TECHNICAL FIELD
[0001] The present invention relates to a method for producing a hot-dip aluminum-coated
steel wire. More particularly, the present invention relates to a method for producing
a hot-dip aluminum-coated steel wire which can be suitably used in, for example, a
wire harness of an automobile, and the like.
[0002] In the present description, the hot-dip aluminum-coated steel wire means a steel
wire which has been plated with aluminum by dipping a steel wire in molten aluminum,
and then continuously drawing up the steel wire from the molten aluminum. In addition,
the molten aluminum means a plating liquid of molten aluminum.
BACKGROUND ART
[0003] A copper wire has been hitherto used as an electric wire which is used in a wire
harness of an automobile, and the like. In recent years, it has been desired to develop
an electric wire in which a metal wire having a weight lighter than a copper wire
is used in view of requirement of weight saving.
[0004] As an electric wire having a weight lighter than the copper wire, a hot-dip Al-coated
steel wire obtained by plating a steel wire with hot-dip aluminum has been proposed
(for example, see claim 1 of Patent Literature 1). The above-mentioned hot-dip Al-coated
steel wire has been produced by dipping a steel wire or a steel wire having a zinc
plated layer or a nickel plated layer on its surface as a staring wire in molten aluminum,
and then continuously drawing up the steel wire from the molten aluminum to the air
(see, for example, paragraph [0024] of Patent Literature 1).
[0005] In addition, as a method for producing a hot-dip aluminum-coated steel wire, there
has been proposed a method for producing a hot-dip aluminum-coated steel wire by dipping
a steel wire in molten aluminum, and then continuously drawing up the steel wire from
the molten aluminum, to produce a hot-dip aluminum-coated steel wire, which includes
the steps of dipping a steel wire in molten aluminum; and then contacting a stabilization
member with a surface of the molten aluminum and the steel wire when the steel wire
is drawn up from the molten aluminum; providing a nozzle having an inner diameter
of 1 mm to 15 mm so that a tip of the nozzle is positioned at a place apart from the
steel wire in a distance of 1 mm to 50 mm, and blowing an inactive gas having a temperature
of 200 to 800°C toward the boundary between the steel wire and the surface of the
molten aluminum in a volume flow rate of 2 to 200 L/min (see, for example, Patent
Literature 2). According to the above-mentioned method for producing a hot-dip aluminum-coated
steel wire, there can be exhibited excellent effects such that a hot-dip aluminum-coated
steel wire having a uniform wire diameter and hardly having an aluminum lump can be
efficiently produced. However, when a hot-dip aluminum-coated steel wire is produced
by the above-mentioned method for producing a hot-dip aluminum-coated steel wire,
there is a possibility that a thin part of a plating layer is generated on the hot-dip
aluminum-coated steel wire.
[0006] In addition, it is preferred that the temperature of the molten aluminum is lower
in consideration of thermal efficiency. However, when the temperature of the molten
aluminum is a temperature 20°C higher than the melting temperature of the molten aluminum,
or less, there is a possibility that an aluminum lump is adhered to the surface of
the hot-dip aluminum-coated steel wire (see comparative examples 1, 2, 6 and 7 of
this description).
[0007] When the hot-dip aluminum-coated steel wire having a thin part of a plating layer
or the hot-dip aluminum-coated steel wire having an aluminum lump on its surface is
subjected to a wire-drawing process, there is a possibility that the steel wire included
in the hot-dip aluminum-coated steel wire is exposed to the outside, and that the
hot-dip aluminum-coated steel wire is broken due to fluctuation of drawing resistance
of the hot-dip aluminum-coated steel wire in the wire-drawing process.
PRIOR ART LITERATURES
PATENT LITERATURES
[0008]
Patent Literature 1: Japanese Patent Unexamined Publication No. 2014-185355
Patent Literature 2: Japanese Patent Unexamined Publication No. 2015-134961
SUMMARY OF THE INVENTION
PROBLEMS TO BE SOLVED BY THE INVENTION
[0009] The present invention has been made in view of the above-mentioned prior art. An
object of the present invention is to provide a method for producing a hot-dip aluminum-coated
steel wire, which can efficiently provide a hot-dip aluminum-coated steel wire, and
which hardly forms a thin part of a plating film and an aluminum lump on the surface
of the plating film, even when the temperature of the molten aluminum is a low temperature.
MEANS FOR SOLVING THE PROBLEMS
[0010] The present invention relates to:
- (1) a method for producing a hot-dip aluminum-coated steel wire by dipping a steel
wire in molten aluminum, and then continuously drawing up the steel wire from the
molten aluminum, to produce a hot-dip aluminum-coated steel wire, which includes the
steps of:
dipping a steel wire in molten aluminum; thereafter drawing up a resulting hot-dip
aluminum-coated steel wire from the molten aluminum;
contacting a stabilizing member with the surface of the molten aluminum and the hot-dip
aluminum-coated steel wire at the boundary between the hot-dip aluminum-coated steel
wire and the surface of the molten aluminum; disposing a nozzle for blowing an inert
gas at a place where the nozzle is faced to the stabilizing member through the hot-dip
aluminum-coated steel wire; and blowing the inert gas having a temperature of 600
to 1000°C from the tip of the nozzle to the above-mentioned boundary at a pressure
of 0.1 to 20 kPa;
- (2) the method for producing a hot-dip aluminum-coated steel wire according to the
above item (1), wherein the steel wire is a steel wire made of stainless steel or
carbon steel; and
- (3) the method for producing a hot-dip aluminum-coated steel wire according to the
above item (1) or (2), wherein the temperature of the molten aluminum is adjusted
to a temperature 15°C or more higher than the melting point of the molten aluminum.
EFFECTS OF THE INVENTION
[0011] According to the method for producing a hot-dip aluminum-coated steel wire of the
present invention, there can be exhibited excellent effects such that a hot-dip aluminum-coated
steel wire can be efficiently produced so that a plating film having a thin portion
of the plating film is hardly formed, and an aluminum lump is hardly deposited on
the surface of the plating film, even when the temperature of the molten aluminum
is a low temperature.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012]
Fig. 1 is a schematic view showing one embodiment of a method for producing a hot-dip
aluminum-coated steel wire according to the present invention.
Fig. 2 is a schematic cross-sectional view showing one embodiment of a steel wire-introducing
controller shown in Fig. 1.
Fig. 3 is a schematic cross-sectional view showing one embodiment of a liquid surface-controlling
device used in the steel wire-introducing controller shown in Fig. 1 and Fig. 2.
Fig. 4 is a schematic explanatory view showing the boundary between a steel wire and
a surface of molten aluminum when the steel wire is drawn up from the molten aluminum
in the method for producing a hot-dip aluminum-coated steel wire according to the
present invention.
Fig. 5 is a schematic explanatory view showing one embodiment of a method for determining
an average thickness of a plating film of a hot-dip aluminum-coated steel wire obtained
in each of working examples and comparative examples.
MODE FOR CARRYING OUT THE INVENTION
[0013] The method for producing a hot-dip aluminum-coated steel wire according to the present
invention includes a process for dipping a steel wire in molten aluminum, and then
continuously drawing up the steel wire from the molten aluminum, to produce a hot-dip
aluminum-coated steel wire. The method includes one of characteristics in dipping
the steel wire in molten aluminum; thereafter drawing up a resulting hot-dip aluminum-coated
steel wire from the molten aluminum; contacting a stabilizing member with the surface
of the molten aluminum and the hot-dip aluminum-coated steel wire at the boundary
between the hot-dip aluminum-coated steel wire and the surface of the molten aluminum;
disposing a nozzle for blowing an inert gas at a place where the nozzle is faced to
the stabilizing member through the hot-dip aluminum-coated steel wire; and blowing
the inert gas having a temperature of 600 to 1000°C from the tip of the nozzle to
the above-mentioned boundary at a pressure of 0.1 to 20 kPa, as mentioned above.
[0014] According to the method for producing a hot-dip aluminum-coated steel wire of the
present invention, since the above-mentioned operations are employed in the method,
a hot-dip aluminum-coated steel wire can be efficiently produced so that a plating
film having a thin portion of the plating film is hardly formed, and an aluminum lump
is hardly deposited on the surface of the plating film, even when the temperature
of the molten aluminum is a low temperature.
[0015] In the present description, the term that temperature of the molten aluminum is a
low temperature means that the temperature of the molten aluminum is a temperature
which is 15°C or more higher than the melting temperature of the molten aluminum,
and which is equal to or lower than a temperature 20°C higher than the melting temperature
of the molten aluminum.
[0016] Hereinafter, the method of producing a hot-dip aluminum-coated steel wire according
to the present invention will be described based on drawings. However, the present
invention is not limited only to those embodiments described in the drawings.
[0017] Fig. 1 is a schematic explanatory view showing one embodiment of the method for producing
a hot-dip aluminum-coated steel wire according to the present invention.
[0018] According to the method of producing a hot-dip aluminum-coated steel wire of the
present invention, a steel wire 2 is dipped in molten aluminum 1, and then the steel
wire 2 is continuously drawn up from the molten aluminum 1, to produce a hot-dip aluminum-coated
steel wire 3.
[0019] Examples of steel used in the steel wire 2 include, for example, stainless steel,
carbon steel and the like, and the present invention is not limited only to those
exemplified ones.
[0020] The stainless steel is an alloy steel containing 10% by mass or more of chromium
(Cr). Examples of the stainless steel include, for example, austenitic steel materials,
ferritic steel materials and martensitic steel materials defined in JIS G4309, and
the like, and the present invention is not limited only to those exemplified ones.
Specific examples of the stainless steel include stainless steel in which an austenitic
phase is generally considered to be metastable, such as SUS301 and SUS304; stable
austenitic stainless steel such as SUS305, SUS310 and SUS316; ferritic stainless steel
such as SUS405, SUS410L, SUS429, SUS430, SUS434, SUS436, SUS444 and SUS447; martensitic
stainless steel such as SUS403, SUS410, SUS416, SUS420, SUS431 and SUS440; chromium-nickel-manganese-based
stainless steel classified into SUS200 series, and the like, and the present invention
is not limited only to those exemplified ones.
[0021] The carbon steel contains 0.02% by mass or more of carbon (C). Examples of the carbon
steel include, for example, high carbon steel wire rods defined in JIS G3506, low
carbon steel wire rods defined in JIS G3505, and the like, and the present invention
is not limited only to those exemplified ones. Specific examples of the carbon steel
include high carbon steel, low carbon steel and the like, and the present invention
is not limited only to those exemplified ones.
[0022] Among the above-mentioned steels, the stainless steel and the carbon steel are preferred,
and the stainless steel is more preferred, from the viewpoint of increase in tensile
strength of the hot-dip aluminum-coated steel wire 3.
[0023] The diameter of the steel wire 2 is not particularly limited. It is preferred that
the diameter of the steel wire 2 is appropriately controlled in accordance with uses
of the hot-dip aluminum-coated steel wire 3. For example, when the hot-dip aluminum-coated
steel wire 3 is used in a wire harness of an automobile and the like, it is preferred
that the diameter of the steel wire 2 is usually 0.05 to 0.5 mm or so.
[0024] The steel wire 2 can be previously degreased before carrying out hot-dip aluminum
plating of the steel wire 2. The degreasing of the steel wire 2 can be carried out
by, for example, a method which includes dipping the steel wire 2 in an alkaline degreasing
liquid, taking out the steel wire 2 from the alkaline degreasing liquid, neutralizing
the alkaline degreasing liquid deposited on the steel wire 2 by washing with water,
and washing again the steel wire 2 with water; a method which includes carrying out
electrolytic degreasing of the steel wire 2 by passing electricity through the steel
wire 2 under a condition so that the steel wire 2 is dipped in an alkaline degreasing
liquid; and the like. Incidentally, the above-mentioned alkaline degreasing liquid
may contain a surfactant from the viewpoint of improvement in degreasing property.
[0025] In Fig. 1, the steel wire 2 is provided from a delivery device 4 of the steel wire
2. Thereafter, the steel wire 2 is continuously transferred in the direction of arrow
A, and dipped in the molten aluminum 1 charged in a plating bath 5.
[0026] Incidentally, when the steel wire 2 is made of carbon steel, it is preferred that
degreasing of the steel wire 2 is carried out between the delivery device 4 and the
molten aluminum 1, because there is a possibility that rust is generated on the surface
of the steel wire 2 due to degreasing of the steel wire 2 until hot-dip aluminum plating
of the steel wire 2 is carried out. The degreasing of the steel wire 2 made of carbon
steel can be carried out in the same manner as the above-mentioned method for degreasing
the steel wire 2.
[0027] The molten aluminum 1 may contain only aluminum. Alternatively, the molten aluminum
1 may contain an element other than aluminum as occasion demands within a scope which
would not hinder an object of the present invention. Examples of the element other
than aluminum include, for example, nickel, chromium, zinc, silicon, copper, iron
and the like, and the present invention is not limited only to those exemplified ones.
When the element other than aluminum is contained in aluminum, mechanical strength
of a plating film can be increased, and moreover, tensile strength of the hot-dip
aluminum-coated steel wire 3 can be increased. Among the elements other than aluminum,
although the kind of the element depends on the kind of the steel wire 2, silicon
is preferred from the viewpoint of suppression of generation of a brittle iron-aluminum
alloy layer between iron contained in the steel wire 2 and aluminum contained in the
plating film, increase in mechanical strength of the plating film and lowering in
melting point of the molten aluminum 1, thereby increase in efficiency of plating
of the steel wire 2.
[0028] The plating film (not shown in the figure) made of aluminum or an aluminum alloy
has been formed on the surface of the hot-dip aluminum-coated steel wire 3. The lower
limit of the content of the above-mentioned element other than aluminum in the plating
film is 0% by mass. From the viewpoint of sufficient exhibition of properties based
on the element other than aluminum, the lower limit thereof is preferably 0.3 % by
mass or more, more preferably 0.5 % by mass or more, and furthermore preferably 1
% by mass or more. From the viewpoint of suppression of galvanic corrosion caused
by contacting with an aluminum wire, the upper limit thereof is preferably 50 % by
mass or less, more preferably 20 % by mass or less, and furthermore preferably 15
% by mass or less.
[0029] Incidentally, an element such as nickel, chrome, zinc, copper or iron is possibly
inevitably incorporated in the molten aluminum 1.
[0030] According to the present invention, since an operation for blowing the inert gas
having a temperature of 600 to 1000°C to the boundary between the steel wire 2 and
the surface of the molten aluminum 1 at a pressure of 0.1 to 20 kPa is employed as
described below, a hot-dip aluminum-coated steel wire can be efficiently produced
so that a plating film having a thin portion of the plating film is hardly formed,
and an aluminum lump is hardly deposited on the surface of the plating film, even
when the temperature of the molten aluminum is a low temperature.
[0031] It is preferred that the lower limit of the temperature of the molten aluminum 1
is adjusted so that the temperature of the molten aluminum 1 is a temperature 15°C
or more higher than the melting point of the molten aluminum 1, from the viewpoint
that a hot-dip aluminum-coated steel wire is efficiently produced so that a plating
film having a thin portion of the plating film is hardly formed, and an aluminum lump
is hardly deposited on the surface of the plating film.
[0032] The upper limit of the temperature of the molten aluminum 1 is preferably adjusted
to a temperature equal to or lower than a temperature 150°C higher than the melting
point of the molten aluminum 1, more preferably adjusted to a temperature equal to
or lower than a temperature 120°C higher than the melting point of the molten aluminum
1, still more preferably adjusted to a temperature equal to or lower than a temperature
80°C higher than the melting point of the molten aluminum 1, furthermore preferably
adjusted to a temperature equal to or lower than a temperature 50°C higher than the
melting point of the molten aluminum 1, still furthermore preferably adjusted to a
temperature equal to or lower than a temperature 25°C higher than the melting point
of the molten aluminum 1, and particularly preferably adjusted to a temperature equal
to or lower than a temperature 20°C higher than the melting point of the molten aluminum
1, from the viewpoint of improvement in thermal efficiency.
[0033] Incidentally, the temperature of the molten aluminum 1 is a temperature as determined
by dipping a temperature sensor produced by inserting a thermocouple into a protective
pipe for protecting the thermocouple in the molten aluminum 1 at a depth of about
300 mm from the surface of the molten aluminum 1 near the steel wire 2 which is drawn
up from the molten aluminum 1.
[0034] In the present invention, it is preferred that the steel wire 2 is passed through
a steel wire-introducing controller 8 having a heating device 6 for heating the steel
wire 2 and a liquid surface-controlling device 7 for preventing the surface of the
steel wire 2 from adhesion of an oxide film, prior to dipping of the steel wire 2
in the molten aluminum 1, from the viewpoint of efficient production of the hot-dip
aluminum-coated steel wire 3 so that a plating film having a thin portion of the plating
film is hardly formed, and an aluminum lump is hardly deposited on the surface of
the plating film.
[0035] As the steel wire-introducing controller 8, there can be cited, for example, a steel
wire-introducing controller 8 shown in Fig. 2 and the like, and the present invention
is not limited to the exemplified one. Fig. 2 is a schematic cross-sectional view
showing one embodiment of the steel wire-introducing controller 8 shown in Fig. 1.
The steel wire-introducing controller 8 has the heating device 6 and the liquid surface-controlling
device 7.
[0036] As shown in Fig. 2, the heating device 6 has a heating device body 6a having a cylindrical
shape, made of, for example, steel such as stainless steel. An inside 6b of the heating
device body 6a is vacant in order to pass through the steel wire 2 in a direction
of arrow B. A branch pipe 6e having a heating gas inlet 6c for introducing a heating
gas is provided at the side surface of the heating device body 6a.
[0037] The heating gas which is introduced into the heating device 6 includes, for example,
air, inert gases such as nitrogen gas, argon gas and helium gas, and the like, and
the present invention is not limited only to those exemplified ones. Among them, the
inert gases are preferred from the viewpoint of prevention of oxidization of the molten
aluminum 1 existing in the liquid surface-controlling device 7 by ventilating the
heating gas exhausted from the lower end 6d of the heating device 6 to an introducing
port equipped at the upper end 7a of the liquid surface-controlling device 7 which
is provided below of the heating device 6, to make the inside of the liquid surface-controlling
device 7 an inert gas atmosphere. The temperature of the heating gas cannot be absolutely
determined because the temperature of the heating gas differs depending on the kind
and diameter of the steel wire 2 being used, conditions such as a line speed of the
steel wire 2 and a flow rate of the heating gas, and the like. Accordingly, it is
preferred that the temperature of the heating gas is controlled so that the steel
wire 2 is appropriately heated under the above conditions.
[0038] The heating temperature of the steel wire 2 is preferably 60°C or higher, more preferably
80°C or higher, furthermore preferably 150°C or higher, and still more preferably
200°C or higher, from the viewpoint of efficient production of the hot-dip aluminum-coated
steel wire 3. The upper limit of the heating temperature cannot be absolutely determined
because the upper limit of the heating temperature differs depending on the kind of
the steel wire 2 and the like. It is preferred that the upper limit of the heating
temperature is usually preferably 1000°C or lower, more preferably 900°C or lower,
and furthermore preferably 800°C or lower, in consideration of energy efficiency.
Incidentally, the above-mentioned heating temperature is a temperature as determined
in accordance with a method described in the following working examples.
[0039] The length of the heating device body 6a shown Fig. 2 can be a length where the steel
wire 2 is heated to a predetermined temperature, and is not particularly limited.
As one example of the length thereof, for example, the length can be 1 m to 5 m or
so. In addition, it is preferred that a diameter of the inside 6b of the heating device
body 6a cannot be absolutely determined, because the diameter of the inside 6b differs
depending on the diameter and kind of the steel wire 2 being used. The diameter of
the inside 6b of the heating device body 6a is usually about 1.5 times to about 50
times larger than the diameter of the steel wire 2. As one example of the diameter
of the inside 6b of the heating device body 6a, it is preferred that the diameter
of the inside 6b of the heating device body 6a is, for example, 0.3 mm to 10 mm or
so when the steel wire 2 having a diameter of 0.2 mm is used.
[0040] The branch pipe 6e having the heating gas inlet 6c is provided on the side surface
of the heating device body 6a. The steel wire 2 passing through the heating device
6 can be heated by introducing the heating gas into the heating gas inlet 6c of the
branch pipe 6e. Alternatively, the steel wire 2 can be heated by providing a heater
(not shown in the figure) inside the branch pipe 6e, and heating the heating gas passing
through the branch pipe 6e with the heater. In the embodiment shown in Fig. 2, seven
branch pipes 6e are provided. However, the number of the branch pipe 6e is not particularly
limited, and the number of the branch pipe 6e can be only one, or can be 2 to 10 or
so.
[0041] In the embodiment shown in Fig. 2, a gap D is provided between a lower end 6d of
the heating device 6 and an upper end 7a of the liquid surface-controlling device
7 provided below the heating device 6. It is preferred that the above-mentioned gap
D is 3 mm to 10 mm or so from the viewpoint of efficient discharge of the heating
gas from the gap D. Incidentally, there is no necessity that the above-mentioned gap
D is always provided. The heating device 6 can be separately produced from the liquid
surface-controlling device 7, and the heating device 6 and the liquid surface-controlling
device 7 can be united into one body by, for example, screw mating and the like. When
the heating device 6 and the liquid surface-controlling device 7 are united into one
body, an exhaust port (not shown in the figure) for exhausting the heating gas, which
is passed through the inside of the heating device 6, can be provided on the side
surface of the heating device 6 or the liquid surface-controlling device 7 as occasion
demands.
[0042] Incidentally, a heating device such as an electric heating device or an induction
heating device can be used in place of the heating device 6 in the present invention.
[0043] As the liquid surface-controlling device 7, there can be cited, for example, a liquid
surface-controlling device 7 shown in Fig. 3 and the like, and the present invention
is not limited to the exemplified one. Fig. 3 is a schematic cross-sectional view
showing one embodiment of the liquid surface-controlling device 7 used in the steel
wire-introducing controller 8 shown in Fig. 1 and Fig. 2.
[0044] As shown in Fig. 3, the liquid surface-controlling device 7 includes a tubular body
9 having a through hole 9a for introducing the steel wire 2 into the tubular body
9 in the direction of arrow C. The total length L of the liquid surface-controlling
device 7 is usually preferably 30 mm to 500 mm, more preferably 40 mm to 300 mm, and
furthermore preferably 50 mm to 100 mm.
[0045] The tubular body 9 has a dipping region 9b for dipping the tubular body 9 in the
molten aluminum 1 from one end part of the tubular body 9 which is to be dipped in
the molten aluminum 1 to a virtual line P shown in Fig. 3 along a longitudinal direction
of the tubular body 9. The length of the dipping region 9b is preferably 2 mm to 20
mm, and more preferably 5 mm to 15 mm.
[0046] The length of the tubular body 9 along the longitudinal direction of the tubular
body 9 where the tubular body 9 is not dipped in the molten aluminum 1 is usually
preferably 5 mm or more, and more preferably 10 mm or more.
[0047] A value of a ratio of an area of the opening part of the through hole 9a of the tubular
body 9 to an area of the cross section of the steel wire 2 used in hot-dip aluminum
plating, which is a so-called cross-section of the steel wire 2 [area of the opening
part of the through hole 9a of the tubular body 9/area of the cross section of the
steel wire 2] is preferably 3 or more from the viewpoint of smooth introduction of
the steel wire 2 into the through hole 9a of the tubular body 9. The value of the
ratio is preferably 4000 or less, more preferably 3000 or less, furthermore preferably
2000 or less, and still more preferably 1000 or less, from the viewpoint of prevention
of the steel wire 2 from adhesion of an oxide film.
[0048] The shape of the opening part of the through hole 9a of the tubular body 9 is arbitrary,
and can be circular or other shape. The gap (clearance) between the opening part of
the through hole 9a of the tubular body 9 and the steel wire 2 is preferably 10 n
or more, more preferably 20 µm or more, furthermore preferably 50 µm or more, and
still more preferably 100 µm or more, from the viewpoint of avoidance of sliding of
an inner wall of the through hole 9a of the tubular body 9 and the steel wire 2.
[0049] Incidentally, the opening parts of the through hole 9a provided in the tubular body
9 are an opening part 9d provided at the introducing port 9c for introducing the steel
wire 2 from one end of the tubular body 9, and an opening part 9f provided at a discharge
port 9e for discharging the steel wire 2 from another end of the tubular body 9 as
shown in Fig. 3. The area and shape of the opening part 9d can be the same as those
of the opening part 9f. Alternatively, the area and shape of the opening part 9d can
be different from those of the opening part 9f. However, it is preferred that the
area and shape of the opening part 9d are the same as those of the opening part 9f,
respectively, as shown in Fig. 3 from the viewpoint that the steel wire 2 is smoothly
passed through the through hole 9a of the tubular body 9, that sliding of the inner
wall of the through hole 9a of the tubular body 9 with the steel wire 2 is avoided,
and that the hot-dip aluminum-coated steel wire 3 having a plating film over the whole
surface is efficiently produced.
[0050] The steel wire 2 passed through the steel wire-introducing controller 8 as occasion
demands is dipped in the molten aluminum 1.
[0051] The line speed of the steel wire 2 is 100 m/min or more from the viewpoint of efficient
production of the hot-dip aluminum-coated steel wire 3, and is preferably 1000 m/min
or lower, and more preferably 800 mm/min or lower, from the viewpoint of prevention
of scatter of an oxide film formed on the surface of the molten aluminum 1, and efficient
production of the hot-dip aluminum-coated steel wire 3 having little oxide film adhered
to its surface.
[0052] The period of time for dipping the steel wire 2 in the molten aluminum 1 (plating
period of time) is controlled so that the plating film formed on the surface of the
steel wire 1 has a predetermined thickness. The period of time for dipping the steel
wire 2 in the molten aluminum 1 (plating period of time) cannot be absolutely determined
because the plating period of time differs depending on a required thickness of the
plating film, a temperature of the molten aluminum 1 and the like. The plating period
of time is usually 0.3 seconds to 1 second or so.
[0053] Next, as shown in Fig. 1, the steel wire 2 dipped in the molten aluminum 1 is drawn
up from the surface 10 of the molten aluminum 1, to form a plating film made of the
molten aluminum 1 on the surface of the steel wire 2, and thereby the hot-dip aluminum-coated
steel wire 3 is obtained.
[0054] When the steel wire 2 is drawn up from the molten aluminum 1 in the direction of
arrow E as illustrated in Fig. 4, the surface 10 of the molten aluminum is lifted
upward together with the hot-dip aluminum-coated steel wire 3 which is drawn up from
the molten aluminum 1, and thereby a meniscus 17 is formed. When the tip 17a of the
meniscus grows upward, the tip 17a of the meniscus 17 is solidified to form an aluminum
lump. Accordingly, there is a possibility that the aluminum lump is adhered as a foreign
substance to the surface of the plating film 18 of the hot-dip aluminum-coated steel
wire 3.
[0055] In order to prevent the surface of the hot-dip aluminum-coated steel wire 3 from
adhering the foreign substance such as an aluminum lump by inhibiting the excess growth
of the tip 17a of the meniscus 17 upward, a stabilizing member 11 is contacted with
the surface 10 of the molten aluminum 1 and the hot-dip aluminum-coated steel wire
3 at the boundary between the hot-dip aluminum-coated steel wire 3 drawn up from the
molten aluminum 1 and the surface 10 of the molten aluminum1, and a nozzle 12 for
blowing an inert gas is disposed at a place where the nozzle 12 is faced to the stabilizing
member 11 through the hot-dip aluminum-coated steel wire 3.
[0056] Incidentally, Fig. 4 is a schematic explanatory view showing the boundary between
the steel wire 2 and the surface 10 of the molten aluminum 1 when the steel wire 2
is drawn up from the molten aluminum 1 in the method for producing a hot-dip aluminum-coated
steel wire according to the present invention.
[0057] The stabilization member 11 includes, for example, a square rod made of stainless
steel, in which a heat-resistant cloth 11a is wound around the surface of the square
rod, and the like. The heat-resistant cloth 11a includes, for example, woven fabric
and non-woven fabric, containing a heat-resistant fiber such as a ceramic fiber, a
carbon fiber, an aramid fiber or an imide fiber, and the present invention is not
limited only to those exemplified ones. It is preferred that a virgin surface (new
surface) of the heat-resistant cloth 11a is contacted with the hot-dip aluminum-coated
steel wire 3 from the viewpoint of suppression of deposition of an aluminum lump on
the surface of the hot-dip aluminum-coated steel wire 3.
[0058] It is preferred that the stabilization member 11 is contacted with both of the surface
10 of the molten aluminum 1 and the hot-dip aluminum-coated steel wire 3 at the same
time. When the stabilization member 11 is contacted with both of the surface 10 of
the molten aluminum 1 and the hot-dip aluminum-coated steel wire 3 at the same time
as mentioned above, pulsation of the surface 10 of the molten aluminum 1 is suppressed,
and thereby pulsation of the meniscus 17 is suppressed. Accordingly, a plating film
18 can be uniformly formed on the surface of the steel wire 2. Incidentally, when
the stabilization member 11 is contacted with the hot-dip aluminum-coated steel wire
3, the stabilization member 11 can be slightly pressed toward the hot-dip aluminum-coated
steel wire 3 as occasion demands in order to suppress minute vibration of the hot-dip
aluminum-coated steel wire 3.
[0059] A nozzle 12 for blowing an inert gas is disposed at a place where the nozzle 12 is
faced to the stabilizing member 11 through the hot-dip aluminum-coated steel wire
13. The tip 12a of the nozzle 12 is placed so that an inert gas is blown to the boundary
between the hot-dip aluminum-coated steel wire 3 and the surface 10 of the molten
aluminum 1. The distance (the shortest distance) from the hot-dip aluminum-coated
steel wire 3 to the tip 12a of the nozzle 12 is preferably 1 mm or more from the viewpoint
of avoidance of contact of the tip 12a of the nozzle 12 with the hot-dip aluminum-coated
steel wire 3, and efficient production of the hot-dip aluminum-coated steel wire 3.
The distance (the shortest distance) from the steel wire 2 to the tip 12a of the nozzle
12 is preferably 50 mm or less, more preferably 40 mm or less, still more preferably
30 mm or less, furthermore preferably 10 mm or less, and still furthermore preferably
5 mm or less, from the viewpoint of production of a hot-dip aluminum-coated steel
wire 3 so that the plating film 18 having a thin portion of the plating film 18 is
hardly formed, and an aluminum lump is hardly deposited on the surface of the plating
film 18, even when the temperature of the molten aluminum is a low temperature.
[0060] The inside diameter of the tip 12a of the nozzle 12 is preferably 1 mm or more, and
more preferably 2 mm or more, from the viewpoint of efficient production of the hot-dip
aluminum-coated steel wire 3 by accurately blowing the inert gas from the tip 12a
of the nozzle 12 to the boundary between the hot-dip aluminum-coated steel wire 3
and the surface 10 of the molten aluminum 1. The inside diameter of the tip 12a of
the nozzle 12 is preferably 15 mm or less, more preferably 10 mm or less, and furthermore
preferably 5 mm or less, from the viewpoint of production of a hot-dip aluminum-coated
steel wire 3 so that the plating film 18 having a thin portion of the plating film
is hardly formed, and an aluminum lump is hardly deposited on the surface of the plating
film 18, even when the temperature of the molten aluminum is a low temperature.
[0061] The inert gas can be provided, for example, from an inert gas-providing apparatus
13 shown in Fig. 1 through a pipe 14 to the nozzle 12. Incidentally, a flow controller
such as a valve (not shown in the figure) can be provided in the inert gas-providing
apparatus 13 or the pipe 14 in order to control the flow rate of the inert gas.
[0062] The inert gas means a gas which is inert to molten aluminum. Examples of the inert
gas include, for example, nitrogen gas, argon gas, helium gas and the like, and the
present invention is not limited only to those exemplified ones. Among the inert gases,
nitrogen gas is preferable. Incidentally, the inert gas may contain, for example,
oxygen gas, carbon dioxide gas and the like within a scope which would not hinder
an object of the present invention.
[0063] The pressure of the inert gas exhausted from the tip 12a of the nozzle 12 is controlled
to 0.1 to 20 kPa, and the temperature of the inert gas is adjusted to 600 to 1000°C.
According to the present invention, when the steel wire 2 is dipped in the molten
aluminum 1, and thereafter the hot-dip aluminum-coated steel wire 3 is drawn up from
the molten aluminum 1, the pressure of the inert gas blown from the tip 12a of the
nozzle 12 to the boundary between the hot-dip aluminum-coated steel wire 3 and the
surface 10 of the molten aluminum 1 is controlled to 0.1 to 20 kPa, and the temperature
of the inert gas is adjusted to 600 to 1000°C. Accordingly, the hot-dip aluminum-coated
steel wire 3 can be produced so that the plating film 18 having a thin portion of
the plating film is hardly formed, and an aluminum lump is hardly deposited on the
surface of the plating film 18, even when the temperature of the molten aluminum is
a low temperature.
[0064] The pressure of the inert gas exhausted from the tip 12a of the nozzle 12 is 0.1
kPa or higher from the viewpoint of production of the hot-dip aluminum-coated steel
wire 3 so that an aluminum lump is hardly deposited on the surface, even when the
temperature of the molten aluminum is a low temperature. The pressure of the inert
gas is 20 kPa or lower, preferably 2 kPa or lower, from the viewpoint of production
of the hot-dip aluminum-coated steel wire 3 so that the plating film 18 having a thin
portion of the plating film is hardly formed, and an aluminum lump is hardly deposited
on the surface of the plating film 18, even when the temperature of the molten aluminum
is a low temperature.
[0065] Incidentally, the pressure of the inert gas discharged from the tip 12a of the nozzle
12 is a pressure as determined by inserting a tube made of stainless steel having
an inner diameter of 0.5 mm into the inert gas inside the nozzle 12 at a place apart
from the tip 12a of the nozzle 12 in a distance of 2 mm so that the tip of the tube
is opposed to the tip 12a of the nozzle 12, and determining the pressure of the inert
gas applied to the tip of the tube by means of a pressure sensor.
[0066] In general, it is preferred that the temperature of the molten aluminum 1 is lower
when thermal efficiency is considered. However, when the temperature of the molten
aluminum 1 is lower, it tends to generate an aluminum lump on the surface of the hot-dip
aluminum-coated steel wire 3.
[0067] In contrast, according to the present invention, the hot-dip aluminum-coated steel
wire 3 having little aluminum lump adhered to its surface can be obtained even when
the temperature of the molten aluminum 1 is low, because the temperature of the inert
gas discharged from the tip 12a of the nozzle 12 is adjusted to 600°C or higher.
[0068] The temperature of the inert gas discharged from the tip 12a of the nozzle 12 is
600°C or higher from the viewpoint of production of a hot-dip aluminum-coated steel
wire 3 so that the plating film 18 having a thin portion of the plating film is hardly
formed, and an aluminum lump is hardly deposited on the surface of the plating film
18, even when the temperature of the molten aluminum 1 a low temperature. The temperature
of the inert gas thereof is 1000°C or lower, preferably 800°C or lower, and more preferably
750°C or lower, from the viewpoint of increase in thermal efficiency.
[0069] Incidentally, the temperature of the inert gas discharged from the tip 12a of the
nozzle 12 is a temperature as determined by inserting a thermocouple for measuring
a temperature, such as a sheath thermocouple having a diameter of 1.6 mm into the
inert gas at a place apart from the tip 12a of the nozzle 12 in a distance of 2 mm.
[0070] The volume flow rate of the inert gas discharged from the tip 12a of the nozzle 12
is preferably 2 L (liter)/min or more, more preferably 5 L/min or more, and furthermore
preferably 10 L/min or more, from the viewpoint of efficient inhibition of oxidization
of the surface of the meniscus 17. The volume flow rate of the inert gas thereof is
preferably 200 L/min or less, more preferably 150 L/min or less, and furthermore preferably
100 L/min or less, from the viewpoint of production of the hot-dip aluminum-coated
steel wire 3 so that the plating film 18 having a thin portion of the plating film
is hardly formed, and an aluminum lump is hardly deposited on the surface of the plating
film 18, even when the temperature of the molten aluminum 1 is a low temperature.
[0071] The line speed of the hot-dip aluminum-coated steel wire 3 drawing up from the surface
10 of the molten aluminum 1 is not particularly limited. The average thickness of
the plating film 18 formed on the surface of the hot-dip aluminum-coated steel wire
3 can be controlled by appropriately controlling the line speed of the hot-dip aluminum-coated
steel wire 3. Accordingly, it is preferred that the line speed of the hot-dip aluminum-coated
steel wire 3 is appropriately adjusted in accordance with the average thickness of
the plating film 18 formed on the surface of the hot-dip aluminum-coated steel wire
3.
[0072] Incidentally, a cooling device 15 can be provided above the nozzle 12 as occasion
demands as illustrated in Fig. 1 in order to cool the hot-dip aluminum-coated steel
wire 3 in the course of drawing up of the hot-dip aluminum-coated steel wire 3, and
efficiently solidify the plating film 18 formed on the surface of the hot-dip aluminum-coated
steel wire 3. The hot-dip aluminum-coated steel wire 3 can be cooled by blowing, for
example, gas, liquid mist or the like to the hot-dip aluminum-coated steel wire 3
in the cooling device 15.
[0073] The hot-dip aluminum-coated steel wire 3 produced in the above can be collected by
means of, for example, a winding device 16 or the like as shown in Fig. 1.
[0074] The average thickness of the plating film 18 formed on the surface of the hot-dip
aluminum-coated steel wire 3 is preferably 5 µm to 10 µm or so from the viewpoint
of suppression of exposure of the steel wire 2 included in the hot-dip aluminum-coated
steel wire 3 to the air in carrying out a process such as a wire stranding process
or a crimpling process, and increase in mechanical strength per unit diameter of the
hot-dip aluminum-coated steel wire 3.
[0075] The minimum thickness of the thin part of the plating film 18 formed on the surface
of the hot-dip aluminum-coated steel wire 3 is preferably 1 µm or more, and more preferably
2 µm or more, from the viewpoint of suppression of exposure of the steel wire 2 included
in the hot-dip aluminum-coated steel wire 3 to the air in carrying out a process such
as a wire stranding process or a crimpling process, and increase in mechanical strength
per unit diameter of the hot-dip aluminum-coated steel wire 3.
[0076] Before the steel wire 2 is dipped in the molten aluminum 1, pre-plating of the surface
of the steel wire 2 can be carried out from the viewpoint of efficient formation of
the smooth plating film 18. The metal used in the pre-plating includes, for example,
zinc, nickel, chrome, an alloy thereof and the like, and the present invention is
not limited only to those exemplified ones. In addition, the plating layer 18 formed
on the surface of the steel wire by pre-plating can be formed only by one layer. Alternatively,
the plating layer 18 can be formed by plural plating layers made of the same kind
or a different kind of a metal.
[0077] The hot-dip aluminum-coated steel wire 3 obtained by the method for producing a hot-dip
aluminum-coated steel wire according to the present invention can be subjected to
a drawing process using dies and the like as occasion demands so that the hot-dip
aluminum-coated steel wire 3 has an appropriate outer diameter.
[0078] The hot-dip aluminum-coated steel wire 3 obtained in the present invention can be
suitably used, for example, in a wire harness of an automobile, and the like.
EXAMPLES
[0079] Next, the present invention will be more specifically described based on working
examples. However, the present invention is not limited only to those working examples.
Examples 1 to 100 and comparative examples 1 to 11
[0080] In each of working examples and each of comparative examples, a hot-dip aluminum-coated
steel wire was produced based on the embodiment of the method for producing a hot-dip
aluminum-coated steel wire according to the present invention as illustrated in Fig.
1.
[0081] As a steel wire, a steel wire having a diameter shown in each table, and made of
steel shown in each table was used. A steel wire on which surface was not treated
by zinc plating (referred to as "non" in the column "pre Zn" in each table), or a
steel wire having an average thickness of 5 µm or less of a zinc plating layer (referred
to as "existing" in the column "pre Zn" in each table) was used. In each table, the
term "37A" listed in the column of "kind of steel" means a steel wire made of high
carbon steel containing 0.37% by mass of carbon.
[0082] Incidentally, the steel wire on which surface was not treated by zinc plating was
subjected to degreasing by dipping the steel wire in a degreasing liquid containing
sodium orthosilicate and a surfactant, before the steel wire was dipped in the hot-dip
aluminum.
[0083] In addition, before the steel wire was dipped in the molten aluminum, the steel wire
was passed through the steel wire-introducing controller 8 shown in Fig. 2, and the
steel wire was preheated to about 400°C by using the heating device 6. As a heating
gas, nitrogen gas was used. Incidentally, a steel wire connected with a thermocouple
was prepared, and the thermocouple was passed through the heating device together
with the steel wire, to determine the preheating temperature.
[0084] In addition, as the liquid surface-controlling device 7 which was used in the steel
wire-introducing controller 8 shown in Fig. 2, the liquid surface-controlling device
7 as shown in Fig. 3, in which the shape, size and area of the opening part 9d of
the introducing port 9c of the through hole 9a of the tubular body 9 were the same
as those of the opening part 9f of the discharge port 9e of the through hole 9a of
the tubular body 9, was used. The value of the ratio of the area of the opening part
of the through hole 9a of the tubular body 9 to the area of the cross section of the
steel wire (area of the opening part of the through hole 9a of the tubular body 9/
area of the cross section of the steel wire) was adjusted to 57. The steel wire was
dipped in the molten aluminum through the liquid surface-controlling device 7 for
0.3 seconds to 1 second.
[0085] As the molten aluminum, molten aluminum (purity of aluminum: 99.7 % or more, referred
to as "Al" in the column "kind" of "hot-dip Al" in each table), molten aluminum containing
4% by mass of silicon (referred to as "4%Si" in the column "kind" of "hot-dip Al"
in each table), molten aluminum containing 8% by mass of silicon (referred to as "8%Si"
in the column "kind" of "hot-dip Al" in each table), molten aluminum containing 11%
by mass of silicon (referred to as "11%Si" in the column "kind" of "hot-dip Al" in
each table), or molten aluminum containing 13% by mass of silicon (referred to as
"13%Si" in the column "kind" of "hot-dip Al" in each table) was used. The steel wire
was dipped in the molten aluminum having a temperature shown in each table at a line
speed (speed of drawing up of steel wire) shown in each table, and then the steel
wire was drawn up from the molten aluminum.
[0086] At that time, a stabilizing member having a width of 40 mm was contacted with the
surface of the molten aluminum and the hot-dip aluminum-coated steel wire which was
drawn up from the molten aluminum at the boundary between the hot-dip aluminum-coated
steel wire and the surface of the molten aluminum. Incidentally, as the stabilizing
member, a square rod made of stainless steel of which surface was wound with a heat-resistant
cloth was used. The length for contacting the hot-dip aluminum-coated steel wire with
the heat-resistant cloth was adjusted to 5 mm.
[0087] In addition, a nozzle having an inner diameter shown in each table was arranged so
that the tip of the nozzle was located at a place apart from the hot-dip aluminum-coated
steel wire in a distance of 2 mm. An inert gas (nitrogen gas) of which temperature
was controlled to a temperature shown in each table was discharged from the tip of
the nozzle at a volume flow rate shown in each table, and was blown to the boundary
between the hot-dip aluminum-coated steel wire and the surface of the molten aluminum
at a pressure shown in each table.
[0088] The above operations were carried out, to obtain a hot-dip aluminum-coated steel
wire having a plating film of an average thickness shown in each table and the minimum
thickness of the thin part of the plating film shown in each table.
[0089] Incidentally, a method for determining the average thickness of the plating film
is shown below. In addition, a method for determining the minimum thickness of the
thin part of the plating film is described in the following paragraph "(2) Measuring
of the minimum thickness of the thin part of the plating film".
[Method for determining average thickness of plating film]
[0090] The average thickness of the plating film of the hot-dip aluminum-coated steel wire
obtained in each working example and each comparative example was determined on the
basis of an embodiment shown in Fig. 5. Fig. 5 is a schematic explanatory view showing
one embodiment of the method for determining the average thickness of the plating
film of the hot-dip aluminum-coated steel wire obtained in each working example and
each comparative example.
[0091] As a device 19 for measuring a diameter of a steel wire by passing through the steel
wire, a device for measuring a diameter having two optical micrometers each of which
was commercially available from KEYENCE CORPORATION under the product number of LS-7000
was used as shown in Fig. 5. The device 19 for measuring a diameter had a pair of
a pulley 19c and a pulley 19d which were positioned in a vertical direction against
the steel wire, and a pair of a light emitting unit 19a and a light receiving unit
19b which were arranged in a horizontal direction at a central position between the
pulley 19c and the pulley 19d. The light emitting unit 19a and the light receiving
unit 19b were arranged so that the light emitting unit 19a and the light receiving
unit 19b were opposed to each other. The light emitting unit 19a and the light receiving
unit 19b adjacent each other were arranged so that an angle between the light emitting
unit 19a and the light receiving unit 19b was 90° as shown in Fig. 5.
[0092] While the hot-dip aluminum-coated steel wire 3 having a length of 100 m obtained
in each working example or each comparative example was run at a line speed of 100
m/min in a direction of arrow F between the pulley 19c and the pulley 19d, the outer
diameter of the hot-dip aluminum-coated steel wire 3 was measured at an interval of
about 1.4 mm in the longitudinal direction of the aluminum-plated steel wire 3 by
means of the device 19 for measuring a diameter. Incidentally, the number of measurement
points of the outer diameter was adjusted to about 71000 points.
[0093] Next, an average value of the outer diameters of the hot-dip aluminum-coated steel
wire as measured in the above was calculated. The value of the diameter of the steel
wire before forming a plating film (diameter of steel wire shown in the following
each table) was subtracted from the average value, and an obtained value was divided
by 2, to give an average thickness of a plating film. The results are shown in each
table.
[Evaluation of properties of plating film]
[0094] As the properties of the hot-dip aluminum-coated steel wire obtained in each working
example or each comparative example, adhesion of aluminum lump and stability of the
plating film at the thin part of the plating film having the minimum thickness were
examined in accordance with the following methods. Its results are shown in each table.
(1) Adhesion of aluminum lump
[0095] A hot-dip aluminum-coated steel wire having a length of 300 m was run at a line speed
of 100 m/min, and the outer diameter of the hot-dip aluminum-coated steel wire was
measured over the whole length of the hot-dip aluminum-coated steel wire. At that
time, whether or not a convex portion due to local increase in outer diameter exists
was examined. Whether or not an aluminum lump exists in the convex portion due to
local increase in outer diameter was observed with naked eyes, and adhesion of the
aluminum lump was evaluated in accordance with the following evaluation criteria.
Incidentally, the outer diameter of the hot-dip aluminum-coated steel wire was determined
by means of an optical micrometer commercially available from KEYENCE CORPORATION
under the product number of LS-7000.
[Evaluation criteria]
[0096]
○: Adhesion of an aluminum lump is not observed.
×: Adhesion of an aluminum lump is observed.
(2) Measuring of the minimum thickness of the thin part of the plating film
[0097] In order to measure the minimum thickness at the thin part of the plating film, the
section of the hot-dip aluminum-coated steel wire was observed. More specifically,
a specimen having a length of 300 mm was obtained by arbitrarily cutting the hot-dip
aluminum-coated steel wire, and six test pieces were obtained from the specimen by
cutting the specimen. Thereafter, the test pieces were embedded in a resin. The resulting
embedded resin product was cut, and its cross section was polished, to expose the
cross section of the hot-dip aluminum-coated steel wire. This cross section was observed
with an optical microscope (magnification: 500 times), and the minimum thickness at
the thin part of the plating film was measured. The minimum thickness at the thin
part of the plating film was selected from the six test pieces, and the minimum thickness
was regarded as the minimum thickness of thin part of plating film.
(3) Stability of minimum thickness of thin part of the plating film
[0098] The stability of the minimum thickness of the thin part of the plating film was evaluated
based on the minimum thickness of the thin part of the plating film obtained in the
above, and judged on the basis of the following evaluation criteria:
(Evaluation criteria)
[0099]
⊚: The minimum thickness of the thin part of the plating film is 2 µm or more.
○: The minimum thickness of the thin part of the plating film is 1 µm or more and
less than 2 µm.
×: The minimum thickness of the thin part of the plating film is less than 1 µm.
(4) Comprehensive evaluation
[0100] In accordance with the results for evaluating the adhesion of aluminum lump and the
stability of minimum thickness of thin part of the plating film, comprehensive evaluation
was carried out on the basis of the following evaluation criteria:
(Evaluation criteria)
[0101]
⊚: The evaluation of the adhesion of aluminum lump is ○, and the evaluation of the
stability of minimum thickness of thin part of the plating film is ⊚ (Excellent).
○: The evaluation of the adhesion of aluminum lump and the evaluation of the stability
of minimum thickness of thin part of the plating film are ○, respectively (Good).
×: The evaluation of × is included in any of the evaluation of the adhesion of aluminum
lump and the evaluation of the stability of minimum thickness of thin part of the
plating film (Failure).
[Table 1]
Ex. No. |
Kind of steel wire |
Hot-dip Al |
Nozzle |
Inert gas |
Plating film |
Evaluation of Al-plated steel wire |
Comprehensive evaluation |
Pre Zn |
Diameter (mm) |
Kind of steel |
Kind |
Melting temp. (°C) |
Temp. of hot-dip Al (°C) |
Line speed (m/min) |
Inner diameter (mm) |
Temp. (°C) |
Volume flow rate (L/min) |
Pressure (kPa) |
Average thickness (µm) |
Minimum thickness of thin part (µm) |
Adhesion of aluminum lump |
Stability of minimum thickness of thin part |
1 |
Non |
0.20 |
SUS304 |
8%Si |
615 |
680 |
300 |
7.6 |
780 |
100 |
3.8 |
7.1 |
2.1 |
○ |
⊚ |
⊚ |
2 |
Non |
0.20 |
SUS304 |
8%Si |
615 |
680 |
300 |
7.6 |
740 |
50 |
0.75 |
7.1 |
3.3 |
○ |
⊚ |
⊚ |
3 |
Non |
0.20 |
SUS304 |
8%Si |
615 |
680 |
300 |
7.6 |
680 |
20 |
0.14 |
7.9 |
3.9 |
○ |
⊚ |
⊚ |
4 |
Non |
0.20 |
SUS304 |
8%Si |
615 |
680 |
300 |
6.0 |
660 |
10 |
0.12 |
7.7 |
4.2 |
○ |
⊚ |
⊚ |
5 |
Non |
0.20 |
SUS304 |
8%Si |
615 |
680 |
300 |
3.0 |
720 |
40 |
20 |
8.0 |
1.1 |
○ |
○ |
○ |
6 |
Non |
0.20 |
SUS304 |
8%Si |
615 |
680 |
300 |
3.0 |
710 |
30 |
10 |
7.7 |
1.7 |
○ |
○ |
○ |
7 |
Non |
0.20 |
SUS304 |
8%Si |
615 |
680 |
300 |
3.0 |
670 |
10 |
1.8 |
8.0 |
2.8 |
○ |
⊚ |
⊚ |
8 |
Non |
0.20 |
SUS304 |
8%Si |
615 |
680 |
300 |
2.4 |
660 |
10 |
3.0 |
8.1 |
2.4 |
○ |
⊚ |
⊚ |
9 |
Non |
0.20 |
SUS304 |
8%Si |
615 |
680 |
300 |
1.9 |
620 |
10 |
8.0 |
8.1 |
1.8 |
○ |
○ |
○ |
10 |
Non |
0.20 |
SUS304 |
8%Si |
615 |
660 |
300 |
7.6 |
780 |
100 |
3.8 |
7.4 |
2.0 |
○ |
⊚ |
⊚ |
11 |
Non |
0.20 |
SUS304 |
8%Si |
615 |
660 |
300 |
7.6 |
740 |
50 |
0.75 |
7.3 |
2.9 |
○ |
⊚ |
⊚ |
12 |
Non |
0.20 |
SUS304 |
8%Si |
615 |
660 |
300 |
7.6 |
680 |
20 |
0.14 |
8.4 |
4.0 |
○ |
⊚ |
⊚ |
13 |
Non |
0.20 |
SUS304 |
8%Si |
615 |
660 |
300 |
6.0 |
660 |
10 |
0.12 |
8.2 |
4.1 |
○ |
⊚ |
⊚ |
14 |
Non |
0.20 |
SUS304 |
8%Si |
615 |
660 |
300 |
3.0 |
720 |
40 |
20 |
7.9 |
1.2 |
○ |
○ |
○ |
15 |
Non |
0.20 |
SUS304 |
8%Si |
615 |
660 |
300 |
3.0 |
710 |
30 |
10 |
8.1 |
1.8 |
○ |
○ |
○ |
16 |
Non |
0.20 |
SUS304 |
8%Si |
615 |
660 |
300 |
3.0 |
670 |
10 |
1.8 |
7.5 |
3.0 |
○ |
⊚ |
⊚ |
17 |
Non |
0.20 |
SUS304 |
8%Si |
615 |
660 |
300 |
2.4 |
660 |
10 |
3.0 |
7.5 |
2.4 |
○ |
⊚ |
⊚ |
18 |
Non |
0.20 |
SUS304 |
8%Si |
615 |
660 |
300 |
1.9 |
620 |
10 |
8.0 |
8.2 |
1.9 |
○ |
○ |
○ |
19 |
Non |
0.20 |
SUS304 |
8%Si |
615 |
640 |
300 |
7.6 |
780 |
100 |
3.8 |
7.3 |
2.1 |
○ |
⊚ |
⊚ |
20 |
Non |
0.20 |
SUS304 |
8%Si |
615 |
640 |
300 |
7.6 |
740 |
50 |
0.75 |
7.2 |
3.1 |
○ |
⊚ |
⊚ |
21 |
Non |
0.20 |
SUS304 |
8%Si |
615 |
640 |
300 |
7.6 |
680 |
20 |
0.14 |
8.2 |
4.3 |
○ |
⊚ |
⊚ |
22 |
Non |
0.20 |
SUS304 |
8%Si |
615 |
640 |
300 |
6.0 |
660 |
10 |
0.12 |
8.2 |
4.2 |
○ |
⊚ |
⊚ |
23 |
Non |
0.20 |
SUS304 |
8%Si |
615 |
640 |
300 |
3.0 |
720 |
40 |
20 |
8.0 |
1.3 |
○ |
○ |
○ |
24 |
Non |
0.20 |
SUS304 |
8%Si |
615 |
640 |
300 |
3.0 |
710 |
30 |
10 |
8.4 |
1.9 |
○ |
○ |
○ |
25 |
Non |
0.20 |
SUS304 |
8%Si |
615 |
640 |
300 |
3.0 |
670 |
10 |
1.8 |
7.2 |
3.1 |
○ |
⊚ |
⊚ |
26 |
Non |
0.20 |
SUS304 |
8%Si |
615 |
640 |
300 |
2.4 |
660 |
10 |
3.0 |
8.0 |
2.5 |
○ |
⊚ |
⊚ |
27 |
Non |
0.20 |
SUS304 |
8%Si |
615 |
640 |
300 |
1.9 |
620 |
10 |
8.0 |
8.5 |
1.8 |
○ |
○ |
○ |
28 |
Non |
0.20 |
SUS304 |
8%Si |
615 |
640 |
300 |
16 |
830 |
70 |
1.2 |
7.3 |
3.1 |
○ |
⊚ |
⊚ |
29 |
Non |
0.20 |
SUS304 |
8%Si |
615 |
640 |
300 |
16 |
980 |
50 |
0.83 |
7.0 |
3.2 |
○ |
⊚ |
⊚ |
[Table 2]
Ex. No. |
Kind of steel wire |
Hot-dip Al |
Nozzle |
Inert gas |
Plating film |
Evaluation of Al-plated steel |
Comprehensive evaluation |
Pre Zn |
Diameter (mm) |
Kind of steel |
Kind |
Melting temp. (°C) |
Temp. of hot-dip Al (°C) |
Line speed (m/min) |
Inner diameter (mm) |
Temp. (°C) |
Volume flow rate (L/min) |
Pressure (kPa) |
Average thickness (µm) |
Minimum thickness of thin part (µm) |
Adhesion of aluminum lump |
Stability of minimum thickness of thin part |
30 |
Non |
0.20 |
SUS304 |
Al |
660 |
720 |
300 |
3.0 |
670 |
10 |
1.8 |
7.1 |
2.6 |
○ |
⊚ |
⊚ |
31 |
Non |
0.20 |
SUS304 |
Al |
660 |
700 |
300 |
3.0 |
670 |
10 |
1.8 |
7.1 |
3.1 |
○ |
⊚ |
⊚ |
32 |
Non |
0.20 |
SUS304 |
Al |
660 |
680 |
300 |
3.0 |
670 |
10 |
1.8 |
7.3 |
3.4 |
○ |
⊚ |
⊚ |
33 |
Non |
0.20 |
SUS304 |
4%Si |
640 |
720 |
300 |
3.0 |
670 |
10 |
1.8 |
7.3 |
2.5 |
○ |
⊚ |
⊚ |
34 |
Non |
0.20 |
SUS304 |
4%Si |
640 |
700 |
300 |
3.0 |
670 |
10 |
1.8 |
6.9 |
2.8 |
○ |
⊚ |
⊚ |
35 |
Non |
0.20 |
SUS304 |
4%Si |
640 |
680 |
300 |
3.0 |
670 |
10 |
1.8 |
7.6 |
2.9 |
○ |
⊚ |
⊚ |
36 |
Non |
0.20 |
SUS304 |
4%Si |
640 |
660 |
300 |
3.0 |
670 |
10 |
1.8 |
7.9 |
31 |
○ |
⊚ |
⊚ |
37 |
Non |
0.20 |
SUS304 |
8%Si |
615 |
720 |
300 |
3.0 |
670 |
10 |
1.8 |
6.7 |
2.6 |
○ |
⊚ |
⊚ |
38 |
Non |
0.20 |
SUS304 |
8%Si |
615 |
700 |
300 |
3.0 |
670 |
10 |
1.8 |
7.2 |
2.6 |
○ |
⊚ |
⊚ |
39 |
Non |
0.20 |
SUS304 |
8%Si |
615 |
660 |
300 |
3.0 |
670 |
10 |
1.8 |
7.0 |
2.9 |
○ |
⊚ |
⊚ |
40 |
Non |
0.20 |
SUS304 |
8%Si |
615 |
635 |
300 |
3.0 |
670 |
10 |
1.8 |
7.0 |
3.2 |
○ |
⊚ |
⊚ |
41 |
Non |
0.20 |
SUS304 |
11%Si |
590 |
700 |
300 |
3.0 |
670 |
10 |
1.8 |
7.1 |
2.5 |
○ |
⊚ |
⊚ |
42 |
Non |
0.20 |
SUS304 |
11%Si |
590 |
680 |
300 |
3.0 |
670 |
10 |
1.8 |
7.2 |
2.9 |
○ |
⊚ |
⊚ |
43 |
Non |
0.20 |
SUS304 |
11%Si |
590 |
660 |
300 |
3.0 |
670 |
10 |
1.8 |
6.8 |
3.2 |
○ |
⊚ |
⊚ |
44 |
Non |
0.20 |
SUS304 |
11%Si |
590 |
640 |
300 |
3.0 |
670 |
10 |
1.8 |
7.0 |
3.2 |
○ |
⊚ |
⊚ |
45 |
Non |
0.20 |
SUS304 |
11%Si |
590 |
620 |
300 |
3.0 |
670 |
10 |
1.8 |
7.5 |
3.3 |
○ |
⊚ |
⊚ |
46 |
Non |
0.20 |
SUS304 |
11%Si |
590 |
610 |
300 |
3.0 |
670 |
10 |
1.8 |
7.3 |
3.6 |
○ |
⊚ |
⊚ |
47 |
Non |
0.20 |
SUS304 |
13%Si |
585 |
700 |
300 |
3.0 |
670 |
10 |
1.8 |
7.1 |
2.5 |
○ |
⊚ |
⊚ |
48 |
Non |
0.20 |
SUS304 |
13%Si |
585 |
680 |
300 |
3.0 |
670 |
10 |
1.8 |
7.4 |
2.6 |
○ |
⊚ |
⊚ |
49 |
Non |
0.20 |
SUS304 |
13%Si |
585 |
640 |
300 |
3.0 |
670 |
10 |
1.8 |
7.2 |
2.9 |
○ |
⊚ |
⊚ |
50 |
Non |
0.20 |
SUS304 |
13%Si |
585 |
605 |
300 |
3.0 |
670 |
10 |
1.8 |
7.2 |
3.2 |
○ |
⊚ |
⊚ |
[Table 3]
Ex. No. |
Kind of steel wire |
Hot-dip Al |
Nozzle |
Inert gas |
Plating film |
Evaluation of Al-plated steel wire |
Comprehensive evaluation |
Pre Zn |
Diameter (mm) |
Kind of steel |
Kind |
Melting temp.(°C) |
Temp. of hot-dip Al(°C) |
Line speed (m/min) |
Inner diameter (mm) |
Temp. (°C) |
Volume flow rate (L/min) |
Pressure (kPa) |
Average thickness (µm) |
Minimum thickness of thin part (µm) |
Adhesion of aluminum |
Stability of minimum thickness of thin part |
51 |
Non |
0.20 |
SUS304 |
Al |
660 |
685 |
300 |
7.6 |
780 |
100 |
3.8 |
7.6 |
2.6 |
○ |
⊚ |
⊚ |
52 |
Non |
0.20 |
SUS304 |
4%Si |
640 |
665 |
300 |
7.6 |
780 |
100 |
3.8 |
7.6 |
2.7 |
○ |
⊚ |
⊚ |
53 |
Non |
0.20 |
SUS304 |
8%Si |
615 |
640 |
300 |
7.6 |
780 |
100 |
3.8 |
7.2 |
2.5 |
○ |
⊚ |
⊚ |
54 |
Non |
0.20 |
SUS304 |
11%Si |
590 |
615 |
300 |
7.6 |
780 |
100 |
3.8 |
7.9 |
2.6 |
○ |
⊚ |
⊚ |
55 |
Non |
0.20 |
SUS304 |
13%Si |
585 |
610 |
300 |
7.6 |
780 |
100 |
3.8 |
8.1 |
2.7 |
○ |
⊚ |
⊚ |
56 |
Non |
0.20 |
SUS304 |
Al |
660 |
685 |
300 |
4.0 |
720 |
10 |
0.38 |
7.6 |
3.4 |
○ |
⊚ |
⊚ |
57 |
Non |
0.20 |
SUS304 |
4%Si |
640 |
665 |
300 |
4.0 |
720 |
10 |
0.38 |
7.9 |
3.8 |
○ |
⊚ |
⊚ |
58 |
Non |
0.20 |
SUS304 |
8%Si |
615 |
640 |
300 |
4.0 |
720 |
10 |
0.38 |
7.6 |
3.9 |
○ |
⊚ |
⊚ |
59 |
Non |
0.20 |
SUS304 |
11%Si |
590 |
615 |
300 |
4.0 |
720 |
10 |
0.38 |
8.0 |
3.6 |
○ |
⊚ |
⊚ |
60 |
Non |
0.20 |
SUS304 |
13%Si |
585 |
610 |
300 |
4.0 |
720 |
10 |
0.38 |
7.9 |
3.9 |
○ |
⊚ |
⊚ |
61 |
Non |
0.20 |
SUS304 |
Al |
660 |
685 |
300 |
3.0 |
710 |
30 |
10 |
7.6 |
2.3 |
○ |
⊚ |
⊚ |
62 |
Non |
0.20 |
SUS304 |
4%Si |
640 |
665 |
300 |
3.0 |
710 |
30 |
10 |
8.1 |
2.2 |
○ |
⊚ |
⊚ |
63 |
Non |
0.20 |
SUS304 |
8%Si |
615 |
640 |
300 |
3.0 |
710 |
30 |
10 |
8.2 |
2.1 |
○ |
⊚ |
⊚ |
64 |
Non |
0.20 |
SUS304 |
11%Si |
590 |
615 |
300 |
3.0 |
710 |
30 |
10 |
7.9 |
2.0 |
○ |
⊚ |
⊚ |
65 |
Non |
0.20 |
SUS304 |
13%Si |
585 |
610 |
300 |
3.0 |
710 |
30 |
10 |
7.9 |
2.0 |
○ |
⊚ |
⊚ |
66 |
Non |
0.20 |
SUS304 |
Al |
660 |
685 |
300 |
3.0 |
670 |
10 |
1.8 |
7.5 |
3.3 |
○ |
⊚ |
⊚ |
67 |
Non |
0.20 |
SUS304 |
4%Si |
640 |
665 |
300 |
3.0 |
670 |
10 |
1.8 |
7.6 |
3.2 |
○ |
⊚ |
⊚ |
68 |
Non |
0.20 |
SUS304 |
8%Si |
615 |
640 |
300 |
3.0 |
670 |
10 |
1.8 |
7.6 |
3.1 |
○ |
⊚ |
⊚ |
69 |
Non |
0.20 |
SUS304 |
11%Si |
590 |
615 |
300 |
3.0 |
670 |
10 |
1.8 |
7.6 |
3.6 |
○ |
⊚ |
⊚ |
70 |
Non |
0.20 |
SUS304 |
13%Si |
585 |
610 |
300 |
3.0 |
670 |
10 |
1.8 |
7.4 |
3.2 |
○ |
⊚ |
⊚ |
71 |
Non |
0.20 |
SUS304 |
Al |
660 |
685 |
300 |
2.4 |
650 |
10 |
2.2 |
7.8 |
4.4 |
○ |
⊚ |
⊚ |
72 |
Non |
0.20 |
SUS304 |
4%Si |
640 |
665 |
300 |
2.4 |
650 |
10 |
2.2 |
8.3 |
4.6 |
○ |
⊚ |
⊚ |
73 |
Non |
0.20 |
SUS304 |
8%Si |
615 |
640 |
300 |
2.4 |
650 |
10 |
2.2 |
7.8 |
4.8 |
○ |
⊚ |
⊚ |
74 |
Non |
0.20 |
SUS304 |
11%Si |
590 |
615 |
300 |
2.4 |
650 |
10 |
2.2 |
8.1 |
4.6 |
○ |
⊚ |
⊚ |
75 |
Non |
0.20 |
SUS304 |
13%Si |
585 |
610 |
300 |
2.4 |
650 |
10 |
2.2 |
8.0 |
4.6 |
○ |
⊚ |
⊚ |
76 |
Non |
0.20 |
SUS304 |
Al |
660 |
685 |
300 |
1.9 |
620 |
10 |
8.0 |
8.2 |
2.0 |
○ |
⊚ |
⊚ |
77 |
Non |
0.20 |
SUS304 |
4%Si |
640 |
665 |
300 |
1.9 |
620 |
10 |
8.0 |
8.5 |
2.1 |
○ |
⊚ |
⊚ |
78 |
Non |
0.20 |
SUS304 |
8%Si |
615 |
640 |
300 |
1.9 |
620 |
10 |
8.0 |
8.6 |
2.0 |
○ |
⊚ |
⊚ |
79 |
Non |
0.20 |
SUS304 |
11%Si |
590 |
615 |
300 |
1.9 |
620 |
10 |
8.0 |
8.7 |
2.1 |
○ |
⊚ |
⊚ |
80 |
Non |
0.20 |
SUS304 |
13%Si |
585 |
610 |
300 |
1.9 |
620 |
10 |
8.0 |
8.9 |
2.2 |
○ |
⊚ |
⊚ |
[Table 4]
Ex. No. |
Kind of steel wire |
Hot-dip Al |
Nozzle |
Inert gas |
Plating film |
Evaluation of Al-plated steel wire |
Comprehensive evaluation |
Pre Zn |
Diameter (mm) |
Kind of steel |
Kind |
Melting temp. (°C) |
Temp. of hot-dip Al (°C) |
Line speed (m/min) |
Inner diameter (mm) |
Temp. (°C) |
Volume flow rate (L/min) |
Pressure (kPa) |
Average thickness (µm) |
Minimum thickness of thin part (µm) |
Adhesion of aluminum lump |
Stability of minimum thickness of thin part |
81 |
Non |
0.20 |
SUS430 |
Al |
660 |
685 |
300 |
4.0 |
720 |
10 |
0.38 |
9.1 |
3.2 |
○ |
⊚ |
⊚ |
82 |
Non |
0.20 |
SUS430 |
4%Si |
640 |
665 |
300 |
4.0 |
720 |
10 |
0.38 |
9.1 |
3.1 |
○ |
⊚ |
⊚ |
83 |
Non |
0.20 |
SUS430 |
8%Si |
615 |
640 |
300 |
4.0 |
720 |
10 |
0.38 |
8.6 |
3.2 |
○ |
⊚ |
⊚ |
84 |
Non |
0.20 |
SUS430 |
11%Si |
590 |
615 |
300 |
4.0 |
720 |
10 |
0.38 |
8.9 |
3.4 |
○ |
⊚ |
⊚ |
85 |
Non |
0.20 |
SUS430 |
13%Si |
585 |
610 |
300 |
4.0 |
720 |
10 |
0.38 |
9.0 |
3.1 |
○ |
⊚ |
⊚ |
86 |
Non |
0.20 |
37A |
Al |
660 |
685 |
300 |
4.0 |
720 |
10 |
0.38 |
9.1 |
3.0 |
○ |
⊚ |
⊚ |
87 |
Non |
0.20 |
37A |
4%Si |
640 |
665 |
300 |
4.0 |
720 |
10 |
0.38 |
8.8 |
3.3 |
○ |
⊚ |
⊚ |
88 |
Non |
0.20 |
37A |
8%Si |
615 |
640 |
300 |
4.0 |
720 |
10 |
0.38 |
9.1 |
3.1 |
○ |
⊚ |
⊚ |
89 |
Non |
0.20 |
37A |
11%Si |
590 |
615 |
300 |
4.0 |
720 |
10 |
0.38 |
8.9 |
3.3 |
○ |
⊚ |
⊚ |
90 |
Non |
0.20 |
37A |
13%Si |
585 |
610 |
300 |
4.0 |
720 |
10 |
0.38 |
8.8 |
3.0 |
○ |
⊚ |
⊚ |
91 |
Existing |
0.20 |
37A |
Al |
660 |
685 |
300 |
4.0 |
720 |
10 |
0.38 |
9.4 |
3.3 |
○ |
⊚ |
⊚ |
92 |
Existing |
0.20 |
37A |
4%Si |
640 |
665 |
300 |
4.0 |
720 |
10 |
0.38 |
8.9 |
3.4 |
○ |
⊚ |
⊚ |
93 |
Existing |
0.20 |
37A |
8%Si |
615 |
640 |
300 |
4.0 |
720 |
10 |
0.38 |
8.7 |
3.5 |
○ |
⊚ |
⊚ |
94 |
Existing |
0.20 |
37A |
11%Si |
590 |
615 |
300 |
4.0 |
720 |
10 |
0.38 |
8.9 |
3.3 |
○ |
⊚ |
⊚ |
95 |
Existing |
0.20 |
37A |
13%Si |
585 |
610 |
300 |
4.0 |
720 |
10 |
0.38 |
8.8 |
3.2 |
○ |
⊚ |
⊚ |
[Table 5]
Ex. No. |
Kind of steel wire |
Hot-dip Al |
Nozzle |
Inert gas |
Plating film |
Evaluation of Al-plated steel wire |
Comprehensive evaluation |
Pre Zn |
Diameter (mm) |
Kind of steel |
Kind |
Melting temp. (°C) |
Temp. of hot-dip Al(°C) |
Line speed (m/min) |
Inner diameter (mm) |
Temp. (°C) |
Volume flow rate (L/min) |
Pressure (kPa) |
Average thickness (µm) |
Minimum thickness of thin part (µm) |
Adhesion of aluminum lump |
Stability of minimum thickness of thin part |
96 |
Non |
0.20 |
SUS304 |
Al |
660 |
675 |
300 |
3.0 |
670 |
10 |
1.8 |
7.4 |
3.5 |
○ |
⊚ |
⊚ |
97 |
Non |
0.20 |
SUS304 |
4%Si |
640 |
655 |
300 |
3.0 |
670 |
10 |
1.8 |
7.8 |
3.2 |
○ |
⊚ |
⊚ |
98 |
Non |
0.20 |
SUS304 |
8%Si |
615 |
630 |
300 |
3.0 |
670 |
10 |
1.8 |
7.2 |
3.3 |
○ |
⊚ |
⊚ |
99 |
Non |
0.20 |
SUS304 |
11%Si |
590 |
605 |
300 |
3.0 |
670 |
10 |
1.8 |
7.5 |
3.7 |
○ |
⊚ |
⊚ |
100 |
Non |
0.20 |
SUS304 |
13%Si |
585 |
600 |
300 |
3.0 |
670 |
10 |
1.8 |
7.4 |
3.4 |
○ |
⊚ |
⊚ |
[Table 6]
Comp. Ex. No. |
Kind of steel wire |
Hot-dip Al |
Nozzle |
Inert gas |
Plating film |
Evaluation of Al-plated steel wire |
Comprehensive evaluation |
Pre Zn |
Diameter (mm) |
Kind of steel |
Kind |
Melting temp. (°C) |
Temp. of hot-dip Al (°C) |
Line speed (m/min) |
Inner diameter (mm) |
Temp. (°C) |
Volume flow rate (L/min) |
Pressure (kPa) |
Average thickness (µm) |
Minimum thickness of thin part (µm) |
Adhesion of aluminum lump |
Stability of minimum thickness of thin part |
1 |
Non |
0.20 |
SUS304 |
8%Si |
615 |
635 |
300 |
2.4 |
580 |
5 |
0.92 |
9.7 |
3.9 |
x |
⊚ |
× |
2 |
Non |
0.20 |
SUS304 |
8%Si |
615 |
625 |
300 |
3.0 |
670 |
10 |
1.8 |
10.1 |
4.2 |
× |
⊚ |
× |
3 |
Non |
0.20 |
SUS304 |
8%Si |
615 |
680 |
300 |
2.4 |
700 |
30 |
26.0 |
7.5 |
0.7 |
○ |
× |
× |
4 |
Non |
0.20 |
SUS304 |
8%Si |
615 |
680 |
300 |
1.7 |
660 |
30 |
82.0 |
7.3 |
0.4 |
○ |
× |
× |
5 |
Non |
0.20 |
SUS304 |
8%Si |
615 |
680 |
300 |
7.6 |
640 |
10 |
0.05 |
9.9 |
4.5 |
× |
⊚ |
× |
6 |
Non |
0.20 |
SUS430 |
8%Si |
615 |
635 |
300 |
2.4 |
580 |
5 |
0.92 |
9.8 |
3.6 |
× |
⊚ |
× |
7 |
Non |
0.20 |
37A |
8%Si |
615 |
635 |
300 |
2.4 |
580 |
5 |
0.92 |
9.8 |
3.8 |
× |
⊚ |
× |
8 |
Non |
0.20 |
SUS430 |
8%Si |
615 |
680 |
300 |
1.9 |
690 |
30 |
50 |
7.0 |
0.7 |
○ |
× |
× |
9 |
Non |
0.20 |
37A |
8%Si |
615 |
680 |
300 |
1.9 |
690 |
30 |
50 |
6.8 |
0.6 |
○ |
× |
× |
10 |
Non |
0.20 |
SUS430 |
8%Si |
615 |
680 |
300 |
7.6 |
640 |
10 |
0.05 |
9.9 |
4.9 |
× |
⊚ |
× |
11 |
Non |
0.20 |
37A |
8%Si |
615 |
680 |
300 |
7.6 |
640 |
10 |
0.05 |
9.8 |
4.7 |
× |
⊚ |
× |
[0102] According to each working example, it can be seen that a hot-dip aluminum-coated
steel wire can be efficiently produced so that a plating film having a thin portion
of the plating film is hardly formed, and an aluminum lump is hardly deposited on
the surface of the plating film, as shown in Tables 1 to 5, because the inert gas
for blowing to the boundary between the steel wire and the surface of the molten aluminum
is adjusted to 0.1 to 20 kPa, and the temperature of the inert gas is adjusted to
600 to 1000°C. In addition, according to Example 32, Example 36, Example 40, Example
46, Example 50 and Examples 96 to 100, it can be seen that a hot-dip aluminum-coated
steel wire can be efficiently produced so that a plating film having a thin portion
of the plating film is hardly formed, and an aluminum lump is hardly deposited on
the surface of the plating film, even when the temperature of the molten aluminum
is a low temperature such as a temperature 15°C or more higher than the melting temperature
of the molten aluminum, and equal to or lower than a temperature 20°C higher than
the melting temperature of the molten aluminum, as shown in Table 2 and Table 5.
[0103] In contrast, according to Comparative example 1, Comparative example 6 and Comparative
example 7, it can be seen that a hot-dip aluminum-coated steel wire cannot be produced
without generation of an aluminum lump when the temperature of the molten aluminum
is a temperature 20°C higher than the melting temperature of the molten aluminum,
because the temperature of the inert gas for blowing to the boundary between the steel
wire and the surface of the molten aluminum is lower than 600°C, as shown in Table
6.
[0104] In addition, according to Comparative example 2, it can be seen that a hot-dip aluminum-coated
steel wire cannot be produced without adhesion of an aluminum lump on its surface,
even when the pressure and temperature of the inert gas which is blown to the boundary
between the steel wire and the surface of the molten aluminum are controlled to the
desired pressure and temperature respectively, as shown in Table 6, because the temperature
of the molten aluminum is a temperature lower than a temperature 15°C higher than
the melting temperature of the molten aluminum.
[0105] Also, according to Comparative examples 3 to 5 and Comparative examples 8 to 11,
it can be seen that a hot-dip aluminum-coated steel wire cannot be produced without
generation of a thin part of the plating film and without adhesion of an aluminum
lump on its surface, even when the temperature of the molten aluminum is controlled
to a temperature 20°C or more higher that the melting temperature of the molten aluminum,
because the pressure of the inert gas for blowing to the boundary between the steel
wire and the surface of the molten aluminum is without a range of 0.1 to 20 kPa, as
shown in Table 6.
INDUSTRIAL APPLICABILITY
[0106] The hot-dip aluminum-coated steel wire obtained by the method for producing a hot-dip
aluminum-coated steel wire according to the present invention can be suitably used
in, for example, a wire harness of automobiles.
DESCRIPTION OF SYMBOLS
[0107]
1: molten aluminum
2: steel wire
3: hot-dip aluminum-coated steel wire
4: delivery device
5: plating bath
6: heating device
6a: heating device body
6b: inside of heating device body
6c: heating gas inlet of heating device body
6d: lower end of heating device body
6e: branch pipe of heating device body
7: liquid surface-controlling device
7a: upper end of liquid surface-controlling device
8: steel wire-introducing controller
9: tubular body
9a: through hole of tubular body
9b: dipping region of tubular body
9c: introducing port of tubular body
9d: opening part of introducing port of tubular body
9e: discharge port of tubular body
9f: opening part of discharge port of tubular body
10: surface of molten aluminum
11: stabilizing member
11a: heat-resistant cloth of stabilizing member
12: nozzle
12a: tip of nozzle
13: inert gas-providing apparatus
14: pipe
15: cooling device
16: winding device
17: meniscus
17a: tip of meniscus
18: plating film
19: device for measuring a diameter of a steel wire by passing through a steel wire
19a: light-emitting unit of a device for measuring diameter of a steel wire by passing
through a steel wire
19b: light receiving unit of a device for measuring a diameter of a steel wire by
passing through a steel wire
19c: pulley of a device for measuring a diameter of a steel wire by passing through
a steel wire
19d: pulley of a device for measuring a diameter of a steel wire by passing through
a steel wire