mass Plate thickness (g/m2) (mm) 〜 Hot-dip galvannealed steel sheet and strip Hot-dip galvanized sheet Coating structure (representative example) 1.2 1,300 Features Corrosion resistance Press formability Weldability Paint adhesion Corrosion resistance No treatment ○ ○ Post treatment Chromate-free treatment General Lubricating Other special treatments ̶ ○ ○ ○ Main applications Introduction page ̶ Automobile outer and inner panels home appliance Structural member (shutter) Steel furniture, automatic vending machine 5 ○ Structural member (house, civil engineering structure, road member) Automobile outer and inner panels home appliance Automatic vending machine 6 7 Corrosion resistance (30 times higher than common galvanized sheet) Cut-edge surface corrosion resistance Alkaline resistance Scratch resistance ○ ○ ○ ○ Structural member (house, agriculture/stockbreeding structure, solar panel supporting structure, civil engineering/road structure), home appliance, automobile parts Automatic vending machine Corrosion resistance (3~6 times higher than common galvanized sheet) Thermal resistance, heat reflectivity Decorativeness (spangle) ○ ○ ○ ○ Structural member (civil engineering/ road structure) 8 Corrosion resistance Thermal resistance, heat reflectivity Chemical resistance Decorativeness (aluminum) ○ ○ ̶ ○ Automobile exhaust system parts Heating equipment Toaster, hot-water system 9 Corrosion resistance (bio fuel) Fuel non-permeable property ○ ○ ̶ ̶ Fuel tank 10 Corrosion resistance Conductivity Lubricity, formability Fingerprint resistance Scratch resistance Paint adhesion *Diverse post-treatment menu ○ ○ ○ ○ AV equipment, electronic device home appliance OA equipment Automobile outer and inner panels 11 Corrosion resistance Weldability Paint adhesion ○ ○ ○ ○ Automobile outer and inner panels home appliance Housing equipment 13 Whisker resistance Solder wettability ○ ○ ̶ ̶ AV equipment, electronic device OA equipment 14 Corrosion resistance (particularly after forming) Coating adhesion Thermal resistance, heat reflectivity Decorativeness (luster) ̶ ○ ̶ ̶ Battery Heating equipment 15 ○ home appliance AV equipment, electronic device OA equipment Housing equipment (interior, steel furniture) 12 ○ home appliance, AV equipment, electronic device Fuel cell Housing equipment (steel furniture, door, kitchen, bath) 16 Decorativeness, corrosion resistance, elimination of coating process at user plant (reduction of production process, cost cutting) *Different properties depending on the type Decorativeness, corrosion resistance, elimination of coating process at user plant *Preparation of a variety of product types: high heat absorption, high reflection, self cleaning, deep-drawable metallic, antistatic, grainy, orange-peel-surfaced ○ ̶ ○ ○ ̶ ○ Information about environmental load chemical substances contained in the products of Nippon Steel & Sumitomo Metal Corporation is supplied in the form shown below: 1) Material Safety Data Sheet (MSDS) 2) Information about specified chemical substance content (supplementary MSDS) 3) Specified Chemical Substances Data Sheet (SSDS) For more details, please confirm by accessing our website: http://www.nssmc.com/. 2 3 DURGRIPTM ◆Production Process Hot-dip galvannealed steel sheet and strip Limestone ◆ Main Characteristics Oxygen blowing Iron ore Sintering plant Basic-oxygen furnace Molten iron Coal Coking plant Continuous casting Blast furnace • Excellent paint adhesion and weldability—provided by reheating the zinc-iron alloyed layer produced by heating • Exceptional post-painting corrosion resistance • Excellent press-formability, ranging from bending to deep drawing • Availability of sheet with highly lubricative film treatment Secondary refining Zn-Fe alloy layer Base metal Lubricative film Zn-Fe alloy layer Non-treatment type ● Base metal Lubricative Coating structure film-treated type (representative example) ◆Typical Properties Paint Adhesion Press Formability Reheating The application of lubricative film treatment imparts good press formability. Pickling line Continuous hot-rolling mill •Examples of Paint Adhesion (Primary Adhesion) GA (Lubricative film treatment) Forming tolerance Temper rolling mill 25kN 20kN ×: Split 〇: Pass ×: Split Cold-rolled coil Cold-rolling mill 15kN ×: Split 25kN 〇: Pass 10kN DURGRIP (Galvannealed) Cold-rolled sheet 7kN ×: Creased 〇: Pass 15kN ×: Creased 7kN Treatment condition : Dip-type phosphate treatment Cation ED 20μ baking Assessment test : After drawing grid pattern Erichsen stretch forming, cellophane tape peeling off Forming tolerance (blank folding force) GA (no treatment) Pickled coil Galvanized sheet 10kN 〇: Pass DURGRIP has a finely textured yet rugged surface, ensuring good paint adhesion. 3mm⎫ ⎬Stretching 5mm⎭ Weldability Hot-dip galvanizing line Welder Skin pass Post treatment equipment Tension leveler Pay-off reel The resistance weldability of galvanized steel sheet, in contrast to that of cold-rolled steel sheet, generally requires appropriate welding conditions in the region of high heat input. This is because zinc is a soft metal that easily conforms to the partner metal and because zinc’s low melting point causes it to melt and spread out during the initial welding stage, thereby resulting in lower current density. Consequently, less heat is generated in the overlapped areas. Tension reel Heat Galvanizing treatment bath • Examples of Surface Appearance of Base Substrate Sheet before Coating (Scanning Electron Microscope × 1,000) DURGRIP (galvanized) DURGRIP (Galvannealed) Cold-rolled sheet Direct Spot Weldability Electrogalvanizing line Cleaning tank Post Drying treatment Shear The appropriate welding conditions for coated steel sheets are shown in the figure below. Adequate welding current regions for coated steel sheets are higher than those for cold-rolled steel sheets. ◆Main Applications • Electric appliances Welder Continuous annealing line Galvanizing bath •Example of Appropriate Welding Conditions for Galvanized Sheet t=0.8mm Electrode: Circular type, 5.0 mmø Weld time: 10∞ 13 Coil Welding current (kA) 12 plate, side plate, back plate, bottom plate, parts) • Building and furniture Signboard, door, sash, shutter, cabinet, steel furniture, office equipment Occurrence of expulsion 11 10 Washing machine, refrigerator, air conditioner, automatic vending machine (outer DURGRIP (galvanized)(90/90) • Automobile (outer, inner, parts) DURGRIP (Galvannealed)(90/90) Hood outer, inner Pillar outer Appropriate range (base metal fracture) 9 8 Trunk lid outer, inner Cowl panel Cold-rolled sheet Quarter panel 7 6 Wheel house Outer Shortage of strength 200 250 300 400 Locker outer, inner Welding pressure (Kg) t=0.8mm Front floor Front fender 4 Door outer Door inner 5 DURGRIPTM SuperDymaTM Hot-dip galvanized steel sheet and strip Hot-dip zinc-aluminum-magnesium-silicon alloy coated steel sheet and strip ◆ Main Characteristics ◆ Main Characteristics • High corrosion, and rust resistance similar to that of conventional chromate-treated sheet even with chromatefree treatment • Excellent zinc adhesion and responsiveness to severe fabrication conditions • Product lineup with excellent tribological properties by means of chromate-free treatment Zn Zn-Fe alloy layer Base metal metal Base Chromate-free special film Lubricative film Zn Zn-Fe alloy layer Hot-dip galvanized sheet ● Base Base metal metal Coating structure (representative example) ◆Typical Properties Chromate-free hot-dip galvanized sheet ◆Main Applications Corrosion Resistance Mechanism of Conventional Chromate Treatment and Chromate-free Coating Film • Civil engineering structure and building construction • With remarkably high corrosion resistance compared to hot-dip galvanized steel sheet, inhibits corrosion resistance in cut-end surfaces • Strong alkaline resistance even in direct contact with mortar and concrete • Superior substitute for stainless steel (weak in chlorine resistance) and aluminum (weak in alkaline resistance) • Availability of chromate-free sheet having properties similar to those of chromate-treated sheet Coating Layer Composition and Corrosion Resistance (Salt Spray Tests) Chromate Coating Film ① Shutting out of corrosion factors Chromate-free Coating Film Corrosion factor Coating film H2O ① ③ wall, scaffolding pipe, light-gauge shape, shutter, Coating adhesiveness Coating film O2 sash, door, housing structural member (column, beam) Shutting out of corrosion factors ③ Coating adhesiveness • Automobile Floor, various parts ② ② Self-restorative function Zinc coating layer Corrosionsuppression function Processed/ injured section Steel sheet Steel sheet Chromate coating film When this film is injured, soluble hexavalent chromium leaches out to offer a “self-restorative function” that repairs the film. Function of Chromate Coating Film r#BSSJFSFffect r4FMGrestoration function Zinc coating layer • Shipbuilding R e f r i g e r a t o r, w a s h i n g m a c h i n e , h e a t i n g equipment, air conditioner, automatic vending Corrosion Resistance Mechanism of Chromate-free Coating Film : Chromate-free film uses substances selected because they provide the characteristic features of chromate film such as its barrier effect, self-restorative function and paint adhesiveness. Chromate-free coated sheet has been realized by use of this special coating film. Effects similar to those offered by special coating film containing corrosion-suppression agent 1.02 SuperDyma Zn-11%Al-3%Mg-0.2%Si 0.034 (Reference) In case of no addition of Si Zn-11%Al-3%Mg GALVALUME STEEL SHEET Zn-55%Al Duct, panel Special coating film machine, showcase parts • Industrial machinery Container for transporting agricultural product, 0.060 Surface treatment: No treatment 0.028 0.000 0.100 0.200 0.300 100 DURGRIP (galvanized) 1 2 3 40 SuperDyma K18 20 Hot-dip Zn-coated sheet Z27 2 4 6 8 12.5 12 10 14 pH Zn-coated sheets. Scratch Resistance various parts requiring corrosion resistance Corrosion Protection Mechanism on Cut-end Surfaces and at Welded Sections SuperDyma Repaired section Coating layer The coating layer of SuperDyma is hard, thus offering high scratch resistance. Hot-dip Zn-coated sheet Coating layer GALVALUME STEEL SHEET Iron Load: 0.098 N Red rust Iron Iron 0 20 40 60 80 100 Vicher’s hardness (Hv) 120 140 4 ◆Main Applications As the zinc coating mass increases, the corrosion resistance of the hot-dip galvanized sheet is extended. •Zinc Coating Mass and Time up to Occurrence of Red Rust (Example) (Salt Spray Test) Testing condition (JIS Z 2371) Room temperature : 35˚C Saline solution : 5% Middle period (6 months~several years) Zinc Coating Mass and Corrosion Resistance Moisture Coating layer composition Lapping of coating layer composition Coating layer Moisture Sacrificed corrosion-protection effect Iron Lapping of coating layer composition Iron Iron Bridge (cable rack) 300 Automobile parts 200 100 50 100 150 Coating mass (one side:g/m2) 200 Latter period (Several years~Until zinc around the cut-end surface is lost) Time up to occurrence of red rust (Hrs) GALVALUME STEEL SHEET AZ150 60 The corrosion resistance of SuperDyma (assessed by salt-spray tests to Period (years) 6 80 determine corrosion rate) is extremely high — about 30 times that of hot-dip Initial period (5 days~6 months) Corrosion loss(g/m2) ZINKOTE pH4~6 : Acid rain environment pH9~14 : Cattle and compost shed environment pH12.5 : Mortar and concrete environment 0 Corrosion Resistance of Flat Surfaces Cold-rolled sheet Phosphate-treated sheet (5% NaCl solution, 24 hours) 100 0 • Corrosion Protection Mechanism at Cut-end Surfaces 200 Coating structure (representative example) 0.400 Corrosion loss rate (g/m2/hr) t&YBNQMFPG0VUEPPS&YQPTVSF8FBUIFSJOH5FTUT 4BMU4QSBZ5FTUT 300 Base metal ● 120 Hot-dip zinc-coated sheet Zn • Electric appliance (containing corrosion-suppression agent) Chromate-free special film Zn-Al-Mg-Si Acid and Alkaline Resistance of Various Coated Sheets Corrosion loss (g/m2/side) duct, roofing material, fence, sound-insulation Base metal ◆Typical Properties Guard rail, corrugated pipe, spiral pipe, deck plate, t4USVDUVSFBOE'VODUJPOPG$PBUJOH'JMNT Zn-Al-Mg-Si Protection film Coating layer Iron Iron Iron Air-conditioner outer unit (bottom plate) Compost house (roof, frame) 7 GALVALUME STEEL SHEETTM ALSHEETTM Hot-dip 55% aluminum-zinc alloy-coated steel sheet and strip Hot-dip aluminum-coated steel sheet and strip ◆ Main Characteristics ◆ Main Characteristics • Excellent durability and corrosion resistance • Beautiful silvery white appearance with a finely spangled pattern • Excellent thermal resistance and high heat reflectivity due to aluminum contained in the coating • Available with chromate-free film Zn-55%Al Base metal Chromate-free special film Zn-55%Al Al-Si Base metal Chromate-free special film Al-Si Base metal Base metal ● Coating structure (representative example) ● ◆Typical Properties Coating structure (representative example) ◆Typical Properties Heat Reflectivity Thermal Resistance GALVALUME STEEL SHEET has high aluminum content, 55% of mass and 80% of capacity, and shows better thermal resistance than ordinary hot-dip galvanized steel sheets. Even when exposed to high air temperatures, it shows neither significant increase of mass due to oxidization nor any surface discoloration due to progressive alloying. When used for many hours under temperatures around 350˚C, it undergoes little change. The figure below shows the change in mass when steel sheets are continuously heated in the atmosphere. It is evident that GALVALUME STEEL SHEET undergoes less change due to oxidization than hot-dip galvanized steel sheet. •Example of Oxidation Amount due to Continuous Heating Thermal Resistance The surfaces of GALVALUME STEEL SHEET exhibit excellent heat reflectivity, showing no substantial deterioration after long-term exposure to high temperatures. Materials with high heat reflectivity show a minimal rise in temperature. The use of materials with high heat reflectivity particularly in roofing subjected to large thermal loads is highly effective in preventing increases in indoor temperature. B e c a u s e o f t h e c o m b i n a t i o n o f t h i s p ro p e r t y w i t h t h e aforementioned excellent heat reflectivity, GALVALUME STEEL SHEET is suitable for such applications as the heat shields and the heat reflectors for toasters and microwave ovens. Corrosion resistance The surface appearance of ALSHEET at high temperatures is far superior to that of hot-dip galvanized steel sheet or that of coldrolled steel sheet. No surface discoloration occurs at 350˚C or under. At temperatures above that, the surface becomes an Al-Fe alloy, causing a discoloration. However, this conversion to an alloy prevents oxidization of the base metal, helping to retain the steel sheet’s thermal resistance. •An example of surface conditions after heating (300°C × 200 hours) When heated at temperatures below 350°C, ALSHEET undergoes no surface discoloration, retaining its beautiful appearance. • Example of Comparison of Heat Reflectivity between GALVALUME STEEL SHEET and Hot-dip Galvanized Sheet (3 years after construction) GALVALUME STEEL SHEET 10 • Outstanding weather resistance and corrosion resistance • Discoloration and high thermal resistance in high-temperature application • Excellent high-temperature heat reflectivity, compared to hotdip galvanized steel sheets Hot-dip galvanized sheet [Z 25](400˚C) Solar radiation 850W/m2 (no wind) 9 0 Because ALSHEET, like aluminum, easily generates fine yet stable oxide and hydroxide films in the atmosphere and in water, its corrosion resistance under various conditions is superior to that of galvanized steel sheets. In application, however, it should be borne in mind that, contrary to galvanized steel sheet, galvanic action (sacrificial action) cannot be expected of ALSHEET. •Cyclic wetting and drying tests (Resistance to exhaust gas corrosion) As a result of corrosion tests using automobile exhaust gas-condensed simulated fluids, ALSHEET demonstrates better corrosion resistance than do electrogalvanized steel sheets and cold-rolled steel sheets. •Example of Muffler Test Result (Chrysler's Spec 461H-83) Cold-rolled sheet set as 100 Hot-dip galvanized sheet Type Solar radiation 850W/m2 (no wind) 0 Corrosion rate (%) 50 100 22.9% 18%Cr stainless steel Oxidation amount(g/cm2) 8 7 50 50 100 100 150 150 W/m2 W/m2 6 5 4 GALVALUME STEEL SHEET [AZ 150](400˚C) 3 27.5% 13%Cr stainless steel 30.1%(16m)* ALSHEET 80g/m2 Electrogalvanized sheet 20/20g/m2 ALSHEET Hot-dip galvanized sheet Electrogalvanized sheet 92.8%(80m)※ Cold-rolled sheet 100%(87m)※ Cold-rolled shee 2 GALVALUME STEEL SHEET [AZ 150](300˚C) 0 100 200 300 400 500 600 700 800 900 Note: Data of Bluescope Lysaght •Example of Heat Reflectivity of Various Roofing Materials Oxidation time (hours) Corrosion Resistance •Example of Red Rust Occurrence Time GALVALUME STEEL SHEET (AZ150) Materials Heat Reflectivity (%) GALVALUME STEEL SHEET (no coating) 70 – 75 Prepainted sheet (light color, brightness 6.0 – 8.5) 30 – 70 Prepainted sheet (deep color, brightness 4.5 ‒ 7.0) 15 – 40 Tile, slate (light color) 20 – 30 Tile, slate (dark color) 10 – 20 Concrete, cement 20 – 30 Cut-end surface protection Hot-dip galvanized sheet Hot-dip galvanized sheet (Z27) 0 1,000 * ( ): Corrosion loss Heat reflectivity Hot-dip galvanized sheet [Z 25] (300°C) 1 30 – 40 Because of its extremely beautiful surface, ALSHEET shows exceptional heat reflectivity—nearly 80% at temperatures of 450°C or below. Accordingly, ALSHEET is ideal for use in applications requiring heat reflectivity, including the inner heat shields for toasters and the upper reflectors for gas ovens and kerosene heaters. •Example of Heat Reflectivity of Various Materials Material Item Heat reflectivity Test condition ALSHEET Spangled Non-spangled ( ) 100˚C×24Hrs 90 95 95 95 400˚C×24Hrs 80 30 20 20 2,000 1% red rust occurrence time (hours) 3,000 • Building construction and civil engineering structure •D and S AERP emissivity meter (measurement wave 3 – 30m) Unlike zinc, aluminum has the property of being resistant to weak acidity and vulnerable to alkalinity. ◆Main Applications Hot-dip galvanized sheet ZINKOTE electrogalvanized sheet •Measurement at room temperature after heating ◆Main Applications (unit:%) Chemical resistance • Hot-water system • Oven toaster • Bread machine • Stove • Fan heater • Cloth dryer • Automobile (muffler, manifold cover, converter cover) Roofing material, wall material, partition, other structural metal fittings • Electric appliance Refrigerator, washing machine, air conditioner, automatic vending machine, showcase, range, stove, microwave oven 8 9 ECOKOTETM-S ZINKOTETM Sn-Zn coated steel sheet and strip Electrolytic zinc-coated steel sheet and strip ◆ Main Characteristics ◆ Main Characteristics Chromate-free special film • Higher corrosion resistance than found in conventional fuel tank metallic materials • High corrosion resistance, even when used with bio fuels • Meets hydrocarbon permeation regulations; is free of environmental load substances • Highly recyclable • Demonstrates similar effects in application as chromate-treated sheet due to ZINKOTE’s special film containing a corrosion inhibitor • Availability of characteristic properties that conform to respective customer needs thanks to ZINKOTE’s diverse post-treatment lineup Sn-Zn alloy layer Pretreatment Base metal ● Coating structure (representative example) Responsiveness to Environmental Preservation: ECOKOTE -S is most suitable for use as an eco-friendly fuel tank material. ① Inferior permeation shut-off performance Inferior recyclability Use of lead No inclusion of environment burden substance Concerns about corrosion resistance in case of using common bio fuel Inner surface corrosion resistance No inclusion of environment burden substance Growing concerns about permeation and deterioration • Main End Products Employing ZINKOTE because they provide the characteristic features of chromate film such as its barrier effect, self-restorative function and paint adhesiveness. Chromate-free coated sheet has been realized by use of this special coating film. Application (example) Application member Flat panel display Chassis, various parts Effects similar to those offered by special coating film containing corrosion-suppression agent Copying machine, printer various parts • Various Parts Film Organic film High formability and lubricity due to surface film action Inorganic film Excellent conductivity and adhesion because of thin film thickness Required performance • Importance on conductivity • Importance on corrosion resistance and scratch resistance Audio equipment, etc • Side Plate Refrigerator, washing machine, etc • Importance on conductivity, paintability and ironing property Press formability Weldability Excellent Excellent Excellent Fair Excellent × Fair Fair Fair Excellent Degraded 20%FAMEmixed gasoline Degraded ethanol-mixed gasoline ECOKOTETM-S (Sn-Zn coating) Excellent Excellent ALSHEETTM (aluminum coating) Excellent Excellent Fair Fair Excellent 20 • Example of Corrosion Resistance of Formed Section QS1 QF1・T1N QM 10 QS1 0 30 50 72 Test time (hr) QM QF1 T1N 20 QS1 QF1・T1N QM 10 QS1 0 30 50 QM QF1 T1N T1N 72 Test time (hr) Conductivity (Grounding Property) Outer surface corrosion resistance Degraded gasoline • Fuel tank Resin Lighter weight by use of steel’s rigidity instead of identical capacity Fair Zinc coating layer • Example of Corrosion Resistance of Flat Surface Section (A kind of typical surface treatments is shown) TERNESHEET (Pb-Sn coating) ALSHEET (Aluminum coating) High recyclability because of steel sheet Fair Corrosion Resistance Mechanism of Chromate-free Coating Film : Chromate-free film uses substances selected Salt Spray Test: Flat Surface Section and Formed Section (Erichsen 7 mm Extruded Section) TM Outstandingly high corrosion resistance Processed/ injured section Corrosion Resistance No fuel permeation because of steel sheet Lighter weight ZINKOTE is a chromate-free electrogalvanized sheet used for flat panel displays, copying machines, printers and other devices and equipment. adhesiveness Corrosionsuppression function Automobile Recycling Law Characteristic Properties of Fuel Tank Material Promotion of recycling r#BSSJFSFffect r4FMGrestoration function When this film is injured, soluble hexavalent chromium leaches out to offer a “self-restorative function” that repairs the film. ③ Coating Special coating film Regulation for new fuel efficiency Regulation for upper limit for fuel permeation Coating film (containing corrosion-suppression agent) Lighter weight ECOKOTE -S (Sn-Zn coating) O2 Steel sheet ECOKOTETM-S TM ② Bio fuel Promotion of recycling ZINKOTE: Used for high-performance electric appliances and OA equipment Function of Chromate Coating Film Rust occurrence area rate (%) Regulation for environmental burden substance Increasing use of eco-friendly fuel H2O Shutting out of crrosion factors Rust occurrence area rate (%) ELV regulations (Europe) ◆Main Applications Coating structure (representative example) Corrosion Resistance Mechanism of Chromate-free Coating Film Corrosion factor Requirements of fuel tank materials: total absence of substances that add to environmental burden, resistance to new fuels, no fuel permeation, advantageous for recycling, and light-weight design Regulation for upper limit for fuel permeation TERNESHEET (Pb-Sn coating) ● ◆Main Applications • Chromate-free Coating Film Emerging environmental needs facing fuel tank materials Regulation for environment burden substance Increasing use of ecofriendly fuel Base metal ◆Typical Properties TM Voluntary regulations of Japan Automobile Manufacturers Association (Japan) Zn [Main Properties of ZINKOTE] •Corrosion resistance •Lubricity •Conductivity •Spot weldability •Thermal resistance •Alkaline resistance •Solvent resistance •Fingerprint resistance •Paint adhesion ◆Typical Properties ZEV regulations (US) Surface treatment Paintability t-PSFTUB 1SPWF5ZQF Good Excellent t$PODFQUPG$POUBDU3FTJTUBODF.FBTVSFNFOU%FWJDF -PSFTUB1SPWF5ZQF Measurement device Measurement system Measurement range Probe Loresta EP type made by Mitsubishi Chemical Corp. 4 contact/4 probe method, constant current application system Constant current source TN i 10 〜10 Ω ESP probe (Pin tip 2 mmφ × 4 contacts, pin interval 5 mm spring pressure 2.4 N/spring Conducting cycle* Assessment Conducting rate(%)= × 100 20 cycles -2 t&YBNQMFPG$POUBDU3FTJTUBODF5FTUT(-PSFTUB1SPWF5ZQF) V T1N 6 Test piece QS1 10 20 30 40 50 60 70 80 90 100 Conducting rate (%) *Conducting=Les than 1mΩ 10 11 ZINKOTETM COLOR DURZINKLITETM Pre-Coating Steel Sheet and Strip Electrolytic zinc-nickel alloy-coated steel sheet and strip ◆ Main Characteristics ◆ Main Characteristics • Excellent cost performance and reduced manufacturing term at user plant by coating only one side of ZINKOTE with a beautiful topcoat • Available colors (3): black, silver and white, and preparation of improved scratch-resistant type • Black coated sheets (2): both-sided black coated type, and highconductivity/good heat-absorption type • Outstandingly high corrosion resistance even with conventional electrolytic galvanizing mass • Fine appearance and finishing after coating, similar to cold-rolled sheet • Easy spot and seam welding Topcoat Zn (electrogalvanizing) Base metal Zn (electrogalvanizing) Base metal Conductive film ● Coating structure (representative example) ● ◆Product Lineup Color Coating structure (representative example) ◆Typical Properties Type Heat treatment symbol Surface finish Standard type Excellent cost performance due to improved topcoat performance; Preparation of two kinds of surface roughness depending on appearance̶ general roughness and high roughness KJ1 D (general) D5 (high roughness) Improved scratch-resistant type Improved scratch resistance due to addition of large-diameter beads to film KJ2 D Standard type Excellent cost performance due to improved topcoat performance SJ1 D Improved scratch-resistant type Improved scratch resistance due to addition of large-diameter beads to film SJ2 D White Standard type Excellent cost performance due to improved topcoat performance HJ1 D Black Standard both-sided black type Excellent cost performance due to improved topcoat performance K1K1 D (general) D5 (high roughness) Standard conductive, heat-absorbing black type Standard black film (KJ1 film) on one side, and conductive heat-absorption black film on the other K1KC D (general) D5 (high roughness) Conductive, heat-absorbing type with conductive clear film Conductive clear film (QS film) on one side, and conductive heat-absorption black film on the other KJC D (general) D5 (high roughness) Black Zn-Ni alloy Weldability Bare Corrosion Resistance In commonly conducted salt spray testing, the bare corrosion resistance of DURZINKLITE coated surfaces is more than 3 times greater than galvanized sheets with equal coatings. This product shows favorable corrosion resistance even with a thin coating mass, but the provision of a special chromate treatment further improves corrosion resistance. • Example of Corrosion Resistance Assessment of DURZINKLITE (Non-treated Sheet Salt Spray Test) Individual spot or seam welding of DURZINKLITE can be conducted using low welding current, and because the welding current range is wide, welding is easy. Examples of single spot welding at a range of welding currents for both-side galvanized sheet are shown at right. In each case, adequate nuggets are formed using a comparatively low welding current, and the recommended range of welding currents is wide to allow easy welding. Silver • Example of Welding Current Range for Single Sport Welding of Bothside Galvanized Sheet DURZINKLITE 5% red rust occurrence time (hours) Conductive, heat-absorbing black 300 Shortage of nugget diameter DURGRIP (galvanized) 200 Appropriate welding current range Electrode welding dn=4√t DURZINKLITE (20g/m2) ZINKOTE (20g/m2) 100 DURGRIP(galvannealed) (45g/m2) ◆Main Applications • Home appliance •AV equipment, electronic device •OA equipment •Housing equipment (interior, steel furniture) 12 ZINKOTE Cold-rolled sheet 0 20 40 60 80 100 Type Coating mass (g/m2) 6 7 8 9 Welding current (KA) Reference: Time required for the occurrence of red rust in the salt spray test JIS Z 2371 13 ECOTRIOTM SUPERNICKELTM Zn-Si-Ni alloy coated steel sheet and strip Nickel Coated Steel Sheet and strip ◆ Main Characteristics ◆ Main Characteristics • Lead-free and chromate-free, and conforms to RoHS (Restriction of Hazardous Substances) Directive • Greater suppression of whiskers compared to electrolytic tinplate • Solderability and conductivity that are similar to electrolytic tinplate and higher than those of galvanized steel sheet • Availability of thin-gauge products with a minimum thickness of 0.15 mm • NEW ECOTRIO even in thin coating mass specifications: Taking over the basic properties of ECOTRIO • High-strength ECOTRIO: Cost-cutting substitute for nickel silver and stainless steel sheets ● ◆Typical Properties ◆Main Applications t5FTU3FTVMUGPS0DDVSSFODFPS/P0DDVSSFODFPG 8IJTLFSVOEFS)JHI5FNQFSBUVSFBOE)JHI)VNJEJUZ$POEJUJPO [Test condition] Test piece: Plate thickness 0.3 mm, cup forming Environment:60˚C × 90%RH Time:1000hrs Observed maximum whisker length (μm) 200 160 120 80 40 0 ECOTRIO 3X/3X ECOTRIO 8/8 Electrolytic tinplate 2.8g/m2 * The data shown here is an example of test results, which therefore does not mean any quality guarantee. * In cases when the whisker resistance under strict high-temperature conditions (for example, high temperature and high humidity surpassing 60°C) is required, the product with importance on whisker resistance can be proposed. For details, please send inquiries. Zn-Sn-Ni alloy layer Base metal • High adhesion and corrosion resistance due to formation of Fe-Ni alloy layer • Availability of material quality that conforms to the particular application and the degree of fabrication • Diverse surface finishes are available, from an outstandingly fine mirror finish to a rough dull finish. • Availability of coatings from thin to heavy and of differential coatings on front and rear surfaces • Same thermal resistance as that of stainless steel Coating structure (representative example) •Game console •Automobile AV equipment •TV set •Personal computer •Electric and electronic parts •Audio system ◆Typical Properties 700 External appearances of the top and body parts of size C and AA batteries made of SUPERNICKEL steel sheets and Ni-coated sheets without alloy layer, after subjected to 60 minutes of salt spray tests are shown below. In both cases, batteries made of SUPERNICKEL steel sheet shows better post-fabrication corrosion resistance. 600 •External appearances after SST (coating thickness: 2μm) •Glossiness of surface finish 1000 BM finish 900 800 500 BE finish Top •Switch metal fitting 300 •Flow regulating valve 200 SUPERNICKEL B finish Fabricated into size C batteries 100 1 2 3 4 5 Bad After acceleration Solder wetting time (Zero crossing time) (sec) 6 4 2 ※SST: Pursuant to JIS Z 2371 •Tuner cover Coating Adhesion (workability) Good ECOTRIO 3X/3X ECOTRIO 8/8 SUPERNICKEL • Heat sink metal fitting 100 Ratio of red rust occurrence area (%) Bad △ (Peeling found) Erichsen test ◎ (No peeling found) ◎ (No peeling found) Cupping test ◎ (No peeling found) △ (Peeling found) Work follow Bending test ○ (Virtually no cracks found) × (Many cracks found) (SEM observation) Erichsen test ○ (Virtually no cracks found) × (Many cracks found) Bending test A cellophane tape on the coating is peeled after 0T bend. Test Methods t$PSSPTJPO3FTJTUBODF 4BMU4QSBZ5FTU Good ◎ (No peeling found) adhesion Corrosion Resistance 80 [Test condition] Corrosion resistance: (Salt spray test JIS Z2371) Test piece: Flat sheet with edge seal 8hrs 24hrs 48hrs 60 • Electrical equipment metal fitting • Electrical equipment metal fitting Comparative example: Ni-coated sheet without alloy layer (non-diffusion type) Bending test Coating •Shield cover Electrolytic tinplate 2.8g/m2 Corrosion Resistance of As-coated Flat Sheet Without Fabrication •An example of evaluation of coating adhesion (workability) (tape peeling) 0 Ni-coated sheet without alloy layer Evaluation method Glossiness:Measured in transverse direction at an incidence angle of 60 degrees with Nihon Denshoku Model VGS-ID glossmeter. •Condenser case 8 Body 400 t.FBTVSFNFOU3FTVMUTGPS4PMEFS8FUUJOH5JNF Without acceleration Coating structure (representative example) Post-fabrication Corrosion Resistance Surface gloss Solder Wettability (Solder Wetting Time) 10 Base metal ◆Main Applications Coating thickness (μm) [Test condition] Test piece: 0.3mm×20mm×7mm Kind of solder: Sn-Ag-Cu Solder melting temperature Flux applied: Rosin alcohol active type accleleration conditions: 100°C (saturated humidity), 8 hrs Ni layer Fe-Ni alloy layer ● Glossiness Chromate-free Coating Film Chromate-free special film Erichsen test Cupping test A cellophane tape on the coating is peeled after a 7mmdeep cup is formed. Cellophane tapes on the inside and outside are peeled after a 30mm-deep cup is drawn. SUPERNICKEL steel sheet shows better corrosion resistance than Ni-coated steel sheet without alloy layer on both unfabricated and fabricated parts due to ① reduced pinholes on the coating layer, ② formation of an Fe-Ni alloy layer having good adhesion, and ③ improved ductility due to recrystallization and softening of the Ni coating layer. Heat Resistance SUPERNICKEL steel sheet has heat resistance comparable to stainless steel (SUS) that is normally used as a heat-resistant material (heating temperature ~300°C). As typical evaluation results of heat resistance, changes in glossiness, changes in infrared-ray reflectance and changes in color tone on heating are shown below. ◆Main Applications 40 •Binder 20 0 ECOTRIO 3X/3X ECOTRIO 8/8 Electrolytic tinplate 2.8g/m2 •Portable cooking stove •Stove reflection plate High in whisker resistance, solder wettability and corrosion resistance 14 •Battery •Toaster 15 VIEWKOTETM Pre-Coating Steel Sheet and Strip Self-Cleaning Type VIEWKOTE ◆ Main Characteristics ❶ Hydrophilic coating vastly improves Topcoat • Smooth and fine painted surface • Selection of colors and material properties that meet specific needs, through the combined use of diverse paints and base substrates • Improved such factors as process, space, energy and load savings at user plant resistance against rain drop stains. ❷ Offers high workability thanks to optimal substrate design. ❸ Also offers excellent weatherability and stain resistance in processed areas. ❹ A wide range of color variations, including metallic tones. ❺ Chromate-free and eco-friendly. Primary coating Surface treatment Base metal Surface treatment [Paint type of VIEWKOTE] • TypeⅠ/ Highly workable type • Type Ⅱ / Balanced type in workability surface physical properties • Type Ⅲ / Stain-resistance type • Type Ⅳ / Highly workable, stain-resistant type(universal type) • Type Ⅴ / Highly corrosion-resistant type Rear surface coating ● Coating structure (representative example) ◆Typical Properties Lighting equipment Flat-panel TV Digital recorder Auto on-board equipment Reflecting board Back panel Chassis Chassis Outdoor exposure for 1.5 years at Kimitsu City, Chiba, Japan (industrial zone) Hydrophilic coating Water Self-Cleaning Type Coating Stain Primer coating Chemical treatment Galvanized steel sheet The hydrophilic coating allows drops of water to penetrate under stains Chemical treatment Back coating The stains are then washed away SelfCleaning Type Conventional VIEWKOTE for outdoor airconditioner units Deep Drawable Metallic VIEWKOTE VIEWKOTE recommended specifications Front side VIEWKOTE TypeⅠ Back side VIEWKOTE TypeⅠ Front side VIEWKOTE Type Ⅳ Back side Electroconductivity Type Front side VIEWKOTE Type Ⅳ Back side Electroconductivity type Front side VIEWKOTE Type Ⅳ Back side Heat Absorption Type Application Outdoor air-conditioner unit Refrigerator, washing machine Automobile parts Application parts/ materials VIEWKOTE recommended specifications ❶ Offers attractive appearances. ❷ Suitable for processing applications Front side VIEWKOTE Type Ⅳ Top, outside panel Back side that require bending or drawing. VIEWKOTE Type Ⅱ ❸ Add functions by selecting the Front side VIEWKOTE Type Ⅳ Side panel Back side appropriate back coating. Example: To discharge internal heat, select high heat absorption type coating. ❹ Chromate-free and eco-friendly. Rear surface coating Front side VIEWKOTE Type C Oil filter Back side Lubrication Type • Home appliance •AV equipment, electronic device •Fuel Cell •Housing equipment (door, kitchen, bath) ❶ Prevents static electricity caused by High Heat Absorption Type VIEWKOTE discharges heat from devices/ equipment. ❷ Heat absorption coating inside the device enclosure facilitates heat absorption and discharge. The broad VIEWKOTE menu allows ❸VIEWKOTE steel sheets are chromate-free and eco-friendly. Coating Structure(Example) • Atmospheric thermometry result of the interior of the Box (example) 80 ZINKOTE Colored top coating Primer coating Chemical treatment Galvanized steel sheet Chemical treatment Heat Absorption Coating Drop about 70 Temperature (°C) ❶ Heat absorption type VIEWKOTE Under these experimental conditions, steel sheets with an endothermic film can reduce the atmospheric temperature of the interior of the Box by about 10˚C in comparison to the bare specifications of ZINKOTE. 0 20 40 60 80 100 120 Measurement time (min) High Reflection Type VIEWKOTE •Measurement of diffuse reflection factor (example) Improved to diffuse reflectivity of 10% or more. High Reflection Coating Chemical treatment EGC 0.55mm Coating mass 20/20 Back coating VIEWKOTE E type Chemical treatment Galvanized steel sheets Chemical treatment Back coating Top coating Silver metallic (VIEWKOTE Type $ ) Coating Structure(Example) Antistatic Type VIEWKOTE Coating Primer coating Galvanized steel sheet Chemical treatment Chemical treatment Back coating •Example: Comparison of charged voltage 0.3 0.2 0.1 82 0 Antistatic Type VIEWKOTE Conventional VIEWKOTE Experiment conditions: Measurement of the charged voltage of the coating surface by non-contact type static electricity measuring apparatus immediately after VIEWKOTE sample (70×150mm) makes contact with a piece of neoprene resin (50×100mm) and is then detached. Grainy VIEWKOTE ❶ By adding beads with large particle diameters to the coating,this type of VIEWKOTE features highly decorative designs,much better than those of conventional prepainted steel sheets. ❷ The decorative designs can be improved further by combining embossing and/or press forming. ❸ Chromate-free and eco-friendly. Coating Structure(Example) •Example:Appearance after embossing 1mm Grainy VIEWKOTE Coating Primer coating Galvanized steel sheet Chemical treatment Chemical treatment Back coating Beige color Brick colored Orange-Peel-Surfaced VIEWKOTE Reflection film Primer coating Galvanized steel sheet Primer coating Zn standards Indicated thickness General white PCM High Reflection Type VIEWKOTE including corrosion and chemical resistance. ❹ Both electromagnetic shielding and temperature control can be achieved by selecting heat absorption types with good electroconductivity in the back coating. ❺ Chromate-free and eco-friendly. Coating Structure(Example) •Processing Examples of Deep Drawable Metallic Type Deep Drawable Metallic Type Coating Heat Absorption 50 ❶ Diffuse reflectivity of 92-98%. ❷ Can be deep drawn. ❸ Has excellent basic properties friction from conveyors and rubber suction disks in the processing/ production process. ❷ Reduces dust adhesion caused by static electricity. ❸ Reduces electric shocks caused by static electricity. ❹ Chromate-free and eco-friendly. 10˚C 60 40 Coating Structure(Example) Antistatic Type VIEWKOTE ◆Premium Series High Reflection VIEWKOTE (92% type) Chemical treatment Back coating High Reflection VIEWKOTE (98% type) 80 82 84 86 88 90 92 94 96 98 100 Diffuse Reflectivity (Wavelength 555nm) ※ Can be designed with reflectivity of 92 or 98%, depending on the application. 16 •How self-cleaning works Charged voltage (kV) Application Application parts/ materials Coating Structure(Example) ❶ A pebbled surface like that of an orange peel is achieved by special beads in the coating. These beads then melt during heating when the coating is enameled. ❷ This coating improves processing yield by making handling scratches less visible. ❸ Its workability, chemical resistance, and other basic properties are the same as conventional VIEWKOTE. (Can also include antistatic property.) ❹ Chromate-free and eco-friendly. Coating Structure(Example) •Example:Orange-Peel-Surfaced VIEWKOTE Orange-PeelSurfaced VIEWKOTE Coating Primer coating Galvanized steel sheet Chemical treatment Chemical treatment Back coating 17