Contents
Foreword ……………………………2
Features ……………………………3
Production Processes ……………4
Examples of Uses …………………5
Specifications ………………………9
Properties …………………………13
Steel Pipe …………………………23
Standard Specification for
Steel Sheet, Cold-Rolled,
Aluminum-Coated Type 1 ………25
1
Nisshin Steel Quality Products
Foreword
Nisshin Steel Co., Ltd. is Japan's sixth largest producer of iron and steel, with an annual crude
steel production capacity in excess of three million tons. The Company, a member of the
International Iron and Steel Institute, has extensive experience in the production and marketing of
ordinary, specialty, and stainless steel.
Nisshin is particularly strong in coated and stainless steel and has also established a firm
position in the ordinary and specialty steel markets. The Company has maintained the highest
technological standards, developing innovative technology and marketing superior quality steel
products for industry and the home.
Nisshin Steel Co., Ltd., well-known for Moonstar brand galvanized sheet, galvannealed sheet, and
spangle-free galvanized sheet, proudly introduces Alstar, a new type of aluminized steel sheet
and coil that has more versatility than conventional aluminized steel sheet. Aluminized steel
sheet had been produced by the roll-wiping method in Japan since 1962, but the gas-wiping
method developed by Nisshin Steel in 1968 has improved the uniformity and appearance of
aluminum-coated steel sheet. This new process has also widened the scope of aluminized steel
sheet applications. Alstar metallurgically combines the strength of steel with the advantages
of aluminum, and is extensively used where heat resistance is involved. Specific uses are in
heat-resistant parts and products for automobiles, burners, and home appliances. Alstar now
enjoys the largest share of the domestic aluminized steel sheet market.
Aerial view of the Sakai Works
Nisshin Steel Quality Products
2
Features
Alstar features heat resistance, corrosion resistance at high temperature, heat reflectivity, attractive appearance, nonpolluting
properties, and other characteristics that are unique to aluminized steel sheet. The gas-wiping method developed by Nisshin Steel
has been applied to Alstar production to offer the following additional features.
1
Uniform aluminum coating and free control of aluminum thickness.
2
Thin aluminum coating（40g/m2 on both sides）
. This means better weld-ability and formability and hence
better productivity.
3
Even surface finish and silvery white appearance make Alstar useful in applications where a fine finish is
important.
4
Nisshin's aluminizing line is in constant operation so Alstar is available where and when it is needed.
3
Nisshin Steel Quality Products
Production Processes
Figure 1 : Production Processes
8
5
2
4
Coil
1
3
9
10
12
7
14
1
Cut-length
Coil
6
13
2
3
11
4
1.
2.
3.
4.
5.
6.
7.
Uncoiler
Shear
Welder
Looper
Oxidizing, reducing, and annealing furnace
Aluminum coating bath
Gas-wiping
Cold Rolled
Steel Coils
Oxidizing, Reducing,
and Annealing Furnace
8.
9.
10.
11.
12.
13.
14.
Cut-length
Cooling tower
Skin pass mill
Tension leveller
Posttreatment tank
Shear
Recoiler
Skin pass mill
Aluminizing
Cooling
Posttreatment
Aluminum
Coated Steel
1.Annealing process
Nonannealed cold-rolled steel strip is annealed and the oxide film formed on the surface is reduced in the furnace.
2.Coating process
After the strip is reduced to a clean surface, it is passed through the aluminum coating bath. The weight of aluminum coating on
the strip is regulated by the gas-wiping method.
3.Posttreatment process
The aluminum-coated strip is then treated by chromate solution to make it further corrosion resistant. After thorough drying, the
sheet is wound back into a coil.
4.Skin passing process
The aluminum-coated strip is skin passed to make it suitable for specific uses, where such factors as surface conditions and age
hardening are involved.
Nisshin Steel Quality Products
4
Examples of Uses
Kerosene heater
Kerosene heater
Kerosene heater
Large-sized kerosene heater
Large-sized kerosene heater
Large-sized kerosene heater
Kerosene heater
Water heater
5
Nisshin Steel Quality Products
■ Examples of Uses ■
Kitchen utensils
Kitchen utensils
Kitchen utensils
Oven, toaster
Gas oven
Two-burner gas stove
Gas range
Smokestack
Nisshin Steel Quality Products
6
■ Examples of Uses ■
Muffler
Muffler
Muffler
Muffler
Heat insulator
Reactor part
Muffler and converter
7
Nisshin Steel Quality Products
■ Examples of Uses ■
Manifold cover
Manifold cover
Manifold cover
Charcoal stove
Charcoal stove
Chimney
Barbecue grill
Kerosene stove
Fireplace
Nisshin Steel Quality Products
8
Specifications
1.Types of Alstar
(1) Alstar is available in the following types which vary with the uses and the means of processing.
Table 1
Symbol
ASTM（A463）
Surface Finish
Commercial Quality
Type
C
CQ
Dull
Drawing Quality
D
DQ
Dull
Deep Drawing Quality
E
DQSK
Dull
(2) Indication of product's standard is as follows:
MSA
C（D,E）
Quality
Product
symbol
D
△△
×××
Posttreatment
Surface finish
（Dull）
Mass of
aluminum coating
(3) There are several kinds of posttreatment for various uses. These include ordinary chromate and oiling
and oiling nonchromate.
Table 2
Posttreatment
Symbol
Chromate and oiling
N0
Oiling nonchromate
M0
2.Masses of Aluminum Coating
Alstar is available in various masses of aluminum coating as shown in the following table.
Table 3
Item
Symbol
Minimum mass on both
sides（triple-spot test）
ASTM（A463）
Nisshin Standard
T1-25
T1-40
MSA-40
MSA-60
MSA-80
MSA-100
g/m2
（80）
（120）
40
60
80
100
120
ox/ft2
0.25
0.40
（0.13）
（0.20）
（0.25）
（0.33）
（0.40）
Note : Minimum masses on both sides by the triple-spot test are based on the ASTM standards.
9
Nisshin Steel Quality Products
MSA-120
■ Specifications ■
3.Mechanical Properties
Tension and bend tests of Alstar produce the following values.
(1) Tensile strength and elongation
Table 4
Elongation（％）
, Thickness（mm）
Tensile
Strength
（N/mm2）
0.4 to 0.6
excl.
0.6 to 0.8
excl.
0.8 to 1.0
excl.
1.0 to 1.6
excl.
1.6 to 2.3
incl.
Commercial Quality
（270）
（23）
（26）
（28）
（30）
（31）
Drawing Quality
（270）
30
32
33
34
35
Deep Drawing Quality
（270）
34
36
37
38
39
Type
Notes : 1. The No.5 test specimen in JIS Z2201 is used for the tension test which is conducted in conformity with JIS Z2241.
2. Values in parentheses for commercial quality sheet are for reference only.
(2) Bend test
A specimen taken from the aluminized steel sheet in the direction parallel to its rolling is bent through 180°over a radius of 0.5t at
right angles to the rolling direction. The outside of the bend shall be free from flaking of the coating, and cracking and breaking in
the base metal. This does not apply to those par ts of the specimen which are within 7mm of both ends.
Note : The bend test specified in the ASTM standards may be conducted on the product if requested.
4.Available Dimensions
Alstar is available in the dimensions shown in the chart below.
Figure 2
1,200
1,219 or under
1,150 or under
1,100
1,070 or under
Width（mm）
1,000
1,000
914
900
800
700
600
700 or
over
600 or over
0.3 0.4 0.5 0.6 0.7
under
1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0 2.1 2.2 2.3
Thickness（mm）
Nisshin Steel Quality Products 10
■ Specifications ■
5.Dimensional Tolerances
Dimensional tolerances are as shown below.
Alstar can also be manufactured to the dimensional tolerances of the ASTM A463 standards.
(1) Thickness tolerances
Table 5
（mm）
Width
Thickness
Under 1,000
1,000 or Over
0.27 to 0.40 excl.
±0.06
±0.06
0.40 to 0.60 excl.
±0.07
±0.07
0.60 to 0.80 excl.
±0.09
±0.09
0.80 to 1.00 excl.
±0.10
±0.11
1.00 to 1.25 excl.
±0.11
±0.12
1.25 to 1.60 excl.
±0.13
±0.14
1.60 to 2.00 excl.
±0.14
±0.15
2.00 to 2.30
±0.16
±0.17
Notes : 1.The thicknesses shown in the above table indicate sheet thicknesses plus
the thicknesses corresponding to aluminum coating masses.
2.Thickness is measured at any point across the width not less than 50mm
from a side edge.
(2) Length and width tolerances
Table 6
Table 7
（mm）
（mm）
Item
Tolerance
Edge
Tolerance
Length
＋12, −0
Mill edge
＋10, −0
─
Slit edge
±0.5
Applies to widths less than 600mm
Note : The length tolerances shown in
Table 6 do not apply to coil
products.
Remarks
(3) Flatness tolerances
The flatness tolerance shall be less than the figures shown in Table 8.
Table 8
（mm）
Thickness
Type
Long Edge
（maximum deviation from a horizontal flat surface）
Center Buckle
（maximum deviation from a horizontal flat surface）
Under 0.5
0.5 or over
Under 0.5
0.5 or over
Panel Quality
5
5
3
3
Commercial Quality
8
8
5
5
Press Forming Quality
11
8
8
5
Notes : 1. Flatness tolerances apply to cut length sheets.
2. Consult us about tolerances for panel quality and commercial quality sheet when ordering.
11 Nisshin Steel Quality Products
■ Specifications ■
(4) Camber tolerances
Camber is the greatest deviation of a side edge from a straight line. Camber measurement is taken as shown in Figure 3 for cutlengths and Figure 4 for coils.
The camber tolerance for sheet with a width of 50mm or over and less than 200mm, and with a length of 2,000mm or over and
less than 3,048mm, is measured as shown in Figure 4.
Figure 3
Figure 4
Length
Width
Width
Camber
2,000mm
Camber
The camber tolerance values apply to normal parts of coils and cut-lengths. Their camber tolerances must be less than the values
shown below.
Table 9
（mm）
Width
Cut-length
Length under 2,000
Length over 2,000 to 3,658 excl.
Coil
50 to 60 excl.
─
─
8 per 2,000
60 to 200 excl.
─
─
4 per 2,000
200 to 600 excl.
─
─
4 per 2,000
600 or more
2
4
2 per 2,000
Nisshin Steel Quality Products 12
Properties
1.Heat Resistance
Alstar has far greater heat resistance than galvanized and cold-rolled steel sheet and thus keeps its original fine surface luster
even when used for long periods at temperatures below 450℃＊. If it is exposed to temperatures above 450℃, however, the iron
and aluminum become alloyed through mutual diffusion and the surface gradually turns from gray to a darker color. Since this
alloy layer has a high fusing point, it will not melt even if exposed to a temperature above the fusing point of aluminum.
In addition, an oxide layer is produced on the coated surface by high temperature, which suppresses scale formation so that the
sheet will not quickly become oxidized and worn until the diffusion progresses to the point where the aluminum coating becomes
unable to control scale formation (approximately 600℃). The heat-resistant characteristics of Alstar are shown below.
＊We have high grade Alstar which can be used at approximately 500℃.
(1) Heating behavior of aluminized steel sheet
Figure 5
Heating
………………………………
………………………………
Al
………………………………
………………………………
………………………………
………………………………
………………………………
………………………………
………………………………
………………………………
………………………………
………………………………
………………………………
………………………………
Al
………………………………
………………………………
………………………………
Alloy layer
Alloy layer
Fe (before heating)
13 Nisshin Steel Quality Products
Oxidized layer caused by
high temperature
Heating
Fe (after heating)
×
×
×
×
×
×
× ×
×
×
×
×
×
×
×
×
×
×
×
×
Alloy layer
Fe (after more heating)
×
×
■ Properties ■
(2) Microscopic photographs of cross sections of MSA-40 kept at 500℃ for 100 hours and 1,000 hours,
respectively
Cross sectional structures of Alstar before and after heating to 500℃（Drawing Quality）
Before heating
After 100 hours of heating at 500℃
After 1,000 hours of heating at 500℃
(3) Heat resistance comparison of aluminized steel, stainless steel, and cold-rolled steel sheet
Figure 6 shows a mass increase comparison of Alstar with 18-8 stainless steel and cold-rolled steel sheet after high-temperature
oxidation. Alstar shows good heat resistance（at 500℃ to 600℃）similar to stainless steel sheet, and is over 20 times more heatresistant than cold-rolled steel sheet.
(40
she
led
ste
el
teel sh
ldCo
Cold-r
40
rol
olled s
50
Oxygen Pickup (mg/dm2)
et
eet (50
60
0℃
)
0℃)
Figure 6
30
)
00℃
r (6
a
t
s
Al
0℃)
t (60
hee
s
l
e
ste
less
stain
18-8
00℃)
Alstar (5
20
10
el sheet (500℃)
18-8 stainless ste
0
4
8
12
16
20
24
28
32
36
40
44
48
52
Oxidation Time (hours)
Heat resistance comparision of Alstar, stainless steel, and cold-rolled steel sheet
Nisshin Steel Quality Products 14
■ Properties ■
(4) Mass increase/decrease by oxidation through heating and cooling cycles
Figures 7 and 8 show a mass increase and decrease comparison of Alstar's different aluminum coating masses with other
materials after oxidation, and after being exposed to 10 cycles of heating to 600℃ and 750℃ and then cooled. It is clear from the
diagrams that Alstar possesses greater oxidation resistance than cold-rolled and galvanized sheet even at temperatures of 600℃
and 750℃, and can be satisfactorily used below 600℃ without any increase in oxidation.
Figure 7 : Heating and Cooling Cycle
750℃
Temperature (℃)
800
600℃
600
400
200
0
4
8
12
Hours
16
20
24
Figure 8 : Oxidation Increase/Decrease by 600℃ and 750℃ Heating/Cooling Cycles
600℃
750℃
100
Oxidation Increase/Decrease (g/m2)
50
TI-25CQ (MSA-80)
SUS430
SPC (Cold-rolled steel sheet)
Galvanized sheet
Galvannealed sheet
TI-25CQ
30
10
-10
-20
SUS430
2
5
10
Number of Cycles
-30
-50
-70
-100
-200
Galvannealed sheet
-300
-500
15 Nisshin Steel Quality Products
Galvanized sheet
SPC
■ Properties ■
2.Heat Reflectivity
Alstar possesses not only a finely finished surface, but also excellent heat reflectivity. Because Alstar has a very high thermal
efficiency, it is useful for making highly effective heat reflecting plates for toasters, ovens, driers, and other consumer durables.
For reference, here is a surface luster comparison of Alstar with other steel sheets.
Table 10
Surface Finish
Surface Luster（％）
Surface Roughness（μ）
Alstar
Type
Dull
15
Hmax 8 to 9
Stainless steel sheet
2B
15
Hmax 1.2
Stainless steel sheet
BA
60
Hmax
0
Cold-rolled steel sheet coated with silver paint
Dull
6
Hmax
8
Notes : 1. Surface luster measured（with gloss meter Model GM-3）in conformity with JIS 8741.
2. 1/10 light filter Gs（60）is used.
3.Corrosion Resistance
Aluminum has a more active ionization trend than Mn, Mo, Cr, W, Cd, Fe, and Zn and is more easily corroded. Because aluminum
has the characteristic of easily forming a fine oxide film when exposed to air, or a hydroxide film when exposed to water, a
corrosion resistance effect by galvanic action, such as is exhibited in galvanized sheet, cannot be expected.
Because aluminum's oxide film is stable, the aluminum coated surface of Alstar is considerably more corrosion-resistant than that
of galvanized sheet except in certain environments. The corrosion resistance of Alstar under various conditions is shown in the
following pages.
(1) Corrosion resistance in various pH solutions
Unlike zinc, aluminum is relatively resistant to weak acids but not to alkalis. The corrosion resistance of aluminum in pH solutions
is as shown in Figure 9.
Figure 9
120
110
100
90
80
Alstar (room temperature)
Corrosion (g/m2/day)
130
Corrosion resistance
in pH Solutions
Alstar (60℃)
Galvanized sheet (room temperature)
Galvanized sheet (60℃)
Source : Metal Surface Technology Vol.7, No.7.
70
60
50
40
30
20
10
1
2
3
4
Acidity
5
6
7
pH
8
9
10
11
12
13
14
Alkalinity
Nisshin Steel Quality Products 16
■ Properties ■
(2) Saltwater spray test
Aluminum shows a lower potential than iron in saltwater and, in an Fe-Al electrolyte cell with an aluminum anode and steel
cathode, the aluminum, as a sacrificial anode, protects the steel from corrosion.
Table 11 shows the results of a continuous saltwater spray test on Alstar.
Table 11
Pretest Treatment
TI-25DQ Alstar
（MSA-80 Drawing Quality）
Other manufacturers'
electro-galvanized sheet
24 Hours
72 Hours
240 Hours
360 Hours
Red rust
in 384
hours
Room temperature
250℃×24 hours
Room temperature
250℃×24 hours
Red rust
10%
Red rust
60%
Red rust
60%
Red rust
90%
Red rust
100%
(3) Atmospheric exposure test
Aluminized steel sheet develops oxides on the aluminum surfaces when exposed to air, but the stable oxides protect the
aluminum layer and prevent discoloring of the surfaces. Exposed steel parts, such as cut sections and pinholes, however,
develop red rust.
If Cl− is present in a wet state, as in seawater, for example, the oxidized aluminum film is destroyed and starts a sacrificial
corrosion protection action.
Because aluminum has a lower electrolytic solubility than zinc, aluminized steel sheet has greater corrosion resistance in, for
example, coastal areas.［If the coating mass is the same, the ratio is said to be five or six（aluminum）to approximately one（zinc）
］
.
(4) Resistance to chemicals
Alstar has less resistance to alkaline industrial chemicals, but greater resistance to acid industrial chemicals than galvanized
sheet.
Table 12
Chemicals
Light oil
Alstar
Galvanized Sheet
E
G
Palm oil
E
E
Machine oil
E
G
Boiled oil
E
E
Spindle oil
E
E
Glycerine
E
E
Formalin
F
G
Alcohol
G
G
Acetone
E
E
Carbon tetrachloride
E
E
Coal tar
E
E
Printing ink
E
E
Phthalide
E
G
Aqueous ammonia
P
F
5％ caustic soda
P
F
5％ nitric acid
F
P
5％ sulfuric acid
P
P
5％ acetic acid
F
P
17 Nisshin Steel Quality Products
Note : Evaluation scale : E ＝ Excellent
G＝ Good
F ＝ Fair
P ＝ Poor
■ Properties ■
(5) Resistance to automobile exhaust gas
Alstar demonstrates good corrosion resistance in auto exhaust part uses. The results of an exhaust gas test by the Chrysler
Corporation of the U.S. are shown in Table 13.
Table 13
Decrease in Mass（g）
Decrease in Thickness
（converted from the mass decrease）
R
in.
mm
TI-25DQ Alstar（MSA-80 Drawing Quality）
−
x
0.260
0.011
0.0007
0.018
TI-25CQ Alstar（MSA-80 Commercial Quality）
0.191
0.035
0.0005
0.013
Notes : 1. Test method:
Chrysler's spec. 461H-83.
2. Test outline:
（a）A mixed solution of 180°
F（82℃）0.01N hydrobromic acid and 0.05N sulfuric acid was used for the test.
（b）Cold muffler conditions. After immersing the test pieces in the test solution for five seconds, they were kept
over the solution surface for one hour. This was repeated 20 times（20 hours）
.
（c）Hot muffler conditions. Then the test pieces were heated in a furnace at 1,000°
F（538℃）for two hours.
（d）Steps（b）and（c）were repeated for 240 hours.
3. Test results judgment:
（a）Amounts of decrease before and after the test were measured.
（b）Decreased amounts were converted into decrease in sheet thickness.
（c）Converted sheet thickness decrease must be less than 0.002 in.（0.051mm）
.
4. Test results:
The test simulated a running Chrysler car. Sheet thickness decreased in inverse proportion to aluminum coating
mass Alstar passed this test.
Nisshin Steel Quality Products 18
■ Properties ■
4.Weldability
Alstar differs slightly from cold-rolled steel sheet under welding conditions. Since aluminum is soft, flexible and has good electric
conductivity, aluminized steel sheet generates less heat at welds than cold-rolled steel sheet. Alstar does not require as high a
current as galvanized sheet due to the aluminum coating which has a higher melting point, less fluidity, and less spread of molten
area.
Conditions for spot, seam, and other kinds of welding are given below.
(1) Spot welding
Table 14 shows an example of spot welding conditions for Alstar.
Table 14 : MSA-40 Commercial Quality
Electrode Face
Time
（
）
Thickness
（mm）
D
R
Electrode Force
（N）
0.6
16
25
1,800
9
8,700
1,900
0.8
16
25
2,000
10
9,500
2,500
1.0
16
50
2,500
11
10,500
4,100
1.2
16
50
3,100
12
12,000
5,900
1.4
16
50
3,900
14
13,000
7,800
2.0
16
50
5,400
18
14,000
12,700
Current
（A）
Shear Strength
（N）
Note : With a low welding current, sufficient strength cannot be expected. With an overcurrent, the aluminum coating deteriorates more
than necessary and dark gray stripes appear around welds. Suitable welding conditions between these extremes must be
selected. The scope of correct welding conditions narrows in inverse proportion to sheet thickness. Chromium copper
alloy electrode tips may be used and, as with galvanized sheet, aluminum pickup poses a problem. Good water-cooling to
minimize pickup and periodic dressing are necessary. As in the case of welding mild steel, radius-face tips or truncated cone
face（120°to 140°
）tips are recommended.
Figure 10 shows the results of a spot welding test on MSA-40 and MSA-80, which differ in aluminum coating mass. While MSA-40
shows a sharp drop in shear strength after approximately 900 spot welds, MSA-80 develops the same phenomenon after
approximately 600 spot welds. proximately 600 spot welds.
Figure 10 : Electrode Life in Spot Welding Alstar
MSA-80 1.0mm
MSA-40 1.0mm
(Commercial Quality)
9,800
8
6
Shear Strength (N)
Diameter of Electrode
Force Mark (mmφ)
8,800
7,800
6,900
9,800
8,800
7,800
6,900
Shear strength
5,900
5,900
4,900
4,900
3,900
3,900
8
2,900
2,900
6
2,000
4
1,000
2
0
0
4
2,000
2
1,000
0
0
Diameter of electrode force mark
0
100
200
300
400
500
600
Number of Welds
Notes : Welding conditions:
Welding current: 11,200A to 14,500A.
19 Nisshin Steel Quality Products
Electrode force: 2,000N
Welding time: 7
.
700
800
900
1,000
■ Properties ■
(2) Seam welding
Table 15 shows an example of seam welding conditions for Alstar.
Table 15
Time
Thickness
（mm）
Electrode Width
（mm）
Electrode Force
（N）
On
Off
Welding Speed
（cm/min.）
Current
（A）
0.8
7
3,900
3
2
150
17,000 to 19,000
0.95
7
4,200
3
3
150
16,000 to 18,000
0.95
7
4,200
3
2
230
18,000 to 21,000
1.2
7
4,400
3
2
150
18,000 to 20,000
1.2
7
4,900
4
2
230
18,000 to 21,000
(3) Gas welding and arc welding
Gas welding is difficult and requires a certain amount of skill. It is recommended that a two-stage regulator be used for assuring
the correct gas flow. Use killed steel wire for satisfactory results. Flux for stainless steel is suitable for the purpose.
Shielded arc electrodes may be used for arc welding, but care must be taken in selecting the right kind of electrode. Ilmenite or
high titanium type electrodes produce blow holes. For the best results, select a low hydrogen type electrode. If a corrosionresistant characteristic is required, use stainless steel. When oxidation of welds must be reduced to a minimum, argon arc
welding（TIG）produces good results.
Tables 16 and 17 show examples of arc welding and TIG welding.
Table 16 : Example of Arc Welding
Weldability
JIS Rating of
X-ray Results
Tensile Strength
（N/mm2）
Elongation
（％）
D4313
Poor
6
387
24.2
Weld
D4316
Good
1
368
28.9
Base metal
1.2
D30816
Stainless steel
Excellent
1
379
28.0
Base metal
1.2
D4316
Good
1
327
28.4
Base metal
Thickness
（mm）
Welding Rod
T1-25CQ
MSA-80
Commercial
Quality
1.2
1.2
SPCC
Sheet Welded
Rupture Point
Table 17:Example of TIG Welding
Sheet Welded
Thickness
（mm）
T1-25CQ
MSA-80
Commercial
Quality
1.6
Welding Rod
Welding
Current
Weldability
JIS Rating of
X-ray Results
Tensile Strength
（N/mm2）
Elongation
（％）
Rupture Point
GA（gas-welding rod
for mild steel）
AC
Poor
2
380
24
Base metal
DM-2（gas-welding rod
for Si-Mn alloy）
AC
Good
1
389
28
Base metal
D308（18-8 stainless
steel rod）
AC
Good
1
393
24
Base metal
GA
DC
Poor
4
400
24
Base metal
DM-2
DC
Good
1
380
28
Base metal
D308
DC
Excellent
1
398
26
Base metal
Notes : 1. Argon gas flow rate: 6 l/min
2. AC power source: Pure tungsten electrode 3.2φ
3. DC power source: Thorium-containing tungsten electrode 3.2φ
(4) Weld repairs
Welds and damaged aluminum coating can be repaired with silver paint or with molten aluminum spray.
Nisshin Steel Quality Products 20
■ Properties ■
5.Formability
Aluminized steel sheet is generally said to have poor formability as compared with cold-rolled and galvanized sheet because it
has a hard alloy layer of steel and aluminum between the base metal and the aluminum coating. However, Alstar offers good
formability comparable to other steel sheets if proper consideration is taken of its characteristics.
(1) Deep drawing
（a）Die and punch radii and clearances must be used where appropriate to prevent
aluminum exfoliation on the parts pressed by deep drawing.
（b）Die radii 6t to 10t and punch radii similar to those used in cold-rolled steel
sheet drawing may be used, although the figures vary with forms to be drawn.
A clearance of about 1.2t is appropriate.
（c）If redrawing is necessary, a drawing ratio of more than 60 percent is
recommended per drawing.
A sample（0.55mm）formed by a 6
ton cushion pressure
(2) Burring
（a）The hole enlarging ratio of Alstar ranges from 0.3 to approximately 0.8, depending on the forming process
（This compares with 0.5 to 0.9 for cold-rolled steel sheet）
.
（b）The hole enlarging operation can be improved by observing the following instructions:
・Direct burrs inward.
・Use an enlarging punch that has a greater taper.
・Add embossing during the enlarging process.
An example of hole enlarging and drawing is shown below.
Drawn sample（1.2mm）auto muffler end plate
21 Nisshin Steel Quality Products
■ Properties ■
6.Paintability
Alstar requires chemical treatment before painting to assure good adhesion of paint.
(1) Pretreatment
Degreasing alone is insufficient to assure good adhesion. For the best results, the following process is recommended.
Degreasing
・Take note of pH.
・Use trichloroethylene or other
neutral chemicals.
Chemical Treatment
Painting
・Chromate treatment or phosphate
treatment is recommended.
(2) Paint
The same paint as used in painting other steel sheets may be used for Alstar if it is pretreated. To obtain satisfactory corrosion
resistance, adhesion and other qualities, the right paint for the intended use should be selected.
The following are examples of paint that may be used for Alstar:
・Vinyl resin paint.
・Silicon resin paint.
・Polyurethane resin paint.
・Phenol resin paint.
・Alkyd resin paint.
・Lacquer.
7.Food Sanitation
The aluminum coating consists of aluminum, silicon and iron. Tests conducted by prefectural governments in Japan, under the
Food Sanitation Law, have proved that even if these elements enter the human body, they are harmless and will be completely
discharged. An example of analysis of the aluminum coating of a utensil made from Alstar is shown below.
Aluminum（77.2％）
Silicon（7.4％）
Iron（15.4％）
Caution : Chromate treatment for preventing white rust on the aluminum surface is harmful, and therefore only oiling without
chromate is recommended.
Nisshin Steel Quality Products 22
Steel Pipe
Alstar steel pipe is made from Alstar steel sheet by high-frequency welding. It has all the features of Alstar steel sheet. Being
highly heat resistant, Alstar steel pipe is used in large quantities in the automobile industry as exhaust pipe.
1.Features
1）Evenly coated with aluminum
2）Thin aluminized Alstar steel pipe is available.
3）Highly heat resistant
4）High workability
5）Excellent weldability
6）Smooth, aesthetically pleasing surface
2.Quality
(1) Appearance
Alstar steel pipe has an aesthetically pleasing surface peculiar to aluminum. Bare metal is exposed on the outer surface of welded
joints in an area 3mm to 5mm wide after bead cutting but can be aluminized to order. Slight beads are built on the inner surface
of welded joints but can be cut away as necessary.
(2) Workability
Alstar steel pipe has the same workability as the JIS G3445 machine-structure carbon steel pipe STKM-11A.
(3) Effect of pipe production on aluminum coats
Pipe production has little if any detrimental effect on the aluminum coating of Alstar steel sheet.
(4) Corrosion resistance of welds
Since bare metal is exposed at the welds after bead cutting, rust forms at an early stage of the salt spray test. Alstar steel pipe is
generally used unfinished after bead cutting as heat-resistant parts but has not posed any problem in such applications.
3.Mechanical properties
Typical mechanical properties of Alstar steel pipe made of MS-40（drawn material）are shown in Table 18.
23 Nisshin Steel Quality Products
■ Steel Pipe ■
Table 18
Test Piece Size
35.0 φ×1.2mm
38.1 φ×1.2mm
42.7 φ×1.2mm
Number of
Test Cycles
Tensile Test
Flattening Test
（2/3D）
Flaring Test
Bending Test
（3D）
45
Good
1.39
─
─
Good
1.38
─
46
Good
1.39
Creases occurred
Tensile Strength
（N/mm2）
Elongation
（％）
1
366
2
─
1
361
2
─
─
Good
1.30
─
1
362
45
Good
1.37
─
2
─
─
Good
1.40
─
Notes : 1. Tensile test: JIS No.11 test piece
2. Flattening test: 2/3D, the welded portion is placed at right angles to the direction of compression.
3. Flaring test: Using a 60°cone punch, pipe end openings are widened until cracks occur.
4. Flaring ratio: Diameter after flaring/initial diameter
Table 19: Available Dimensions of Alstar Steel Pipe
Outside Diameter or
Side Length
（mm）
Length
（mm）
0.6∼2.3
12.7∼63.5
3,500∼6,100
0.8∼2.0
16×16∼25×25
Thickness
（mm）
Round Pipe
Sharp Edge
Square Pipe
Rounded Edge
Square
Rectangle
0.8∼2.3
22×10∼60×30
Square
0.8∼2.3
25×25∼50×50
Rectangle
0.8∼2.3
25×12∼60×30
3,500∼6,000
Note : Dimensions other than those listed above can be negotiated.
Nisshin Steel Quality Products 24
Extracts from ASTM A 463-83
Standard Specification for
Steel Sheet, Cold-Rolled, Aluminum-Coated Type 1
1. Scope
1.1 This specification covers aluminum-coated steel sheet
Type 1 in coils and cut lengths coated with an aluminumsilicon alloy by the hot-dip process. The aluminum-silicon
alloy for coating has 5％ to 11％ silicon added to promote
better adherence. It is intended principally for heat-resisting
applications and also for uses where corrosion resistance
and heat are involved. The weight of coating expressed as
the total coating on both sides may be specified in
accordance with Table 1. Aluminum-coated steel sheet is
available in the following quality designations: Commercial
Quality, Drawing Quality, Drawing Quality Special Killed, and
Structural（Physical）Quality.
Notes : 1. values stated in U.S. customary units are to be
regarded as the standard.
3. Description of Terms
3.1 Quality Designations:
3.1.1 Commercial Quality -This material is intended for
parts where bending, moderate forming, or moderate
drawing may be involved.
3.1.2 Drawing Quality -This material is intended for
fabricating identified parts where drawing or severe forming
may be involved. Care should be taken to ensure that the
coating designation is compatible with the end use.
3.1.3 Drawing Quality Special Killed -This material is
intended for fabricating identified parts where particularly
severe drawing or forming may be involved or essential
freedom from aging is required. Care should be taken to
ensure that the coating designation is compatible with the
end use.
3.1.4 Structural（Physical）Quality-This material is produced
when mechanical properties are specified or required. Such
properties or values include those indicated by tension,
hardness, or other commonly accepted mechanical tests.
Care should be taken to ensure that the coating designation
is compatible with the end use.
4. General Requirements for Delivery
4.2 Aluminum-coated steel sheet shall be ordered to a
decimal thickness for both coils and cut lengths. The
thickness is the total of the base metal and the coating.
25 Nisshin Steel Quality Products
8. Mechanical Requirements
8.1 Base Metal Bend Test-Commercial quality（CQ）
,
drawing quality（DQ）
, or drawing quality special killed
（DQSK） shall be capable of being bent at room temperature
in any direction through 180 deg. flat on itself without
fracturing of the base metal. Bend test requirements for
structural（physical）
quality are subject to negotiation.
9. Coating Tests
9.1 Weight of Coating:
9.1.1 The weight of coating shall conform to the requirements for triple- and single-spot minimum checks
prescribed in Table 1 for the specific coating designation.
The weight of coating is the total amount on both sides of a
sheet, expressed in ounces per square foot（or grams per
square meter）of sheet.
9.2 Coating Bend Test:
9.2.1 For all qualities other than structural（physical）
quality, the bend test specimens of coated metal shall be
capable of being bent through 180 deg. over a diameter
equal to twice the thickness in any direction without flaking
of the coating on the outside of the bend only. A handoperated vise with smooth jaws should be used for making
the tests, unless excessive thickness makes this impractical.
Any other method used to make the bend test should not
involve impact. Flaking of coating within 1/4 in.（6.4mm）of
the edge of the bend specimen shall not be cause for
rejection. Bend tests are not required of coils or cut lengths
ordered extra-smooth or stretcher-leveled.
This Standard is issued under the fixed designation A 463; the number immediately
following the designation indicates the year of original adoption or, in the case of revision,
the year of last revision. A number in parentheses indicates the year of last reapproval.
TABLE 1 Coating Designation and Minimum Coating Test Limits for Aluminum-Coated Steel Sheet Type1
Note : The weight of coating in ounces per square foot and coating thickness in inches refer to the total coating on both surfaces.
The coating designation is the term by which this product is specified.
Triple-Spot Test
Total Both Sides
Coating
Designation
a
Single-Spot Test
Total Both Sides
TI 40（regular）
oz/ft2
0.40
g/m2
120
oz/ft2
0.30
g/m2
90
TI 25（light）
0.25
75
0.20
60
Calculated Coating Thickness
Based on Minimum
Single Spot Test,a in.
0.0013
0.0008
Calculation based on aluminum density of 0.0975 lb/in.
11. Dimensions, Weights, and Tolerances
11.1 Aluminum-coated steel sheet is produced to decimal thickness only. The density of aluminum is 0.0975 lb/in. as compared
to that of zinc which is 0.258 lb/in.; hence, the weight equivalents are different. Table 3 gives the thickness and weight equivalents
of aluminum-coated steel sheet Type1.
11.2 Thickness tolerances and all other dimensional tolerances are given in Tables 4 through 16.
TABLE 4 Thickness Tolerances of Aluminum-Coated Steel Sheet Type1
Notes : 1. Thickness is measured at any point across the width not less than 3/8 in.
（9.5mm）from a side edge.
2. Regardless of whether total thickness tolerance is specified equally or unequally, over and under, the total tolerance
should be equal to twice the tabular tolerance.
Thickness Tolerances for Widths and Thicknesses, Over and Under, in.
Specified Width, in.
Specified Thickness, in.
Over 0.101
to 0.187, incl
Over 0.075
to 0.101, incl
Over 0.061
to 0.075, incl
Over 0.043
to 0.061, incl
Over 0.023
to 0.043, incl
0.023 and
thinner
To 32 incl
0.008
0.007
0.006
0.005
0.004
0.003
Over 32 to 40, incl
0.008
0.008
0.006
0.005
0.004
0.003
Over 40 to 60, incl
0.009
0.008
0.006
0.005
0.004
0.003
TABLE 5 Width Tolerances of Aluminum-Coated
Steel Sheet Type1（Coils and Cut Lengths Not
Resquared）
Specified Width, in.
（mm）
Over 12（300）to 30（760）
, incl
Tolerance Over Specified
Width, No Tolerance Under
Appendix A1. Metric Equivalents
A1.1 The metric equivalents for the tolerances given in the
tables are shown in Table A1.
TABLE A1 Metric Equivalents a
in.
mm
1/8
3.2
in.
mm
in.
0.0254
3/16
4.762
6.350
mm
Over 30 to 48（760 to 1,220）
, incl
3/16
4.8
0.001
Over 48 to 60（1,220 to 1,520）
, incl
1/4
6.4
0.005
0.127
1/4
0.010
0.254
5/16
7.938
0.050
1.270
3/8
9.525
0.100
2.540
1/2
12.700
0.200
5.080
3/4
19.050
1/16
1.588
7/8
22.225
1/8
3.175
1
25.400
a
Conversion factor : 1 in.×25.4＝mm.
Nisshin Steel Quality Products 26
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Notice
Technical information in this booklet, while every reasonable
effort was made to ensure the accuracy at the time of this
publication, is general information relating to our products
only and is not meant as any warranty, expressed or implied.
Such technical information does not guarantee that any of our
products are suitable for your particular application or
purpose. Use of any information contained in this booklet shall
be at user's risk. Any information in this booklet is subject to
change without prior notice. Please contact Nisshin Steel
office for updated information.
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