Search Results

Organic composite coated steel sheets retain their excellent corrosion resistance during cyclic corrosion tests (CCT). To clarify the corrosion behavior of these sheets during CCT, variations in corrosion products and coating components were examined. Moreover, the contribution of the corrosion products, organic composite coating, and chromate film to corrosion resistance was examined by AC impedance measurements. Formation of crystalline ZnCl2·4Zn(OH)2 and amorphous zinc carbonate were detected by X-ray diffraction (XRD) and Fourier transformation infrared spectroscopy (FT-IR). Crystalline ZnCl2·4Zn(OH)2 is formed during CCT on and under the organic composite coating. The corrosion products formed on the coating contain silicates from the silica in the organic composite coating. Consequently, the contents of zinc and silica in the coating decrease, while nickel and chromium in the chromate film and carbon in the coating remain constant during CCT.

A passenger vehicle in the subtropical marine environment of Okinawa Island for eight years was submitted for corrosion investigation.The precoated sheet steels such as Zn-Ni and Zn-Fe showed excellent corrosion resistance in the door hem flange and a scribed outer panel, compared to cold rolled steel. Cosmetic corrosion of a North America vehicle was more severe than that of a Okinawa vehicle, but a similar corrosion rate for perforation was shown in door hem flange. Basic zinc chloride and β-FeOOH were observed by using micro X-ray diffraction method in the initial stage of corrosion, and then these changed to ZnO and α-FeOOH, Fe304.

The corrosion mechanism of zinc coated steel sheets in automotive bodies was studied in field vehicle tests and several types of accelerated tests. Perforation corrosion starts in unpainted areas of lapped parts, and proceeds in the following steps: i) galvanic protection by the Zn coating, ii) protection by corrosion products, and iii) corrosion of the steel substrate and perforation. Although the corrosion processes were the same in all the cases tested, the corrosion rate depended significantly on the environment, such as atmospheric exposure conditions and the part of the automotive body. In accelerated corrosion environments, Zn coating is largely ineffective against perforation corrosion because galvanic protection and protection by corrosion products cannot be maintained over the long term.

Modifications in the properties of galvannealed steel sheet have been made to meet the needs of the automotive industry. The press formability (powdering and flaking) of the galvannealed steel sheet is very sensitive to the phase composition and coating weight of the coating. The allowable coatings for a satisfactory anti-powdering property may fail to provide the anti-flaking property, showing a high coefficient of friction due to the existence of a soft phase, ζ, at the surface. In this study, the effects of an inorganic film on the surface of the galvannealed coating were studied improving press formability. It was found that a thin borax film was effective to minimize surface friction and to improve unti-flaking properties. Short electrode life is another problem, as it limits continuous spot welding of the galvannealed steel sheet. During welding, electrode tips (Cu) are consumed by an interaction with the coating and the steel substrate.

We have developed a new dry film lubricant with friction properties superior to those of conventional dry film lubricants by optimizing the glass transition temperature of the binder resin and adding polyethylene wax and inorganic lubricants. As described in this paper, the new dry film lubricant was applied as a coating on hot rolled steel sheets and galvannealed steel sheets in thicknesses ranging from 1.5 to 2.5 μm. The influence of the dry film lubricant and a rust preventive lubricant oil on the press formability of these steel sheets was investigated. A comparison of the press formability of high strength steel sheets with the dry film lubricant and sheets with the rust preventive lubricating oil suggested that application of the new dry film lubricant expands the use of high strength steel sheets and galvannealed steel sheets in automotive body panels.

The goal of this study was to identify a pre-coated steel sheet that will satisfy press formability, seam weldability, spot weldability, brazing property, external corrosion resistance and internal fuel resistance. We established an experimental method for anti-fuel resistance measurement by applying synthetic spoiled gasoline by investigating the composition of spoiled gasoline and corrosion products in the fuel tank, which was collected in North America after 160,000 kilometers' running. Newly developed lead-free pre-coated steel sheet shows excellent anti-fuel corrosion resistance in comparison with that of usual terne coated steel sheet according to this method.