Specification
DESCRIPTION
TITLE OF INVENTION: PLATED STEEL SHEET AND FUEL TANK
TECHNICAL FIELD
[0001] The present invention relates to a plated
steel sheet suitable for a fuel tank of a truck, a
bus and others, and a fuel tank made of the plated
steel sheet.
BACKGROUND ART
[0002] A fuel tank of an automobile is often
determined at a final stage of designing in
accordance with a design of a vehicle body, and a
shape thereof is often complex. Therefore, in
general, deep-drawing formability, impact resistance
after forming, fuel resistance, corrosion resistance,
salt-damage corrosion resistance, seam weldability,
spot weldability, and the like are required of a
material of the fuel tank of the automobile.
[0003] On the other hand, a shape of a fuel tank of
a truck and a bus is relatively simple. Accordingly,
formability for a complex shape is not required of a
material of the fuel tank of the truck and the bus as
much as required of the material of the fuel tank of
the ordinary automobile. Further, many trucks and
buses use light oil as fuel, and the light oil is not
easily subjected to oxidation deterioration compared
with gasoline. Accordingly, burning resistance and
corrosion resistance are not required as much as
required of a fuel tank for gasoline either.
Meanwhile, improvement in manufacturing efficiency of
- 1 -
the fuel tank, namely, ability to manufacture the
fuel tank at a lower cost is required of a material
for the fuel tank of the truck and the bus. In
particular, improvement in weldability is required,
and a material excellent in the seam weldability and
the spot weldability is desired. Materials for fuel
tanks of vehicles are described in Patent Literature
1 and Patent Literature 2. However, sufficient seam
weldability and spot weldability cannot be obtained
even by these materials.
[0004] In a fuel injection technology referred to as
a common rail system, because very fine fuel is
ejected, clogging of an injection hole sometimes
occurs due to an effect of metal soap. For example,
it is described that fatty acid zinc salt can cause
clogging in Patent Literature 3. Therefore, a plated
steel sheet containing zinc is not suitable for the
fuel injection technology of the common rail system.
[0005] Al-plated steel sheets are described in
Patent Literatures 4 to 7, but the sufficient seam
weldability and spot weldability cannot be obtained
even by the Al-plated steel sheets mentioned in these
Patent Literatures.
CITATION LIST
PATENT LITERATURE
[ 000 6] Patent Literature 1: Japanese Laid-open
Patent Publication No. 10-72641
Patent Literature 2: International Publication
Pamphlet No. 2007/004671
- 2 -
Patent Literature 3: Japanese Laid-open Patent
Publication No. 2006-306018
Patent Literature 4: Japanese Laid-open Patent
Publication No. 62-161944
Patent Literature 5: Japanese Laid-open Patent
Publication No. 10-265928
Patent Literature 6: Japanese Laid-open Patent
Publication No. 2008-223084
Patent Literature 7: Japane~e Laid-open Patent
Publication No. 10-176287
SUMMARY OF INVENTION
TECHNICAL PROBLEM
[0007] An object of the present invention is to
provide a plated steel sheet which allows improvement
in weldability while securing corrosion resistance to
fuel when used for a fuel tank, and a fuel tank made
thereof.
SOLUTION TO PROBLEM
[0008] The present inventors have conducted earnest
examination in order to study a cause by which
sufficient seam weldability and spot weldability
cannot be obtained in a conventional plated steel
sheet.
[0009] As one of problems which are caused by seam
welding of an Al-plated steel sheet, a blowhole
defect may be cited. A cause of occurrence of the
blowhole defect is considered as follows. In the
seam welding in which upper and lower electrode
wheels are used, Cu which is contained in the
- 3 -
electrode wheel and Al which is contained in a
plating layer react with each other to generate a
reaction product on the interface between the
electrode wheel and the plating layer due to heat.
As a result, adhesion strength acts between the
electrode wheel and the plated steel sheet with the
reaction product interposed therebetween and the
plated steel sheet is pulled by the electrode wheel
when the electrode wheel is separated from the plated
steel sheet, resulting in the occurrence of the
blowhole defect. As the other of the problems which
are caused by the seam welding of the Al-plated steel
sheet, there may be cited a decrease in welding
quality which is caused by adhesion of the reaction
product to the electrode wheel and drop of this
reaction product from the electrode wheel.
[0010] Both of these problems are caused by the
reaction of Cu which is contained in the electrode
wheel and Al which is contained in the plating layer.
The inventors of the present application have focused
attention on the reaction and found that it is very
effective to decrease a coating weight on a surface
of the plated steel sheet which comes in contact with
the electrode wheel, namely, a surface which is to be
an outer surface of a fuel tank. On the other hand,
the other surface of the plated steel sheet is to be
an inner surface of the fuel tank and comes in
contact with fuel. Therefore, it is important that a
coating weight on the other surface of the plated
- 4 -
steel sheet allows securing of corrosion resistance
to the fuel. Then, the inventors of the present
application have conceived that, by making the
coating weight on the surface which is to be the
outer surface of the fuel tank lower than the coating
weight on the surface which is to be the inner
surface thereof, a characteristic which has a balance
of weldability and corrosion resistance of the inner
surface more than a conventional one can be obtained.
[0011] The inventors of the present application have
obtained a finding in which the seam weldability is
improved by phosphoruc; ( P) in a steel sheet. It-has
become clear that when the coating weight is low in
particular, the improvement in the seam weldability
by P is remarkable. It is assumed that P in the
steel sheet diffuses in an alloy layer in the plating
layer containing Al, and AlP is formed on a surface
of the plating layer, thereby suppressing a reaction
with Cu which is contained in the electrode wheel.
[0012] The inventors of the present application have
also obtained a finding in which a thickness of the
steel sheet greatly affects the seam weldability and
the spot weldability. In particular, when the steel
sheet is thin, an effect of the coating weight easily
appears greatly. Accordingly, when the steel sheet
is thin, it is suitable to provide a difference of
the coating weight between both surfaces of the
plated steel sheet. On the other hand, when the
plated steel sheet is thick, a large problem does not
- 5 -
arise even though the difference of the coating
weight therebetween is small.
[0013] Then, the inventors of the present
application have conceived modes of the invention
described below based on these findings.
[0014] (1)
A plated steel sheet comprising:
a steel sheet;
a first plating layer on a first surface of the
steel sheet; and
a second plating layer on a second surface of the
steel sheet,
wherein the steel sheet comprises a chemical
composition represented by' in mass%,
C: 0.0005% to 0.0800%,
Si: 0.003% to 0.500%,
Mn: 0.05% to 0.80%,
P: 0.005% to 0.050%,
S: 0.100% or less,
Al: 0.080% or less,
N: 0.0050% or less,
Ti: 0.000% to 0.100%,
Nb: 0.000% to 0.050%,
B: 0.000% to 0.0100%, and
the balance: Fe and impurities,
wherein the first plating layer comprises:
a first Al-Fe-Si alloy layer on the first
surface; and
a first Al-Si alloy layer on the first Al-
- 6 -
Fe-Si alloy layer,
wherein the second plating layer comprises a
second Al-Fe-Si alloy layer on the second surface,
wherein a coating weight of the first plating
layer is 31 g/m2 to 60 g/m2
, and
wherein a coating weight of the second plating
layer is 5 g/m2 to 29 g/m2
•
[0015] (2)
The plated steel sheet according to (1), wherein
the second plating layer comprises a second Al-Si
alloy layer on the second Al-Fe-Si alloy layer.
[0016] (3)
The plated steel sheet according to (1) or (2),
wherein in the chemical composition,
Ti: 0.001 to 0.100%,
Nb: 0.001 to 0.050%, or
B: 0.0003% to 0.0100%, or
any combination thereof is satisfied.
[0017] (4)
The plated steel sheet according to any one of
( 1) to ( 3), wherein a relationship of "(X - Y) ( 2 6. 7
- 13. 3T) > 0" holds wherein X (g/m2
) denotes the
coating weight of the first plating layer, Y (g/m2
)
denotes the coating weight of the second plating
layer, and T (mm) denotes a thickness of the steel
sheet.
[0018] (5)
The plated steel sheet according to any one of
( 1) to ( 4), further comprising a conversion coating
- 7 -
that contains Cr, Zr, Ti, Si, or V, or a compound of
any combination thereof on the second plating layer,
wherein a coating weight of the conversion
coating is 50 mg/m2 to 1000 mg/m2
•
[0019] (6)
A fuel tank comprising
a tank body made of the plated steel sheet
according to any one of (1) to (5),
wherein the first plating layer is inside the
tank body and the second plating layer is outside the
tank body.
ADVANTAGEOUS EFFECTS OF INVENTION
[0020] According to the present invention, since
appropriate plating layers are included, it is
possible to improve weldability while securing
corrosion resistance to fuel when a plated steel
sheet is used for a fuel tank.
BRIEF DESCRIPTION OF DRAWINGS
[0021] [Fig. 1] Fig. 1 is a cross-sectional view
illustrating a plated steel sheet according to a
first embodiment;
[Fig. 2] Fig. 2 is a cross-sectional view
illustrating a plated steel sheet according to a
second embodiment;
[Fig. 3] Fig. 3 is a cross-sectional view
illustrating a plated steel sheet according to a
third embodiment;
[Fig. 4] Fig. 4 is a cross-sectional view
illustrating a plated steel sheet according to a
- 8 -
fourth embodiment;
[Fig. 5] Fig. 5 is a cross-sectional view
illustrating a plated steel sheet according to a
modified example of the third embodiment;
[Fig. 6] Fig. 6 is a cross-sectional view
illustrating a plated steel sheet according to a
modified example of the fourth embodiment; and
[Fig. 7] Fig. 7 is a view illustrating an
optical micrograph of a cross section of a plated
steel sheet.
DESCRIPTION OF EMBODIMENTS
[0022] Hereinafter, embodiments of the present.
invention will be described referring to the
accompanying drawings.
[0023] (First embodiment)
First, a first embodiment will be described.
Fig. 1 is a cross-sectional view illustrating a
plated steel sheet according to the first embodiment.
[0024] A plated steel sheet 1 according to the first
embodiment includes: a steel sheet 30; a first
plating layer 10 on a first surface 31 of the steel
sheet 30; and a second plating layer 20 on a second
surface 32 of the steel sheet 30 as illustrated in
Fig. 1. The first plating layer 10 includes: a first
Al-Fe-Si alloy layer 11 on the first surface 31; and
a first Al-Si alloy layer 12 on the first Al-Fe-Si
alloy layer 11. The second plating layer 20
includes: a second Al-Fe-Si alloy layer 21 on the
second surface 32; and a second Al-Si alloy layer 22
- 9 -
on the second Al-Fe-Si alloy layer 21. A coating
weight of the first plating layer 10 is 31 g/m2 to 60
g/m2
, and a coating weight of the second plating layer
20 is 5 g/m2 to 29 g/m2
•
[0025] Here, a chemical composition of the steel
sheet 30 and a steel slab to be used in manufacture
thereof will be described. In the following
description, "%" which is a unit of content of each
element contained in the steel sheet 30 and the steel
slab to be used in the manufacture thereof means
"mass%" as long as there is particularly no
specification. The steel sheet 30 according to, the
embodiment and the steel slab to be used in the
manufacture thereof have the chemical composition
represented by, C: 0.0005% to 0.0800%, Si: 0.003% to
0.500%, Mn: 0.05% to 0.80%, P: 0.005% to 0.050%, S:
0.100% or less, Al: 0.080% or less, N: 0.0050% or
less, Ti: 0.000% to 0.100%, Nb: 0.000% to 0.050%, B:
0.000% to 0.0100%, and the balance: Fe and
impurities. As the impurities, those (Cu, Cr, Sn,
Ni, and others) contained in a raw material such as
ore or scrap and those (REM such as Ce, Ca, and
others) contained in a manufacturing process are
exemplified.
[0026] (C: 0.0005% to 0.0800%)
C is an element which contributes to strength of
the steel sheet. When a C content is less than
0.0005%, sufficient strength cannot be obtained.
Accordingly, the C content is 0.0005% or more. In
- 10 -
order to obtain higher strength, the C content is
preferably 0.0010% or more. When the C content is
more than 0.0800%, sufficient ductility cannot be
obtained. It is rarely that a plated steel sheet for
fuel tank of a truck and a bus is formed into a
complex shape, but when the ductility is too low,
forming may be difficult depending on a portion.
Accordingly, the C content is 0.0800% or less. In
order to obtain more excellent ductility, the C
content is preferably 0.0500%.
[0027] (Si: 0.003% to 0.500%)
Si is an element which contr~butes to the
strength of the steel sheet. When a Si content is
less than 0.003%, the sufficient strength cannot be
obtained. Accordingly, the Si content is 0.003% or
more. When the Si content is more than 0.500%,
sufficient platability cannot be obtained.
Accordingly, the Si content is 0.500% or less.
[ 0 0 2 8 ] ( Mn : 0 . 0 5% to 0 . 8 0% )
Mn is an element which contributes to the
strength of the steel sheet. Mn also contributes to
suppression of hot shortness caused by S in hot
rolling. When a Mn content is less than 0.05%,
effects due to the above-described actions cannot be
sufficiently obtained. Accordingly, the Mn content
is 0.05% or more. When the Mn content is more than
0.80%, sufficient workability cannot be obtained.
Accordingly, the Mn content is 0.80% or less.
[0029] (P: 0.005% to 0.050%)
- 11 -
P is an element which increases the strength of
the steel sheet by solid-solution strengthening.
Further, as described above, P is an element which
contributes also to improvement in seam weldability
when the coating weight is small. When a P content
is less than 0.005%, effects due to the abovedescribed
actions cannot be sufficiently obtained.
Accordingly, the P cont.ent is 0. 005% or more; When
the P content is more than 0.050%, sufficient
toughness cannot be obtained. P segregates on grain
boundaries easily, and when the strength of the steel
sheet is hig-h in particular, P causes low tempera·ture
embrittlement.
or less.
Accordingly, the P content is 0.050%
[0030] (S: 0.100% or less)
S is not an essential element and is contained as
an impurity in the steel sheet, for example. S is an
element which deteriorates hot workability and
workability. Therefore, the lower an S content is,
the better. When the S content is more than 0.100%
in particular, these adverse effects are remarkable.
Accordingly, the S content is 0.100% or less. It
takes cost to reduce the S content, and the cost
remarkably increases to reduce to less than 0.001%.
Therefore, the S content may be 0.001% or more.
[0031] (Al: 0.080% or less)
Al is not an essential element and is contained
as an impurity in the steel sheet, for example. Al
forms an oxide made of alumina mainly in the steel
- 12 -
sheet to cause local deformability to deteriorate.
Therefore, the lower an Al content is, the better.
When the Al content is more than 0.080% in
particular,
Accordingly,
effective in
these adverse effects are remarkable.
the Al content is 0.080% or less. Al is
deoxidation, and when the Al content is
less than 0.005%, the deoxidation in steelmaking is
insufficient, and thereby the oxide remains.in a
large amount in the steel sheet and sufficient local
deformability cannot be sometimes obtained.
Therefore, the Al content may be 0.005% or more.
[0032] (N: 0. 0050% or less)
N is not an essential element and is contained as
an impurity in the steel sheet, for example. N
generates a precipitate and causes the toughness of a
heat affected zone to deteriorate. Therefore, the
lower a N content is, the better. When the N content
is more than 0.0050% in particular, a deterioration
of the toughness of the heat affected zone is
remarkable. Accordingly, the N content is 0.0050% or
less. It takes cost to reduce the N content, and the
cost remarkably increases to reduce to less than
0.0010%. Therefore, the N content may be 0.0010% or
more.
[0033] Ti, Nb, and B are not essential elements but
optional elements which may be appropriately
contained in the plated steel sheet and the steel
slab up to predetermined limit amounts.
[0034] (T: 0.000% to 0.100%, Nb: 0.000% to 0.050%,
- 13 -
B: 0.000% to 0.0100%)
Ti and Nb are elements which form fine carbides
and contribute to improvement in the workability of
the steel sheet. B is an element which improves
secondary workability of the steel sheet.
Accordingly, one or any combination selected from the
group consisting of these elements may be contained.
However, when a Ti content is more than 0.100%, an
effect due to the above-described action is
saturated, which only increases the cost uselessly,
when a Nb content is more than 0.050%, the effect due
to the above-described action is saturated, 0hich
only increases the cost uselessly, and when a B
content is more than 0.0100%, the sufficient
workability cannot be obtained. Accordingly, the Ti
content is 0.100% or less, the Nb content is 0.050%
or less, and the B content is 0.0100% or less. In
order to obtain the effects due to the abovedescribed
actions securely, both of the Ti content
and the Nb content are preferably 0.001% or more, and
the B content is preferably 0.0003% or more. That
is, it is preferred that "Ti: 0.001 to 0.100%", "Nb:
0.001 to 0.050%", or "B: 0.0003% to 0.0100%", or any
combination thereof is satisfied.
[0035] Next, coating weights of the first plating
layer 10 and the second plating layer 20 will be
described.
[0036] As described above, the first plating layer
10 includes the first Al-Fe-Si alloy layer 11 and the
- 14 -
first Al-Si alloy layer 12, and the second plating
layer 20 includes the second Al-Fe-Si alloy layer 21
and the second Al-Si alloy layer 22. Thicknesses of
the Al-Fe-Si alloy layers are not particularly
limited, but because the Al-Fe-Si alloy layers are
hard and brittle, too thick Al-Fe-Si alloy layers do
not sometimes allow good workability to be obtained.
Accordingly, both the thicknesses of the first Al-FeSi
alloy layer 11 and the second Al-Fe-Si alloy layer
21 are preferably each 4 1-!ID or less. Further, a
thickness of the first Al-Si alloy layer 12 is
preferably 3 1-!ID or mor2 in view of securing corro~ion
resistance, workability and others.
[0037] Although details will be described later, the
first plating layer 10 and the second plating layer
20 are formed by a hot-dip plating method by using a
plating bath containing Al and Si, for example. In
the case, the first Al-Si alloy layer 12 having
substantially the same composition as a composition
of the plating bath is included in the first plating
layer 10, and the second Al-Si alloy layer 22 having
substantially the same composition as the composition
of the plating bath is included in the second plating
layer 20. The first Al-Si alloy layer 12 and the
second Al-Si alloy layer 22 contribute to improvement
in the corrosion resistance.
[0038] As described above,
first plating layer 10 is 31
the coating weight of the
g/rn 2 to 60 g/rn2
, and the
coating weight of the second plating layer 20 is 5
- 15 -
g/m2 to 29 g/m2
•
[0039] When a fuel tank is manufactured using a
plated steel sheet, one surface of the plated steel
sheet is to be an inner surface and the other surface
is to be an outer surface. Then, the surface which
is to be the inner surface is exposed to fuel and the
surface which is to be the outer surface is exposed
to a welding environment. Accordingly, the coating
weight preferably is higher in the surface which is
to be the inner surface than the surface which is to
be the outer surface. Hence, in the embodiment, the
coating weights' are made different from each oth:e :r. •between
the first plating layer 10 and the second
plating layer 20. When the fuel tank is manufactured
using the plated steel sheet 1 according to the
embodiment, forming may be performed so that the
first plating layer 10 with thicker coating is to be
an inner surface side and the second plating layer 20
with thinner coating is to be an outer surface side.
[0040] As described above, the plated steel sheet 1
is formed so that the second plating layer 20 is an
outer side of the fuel tank. Accordingly, the second
plating layer 20 greatly affects the seam weldability
and spot weldability. Further, the second plating
layer 20 contributes to improvement in corrosion
resistance to salt damage and the like. When the
coating weight of the second plating layer 20 is more
than 29 g/m2
, good seam weldability and spot
weldability cannot be obtained. Accordingly, the
- 16 -
coating weight of the second plating layer 20 is 29
g/m2 or less. The second plating layer 20 is formed
by the hot-dip plating method, for example, as
described later, and it is difficult to form the
second plating layer 20 with the coating weight of
less than 5 g/m2
• Accordingly, the coating weight of
the second plating layer 20 is 5 g/m2 or more.
[0041] As described above, the plated steel sheet 1
is formed so that the first plating layer 10 is an
inner side of the fuel tank. Accordingly, the first
plating layer 10 greatly affects corrosion resistance
to a fuel s.•1ch as light oil and gasoline end
corrosion resistance to an organic acid such as
formic acid and acetic acid which is generated with
oxidation and deterioration of the fuel. When the
coating weight of the first plating layer 10 is less
than 31 g/m2
, sufficient corrosion resistance cannot
be obtained. Accordingly, the coating weight of the
first plating layer 10 is 31 g/m2 or more. As
described later, the first plating layer 10 is formed
by the hot-dip plating method together with the
second plating layer 20, and it is difficult to form
the first plating layer 10 with the coating weight of
more than 60 g/m2
, since the coating weight of the
second plating layer 20 is 29 g/m2 or less.
Accordingly, the coating weight of the first plating
layer 10 is 60 g/m2 or less.
[0042] The coating weight may be measured by an
ordinary method. For example, it is preferable that
- 17 -
the coating weight is measured with fluorescent Xray,
where a calibration curve between the coating
weight measured by the gravimetric method and a
fluorescent X-ray intensity is created in advance.
These measurements are performed at a central portion
and both end portions (for example, positions 50 mm
close to a center from both edges) in the sheet width
direction of the plated steel sheet, and an average
value of measured values at these three points is
used as a representative value of the measured
surface .
. ,.,. [0043]' ·A sp·ecific relationship between. a: difference
between the coating weight of the first plating layer
10 and the coating weight of the second plating layer
20 and a thickness of the steel sheet 30 preferably
holds. Specifically, when X (g/m2
) denotes the
coating weight of the first plating layer 10, Y (g/m2
)
denotes the coating weight of the second plating
layer 20, and T (mm) denotes the thickness of the
steel sheet 30, a relationship of "(X- Y) (26.7
13.3T) >on preferably holds. This relationship
means that it is preferred that the thinner the steel
sheet 30 is, the larger the difference of the coating
weights is. In both seam welding and spot welding, a
reaction of copper contained in a welding electrode
and a metal element contained in the plating layer is
an underlying cause of a decrease in weldability.
Accordingly, it is considered that the thinner the
steel sheet is, the shorter a distance from a molten
- 18 -
portion to a surface of the plated steel sheet which
is in contact with the welding electrode is, and
thereby an effect thereof is remarkably exerted.
( 0 0 4 4 l Next, a manufacturing method of the plating
steel sheet 1 according to the first embodiment will
be described.
( 0 0 4 5 l In this manufacturing method, a steel slab is
obtained from molten steel having the above-described
chemical composition. The steel slab may be obtained
by, for example, continuous casting. A thin slab
whose thickness is 100 mm or less is cast, and the
thin slab may be used as the steel slab.
[0046] Next, hot rolling of the steel slab is
performed. A condition of the hot rolling is not
particularly limited. A heating temperature is 1400°C
or less, for example, and preferably 1250°C or less.
Further, a finish temperature of final rolling is
preferably Ar3 point or more, and a coiling
temperature is preferably 600°C to 750°C.
hot-rolled steel sheet may be obtained.
Thus, a
(0047] Next, plating treatment of the hot-rolled
steel sheet is performed. In this embodiment, the
coating weights are made different from each other
between the obverse and the reverse of the hot-rolled
steel sheet. The plating treatment is performed by
the hot-dip plating method by using the plating bath
containing Al and Si, for example.
(0048] When the plating treatment by the hot-dip
plating method is performed, the coating weights is
- 19 -
controlled by a gas wiping method, for example. The
coating weights may be controlled with a gas
pressure, a line speed, a steel sheet-nozzle interdistance,
a nozzle gap, a nozzle shape, or others.
In this embodiment, in order to make the coating
weights different from each other between the obverse
and the reverse of the hot-rolled steel sheet, the
gas pressure, the steel sheet-nozzle inter-distance,
or the nozzle gap, or any combination thereof is made
different between the obverse and the reverse, for
example. Industrially, it is assumed that on a
plating production line to be used for manufacturing
the plated steel sheet according to the embodiment, a
steel sheet whose coating weights are the same
between the obverse and the reverse of the steel
sheet is also manufactured. Therefore, the coating
weights are preferably made different from each other
between the obverse and the reverse by an adjustment
of the steel sheet-nozzle inter-distance and/or the
gas pressure.
[0049] When the plating treatment is performed using
the plating bath containing Al and Si, Al and Si,
which are contained in the plating bath, react with
Fe in the hot-rolled steel sheet to form the Al-Fe-Si
alloy layers constituted of an intermetallic compound
on surface layer portions of the hot-rolled steel
sheet. Further, on the Al-Fe-Si alloy layers, the
Al-Si alloy layers having substantially the same
composition as that of the plating bath are formed.
- 20 -
[0050] Thus, it is possible to manufacture the
plated steel sheet l including the steel sheet 30,
the first Al-Fe-Si alloy layer 11, the first Al-Si
alloy layer 12, the second Al-Fe-Si alloy layer 21,
and the second Al-Si alloy layer 22.
[0051] The plated steel sheet 1 may be manufactured
not only by performing a plating treatment for a hotrolled
steel sheet but also by forming a cold-rolled
steel sheet by performing cold rolling of the hotrolled
steel sheet and performing the plating
treatment for the cold-rolled steel sheet. The
plated steel sheet 1 may be manufactured al~o by
performing recrystallization annealing of the coldrolled
steel sheet and thereafter performing the
plating treatment. A condition of the cold rolling
is not particularly limited. For example, a
reduction ratio in the cold rolling may be 40% to 80%
as general, for example. A condition of the
recrystallization annealing is not particularly
limited either.
[0052] A method of the plating treatment is not
limited to the hot-dip plating method. For example,
the plating treatment may be performed by a fusedsalt
electrolysis method or a vapor deposition
method. However, the hot-dip plating method is more
excellent in an aspect of an industrial cost than the
fused-salt electrolysis method and the vapor
deposition method. Accordingly, the plating
treatment is preferably performed by the hot-dip
- 21 -
plating method.
[0053] When the plating treatment is performed by
the hot-dip plating method, the plating bath
preferably contains Al by 85 mass% or more. Further,
when the Si content of the plating bath is less than
mass%, the Al-Fe-Si alloy layers grow too much after
the plating treatment and the workability sometimes
decreases. Accordingly, the Si content of the
plating bath is preferably mass% or more, and more
preferably mass% or more. When the Si content of the
plating bath is more than 15 mass%, the sufficient
corrosinn resistance cannot be sbmetimes obtained.
Accordingly, the Si content of the plating bath is
preferably 15 mass% or less, and more preferably 12
mass% or less.
[0054] When the plating treatment is performed by
the hot-dip plating method, the thicknesses of the
Al-F'e-Si alloy layers may be adjusted by a bath
temperature, a bath composition, a sheet temperature
upon entering the bath, a cooling rate, and the line
speed, and for example, are each 2 ~m to 5 ~m. The
thinner the plated steel sheet is manufactured, the
higher the line speed can be made, and the higher the
line speed is, the thinner the Al-Fe-Si alloy layers
is. Since the Al-F'e-Si alloy layers are hard and
brittle as described above, the too thick Al-F'e-Si
alloy layers do not sometimes allow the good
workability to be obtained. Accordingly, both the
thicknesses of the first Al-Fe-Si alloy layer 11 and
- 22 -
the second Al-Fe-Si alloy layer 21 are preferably
each set to 4 ~m or less.
[0055] According to the first embodiment, it is
possible to obtain excellent weldabi1ity and also
obtain good corrosion resistance to fuel.
Accordingly, the plated steel sheet contributes to
improvement in productivity of the fuel tank for a
truck or a bus and is suitable as a material of the.
fuel tank for the truck or the bus.
[0056] The plating layers are preferably zinc-free.
This is because clogging of an injection hole with
generation of metal soap is avoided:
[0057] (Second embodiment)
Next, a second embodiment will be described.
Fig. 2 is a cross-sectional view illustrating a
plated steel sheet according to the second
embodiment.
[0058] A plated steel sheet 2 according to the
second embodiment does not have an Al-Si alloy layer
22 on a surface layer of a second surface 32 side of
a steel sheet 30 as illustrated in Fig. 2. Other
configurations are the same as those of the plated
steel sheet 1 according to the first embodiment.
According to the second embodiment, since a layer
which is exposed to the outside on the second surface
32 side is an Al-Fe-Si alloy layer 21, more excellent
seam weldability and spot weldability can be obtained
and adhesiveness to an outer surface coating (coating
film) is better.
- 23 -
[0059] The plated steel sheet 2 according to the
second embodiment may be manufactured by the
following two types of methods, for example. In a
first manufacturing method, a plating layer 20 is
reheated after performing the same treatment as that
in the first embodiment. In a second manufacturing
method, a coating weight is made as small as
possible, and a reaction of Al and Si with Fe. is
accelerated by preheating of a plating bath while
keeping a bath temperature of the plating bath
relatively high.
[0060] (Third embodiment)
Next, a third embodiment will be described.
3 is a cross-sectional view illustrating a plated
steel sheet according to the third embodiment.
·.:-
Fig.
[0061] A plated steel sheet 3 according to the third
embodiment includes a conversion coating 23 on a
second plating layer 20 as illustrated in Fig. 3.
Other configurations are the same as those in the
first embodiment. According to the third embodiment,
since the conversion coating 23 is included, more
excellent seam weldability and spot weldability can
be obtained and adhesiveness to an outer surface
coating (coating film) is better.
[0062] The conversion coating 23 contains, for
example, Cr, Zr, Ti, Si, or V, or a compound of any
combination thereof. When a coating weight of the
conversion coating 23 is less than 50 mg/m2
, an effect
of improving the seam weldability and the spot
- 24 -
weldability cannot be sometimes sufficiently
obtained. Accordingly, the coating weight of the
conversion coating 23 is preferably 50 mg/m2 or more.
When the coating weight of the conversion coating 23
is more than 1000 mg/m 2
, surface resistance of the
plated steel sheet 3 is too large, and thereby the
seam weldability and/or the spot weldability
sometimes. decrease/decreases adversely. Accordingly,
the coating weight of the conversion coating 23 is
preferably 1000 mg/m2 or less.
[0063] In measurement of the coating weight of the
conversion ·coatj_ng, similarly to· that of a coating:
weight, for example, it is preferable that the
coating weight is measured with fluorescent X-ray,
where a calibration curve between the coating weight
measured by the gravimetric method and a fluorescent
X-ray intensity is created in advance. These
measurements are performed at a central portion and
both end portions (for example, positions 50 mm close
to a center from both edges) in the sheet width
direction of the plated steel sheet, and an average
value of measured values at these three points is
used as a representative value of the measured
surface.
[0064] (Fourth embodiment)
Next, a fourth embodiment will be described.
Fig. 4 is a cross-sectional view illustrating a
plated steel sheet according to the fourth
embodiment.
- 25 -
[0065] A plated steel sheet 4 according to the
fourth embodiment includes a conversion coating 23 on
a second plating layer 20 as illustrated in Fig. 4.
Other configurations are the same as those in the
second embodiment. According to the fourth
embodiment, the effect in the second embodiment and
the effect in the third embodiment can be obtained.
[0066] As illustrated in Fig. 5, the plated steel
sheet 3 according to the third embodiment may include
a conversion coating 13 on a first plating layer 10.
As illustrated in Fig. 6, the plated steel sheet 4
according to the fourth embodiment may include a
conversion coating 13 on a first plating layer 10.
The conversion coating 13 may be formed together with
the conversion coating 23.
[0067] An Al-Si alloy layer and an Al-Fe-Si alloy
layer may be confirmed by a cross sectional
microscopic observation. Fig. 7 is a view
illustrating an optical micrograph of a cross section
of a plated steel sheet. As illustrated in Fig. 7,
the Al-Si alloy layer and the Al-Fe-Si alloy layer
can be distinguished clearly by an observation with
an optical microscope. They may be confirmed by an
elemental analysis with SEM (scanning electron
microscope)-EDS (energy dispersion X-ray
spectroscopy), EPMA (electron probe micro-analyzer),
or the like.
[0068] Next, a method of manufacturing a fuel tank
using a plated steel sheet according to an embodiment
- 26 -
of the present invention will be described. First,
the plated steel sheet is subjected to bending to be
formed as a square tube, and tank heads are buttwelded
at both end openings of this square tube to
produce a tank body. When the square tube is
produced, a second plating layer with thinner coating
is used as an outer surface side. Partition plates
having fuel flow holes are disposed inside the tank
body, and the partition plates and the tank body are
spot-welded to partition the inside of the tank body
into a plurality of divided chambers. Thereafter, an
oil filler is provided at an upper surface o£ the··
tank body. An inner surface (a surface on which the
first plating layer is exposed) of the fuel tank has
no coating typically, and an outer surface thereof is
often coated. A coating type and a coating film
thickness of the outer surface are not particularly
limited. For example, it is preferable to form a
coating film whose thickness is about 10 ~m to 100 ~m
using a melamine-based water-soluble resin. Thus,
the fuel tank may be manufactured. The thicker the
coating film is, the more excellent a rust prevention
property of the outer surface is, but a cost also
increases, and therefore an appropriate thickness is
preferably selected depending on a position of a
vehicle body where the fuel tank is placed, or the
like. Such a fuel tank is suitable as a fuel tank of
a truck and a bus.
[0069] Note that the above-described embodiments
- 27 -
merely illustrate concrete examples of implementing
the present invention, and the technical scope of the
present invention is not to be construed in a
restrictive manner by these embodiments. That is,
the present invention may be implemented in various
forms without departing from the technical spirit or
main features thereof.
EXAMPLES
[0070] Next, examples of the present invention will
be described. A condition of the examples is one
condition example which is adopted in order to
confirm a possibility of implem~ntation and. a~ ef£ect
of the present invention, and the present invention
is not limited to this one condition example. The
present invention allows an adoption of various
conditions as long as an object of the present
invention is achieved without departing from the gist
of the present invention.
[0071] (First experiment}
In a first experiment, molten steels (steel types
A to N} having chemical compositions presented in
Table 1 were tapped from a converter to obtain steel
slabs, and hot rolling was performed at a heating
temperature of 1220°C, at a finishing temperature of
870°C, and at a coiling temperature of 630°C. Blank
columns in Table 1 indicate that contents of relevant
elements were below detection limits. Then, cold
rolling of hot-rolled steel sheets was performed at a
reduction ratio of 70% to obtain cold-rolled steel
- 28 -
sheets whose thickness was 1.4 mm. Thereafter,
annealing and plating treatment were performed on a
continuous hot-dip plating line. An annealing
temperature was 780°C, a plating bath temperature was
660°C, and a composition of a plating bath was 91
mass% Al-9 mass% Si. An adjustment of coating
weights was performed by a gas wiping method after
the plating treatment. A condition of gas wiping on
the obverse and the reverse of the cold-rolled steel
sheets was controlled independently, and the
respective coating weights were adjusted as presented
in .Table 2. Thus,· various plated·. s·tee.l· shee··ts: wcitb:.
plating layers were produced. Here, in the plating
layers formed on the obverse and the reverse thereof,
the one whose coating weight is larger is referred to
as a first plating layer and the other one, whose
coating weight is smaller, is referred to as a second
plating layer. In a sample No. 4, since the coating
weights of the obverse and the reverse thereof are
equal, one is referred to the first plating layer and
the other is referred to the second plating layer as
a matter of convenience. Any of the plating layers
formed in samples No. 1 to No. 23 presented in Table
2 contained a Fe-Si-Al alloy layer and a Si-Al alloy
layer. Fe which dissolved from the cold-rolled steel
sheets or the like mixed by about 2.5 mass% in the
plating bath. Underlines in Table 1 indicate that
numeric values thereof are out of the range of the
present invention.
- 29 -
[0072] [Table 1]
STEEL CHEMICAL COMPONENT (MASS%)
REMARKS
TYPE c Si Mn p s AI N Ti Nb B
A 0.0360 0.009 0.14 0.003 0.006 0.03 0.0023 0.0017
COMPARATIVE
EXAMPLE
B 0.0360 0.009 0.14 0.007 0.006 0.03 0.0023 0.0017
INVENTIVE
EXAMPLE
c 0.0360 0.009 0.14 0.013 0.006 0.03 0.0023 0.0017
INVENTIVE
- EXAMPLE
D 0.0360 0.009 0.14 0.029 0.006 0.03 0.0023 0.0017
INVENTIVE
EXAMPLE
E 0.0360 0.009 0.14 0.066 0.006 0.03 0.0023 0.0017 INVENTIVE
.. EXAMPLE
F 0.0008 0.004 0.06 0.006 0.004 0.02 0.0015 0.011 0.005 0.0003
COMPARATIVE
EXAMPLE
G 0.0270 0.021 0.21 0.008 0.011 0.04 0.0033 0.012
INVENTIVE
EXAMPLE
H 0.0500 0.120 0.55 0.015 0.017 0.05 0.0042
INVENTIVE
EXAMPLE
. ••j•
I 0.0200 0.080 0.76 0.034 0.035 0.04 0.0021
INVENTIVE
--,__,_,_ -··---- ~-·--
EXAMPLE .
J 0.0700 0.270 0.41 0.045 0.044 0.02 0.0050 INVENTIVE
EXAMPLE
K 0.0300 0.030 0.29 0.009 0.008 0.05 0.0027 0.033 INVENTIVE
EXAMPLE
L 0.0021 0.120 0.21 0.007 0.003 0.02 0.0016 0.024
INVENTIVE
EXAMPLE
M 0.0015 0.140 0.25 0.013 0.005 0.04 0.0040 0.042 0.0012 INVENTIVE
EXAMPLE
N 0.0400 0.190 0.61 0.011 0.021 0.06 0.0055 0.037 0.021
INVENTIVE
EXAMPLE
[0073] Thereafter, evaluation of seam weldability
and spot weldability of the plated steel sheets was
performed. Further, evaluation of corrosion
resistance to an organic acid was also performed.
Table 2 also presents these results. Underlines in
Table 2 indicate that items thereof are out of the
range of the present invention.
[0074] In the evaluation of the seam weldability,
two test pieces whose size was 100 mm x 500 mm were
overlapped and seam welded so that the second plating
layers were the outside. As for the seam welding, an
electrode diameter was 250 mm, an electrode tip R was
- 30 -
8 mm, pressurizing
current was 15 kA,
speed was 4 m/min.
force was 500 kgf, a welding
2on-loff (60 Hz), and a welding
Then, 100 sets of welds were
performed continuously, and a condition of a nugget
of the lOOth set was observed. A maximum diameter of
blowholes which occurred per a weld line of 100 mm
was measured by an X-ray method. The evaluation of
the seam weldability was performed based on the
maximum diameter of the blowholes, and the sample in
which the maximum diameter of the blowholes was 0.1
mm or less was regarded as @, the sample in which the
maximum diameter ~f the blowholes was more th~n-0-.1
mm to 0.5 mm or less was regarded as 0, and the
sample in which the maximum diameter of the blowholes
was more than 0.5 mm was regarded as X. In general,
when a reaction of an electrode and the plated steel
sheet is vigorous, the electrode and the plated steel
sheet tend to adhered to each other, and force of
peeling the plated steel sheet occurs. Therefore,
the more vigorous the reaction is, the larger the
blowhole are.
[0075] In the evaluation of the spot weldability,
two test pieces whose size was 230 mm x 320 mm were
overlapped and spot welded so that the second plating
layers are the outside. As for the spot welding, a
DR electrode with a tip of 6~-40R was used,
pressurizing force was 250 kgf, an energization was
12 cycles (60Hz), and a welding current was 8 kA.
Then, 1000 spot welds were performed, and a condition
- 31 -
- . ~ ' ' '
of a nugget of the lOOOth spot was observed. The
evaluation of the spot weldability was performed
based on a nugget diameter, and the sample in which
the nugget diameter was 4 mm or more was regarded as
0 and the sample in which the nugget diameter was
less than 4 mm was regarded as X
[0076] In the evaluation of the corrosion
resistance, a corrosive solution which contained
about 100 ppm of formic acid and about 200 ppm of
acetic acid in water was prepared. The corrosive
solution was adjusted by mixing 10 vol% of water into
a mixture of oxidii_ed 0" holds wherein X (g/m2
)
denotes the coating weight of the first plating
layer, Y (g/m2
) denotes the coating weight of the
second plating layer, and T (mm) denotes a thickness
of the steel sheet.
[Claim 5] The plated steel sheet according to any
one of claims 1 to 4, further comprising a conversion
coating that contains Cr, Zr, Ti, Si, or V, or a
compound of any combination thereof on the second
plating layer,
wherein a coating weight of the conversion
coating is 50 mg/m2 to 1000 mg/m2
•
[Claim 6] A fuel tank comprising
a tank body made of the plated steel sheet
according to any one of claims 1 to 5,
- 41 -
wherein the first plating layer is inside the
tank body and the second plating layer is outside the
tank body.