Abstract:
This surface treated steel sheet includes: a steel sheet; and a plating layer that is formed on one or both sides of the steel sheet and includes zinc and vanadium or zirconium. The plating layer has dendritic crystals which include zinc metal and an inter crystal fill region which fills a region between the dendritic crystals and shows an amorphous diffraction pattern in electron diffraction. For the plating layer including vanadium the inter crystal fill region includes hydrated vanadium oxide or vanadium hydroxide and for the plating layer including zirconium the inter crystal fill region includes hydrated zirconium oxide or zirconium hydroxide.
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Notices, Deadlines & Correspondence
c/o NIPPON STEEL & SUMITOMO METAL CORPORATION 6 1 Marunouchi 2 chome Chiyoda ku Tokyo
1008071
2. SHOJI Hiromasa
c/o NIPPON STEEL & SUMITOMO METAL CORPORATION 6 1 Marunouchi 2 chome Chiyoda ku Tokyo
1008071
Specification
[Technical Field of the Invention]
[0001]
The present invention relates to a surface-treated steel sheet having excellent
corrosion resistance (batTier property) of plating in corrosive environments and
excellent coating film adhesion.
The present application claims Japm1ese Patent Application No. 2015-116554
and Japanese Patent Application No. 2015-116604 filed on June 9, 2015, the contents
of which are incorporated herein by reference.
[Related Art]
[0002]
From the related art, electrogalvanized steel sheets have been used in a variety
of fields such as home appliances, construction materials, and automobiles. For
electrogalvanized steel sheets, there is a demand for further improving the corrosion
resistance (hereinafter, barrier property) of plating in corrosive environments.
As a method for improving the barrier property of electrogalvanized steel
sheets, at1 increase in the plating amount (basis weight) of galvanized layers is
considered. However, when the basis weight of a galvanized layer is increased, there
has been a problem in that the manufacturing costs increase and the workability or
weldability degrades.
[0003]
In addition, as a method for improving the barrier property or external
appearance of electrogalvanized steel sheets, thus far, techniques of forming coating
- I -
films on surfaces have been widely used. Howeve1~ when the adhesion (coating film
adhesion) between plating layers and coating films in electrogalvanized steel sheets is
insufficient, in spite of the fonnation of coating films on surfaces, the effect of the
formation of coating films cannot be sufficiently obtained. Therefore, there is a
demand for not only improving the barrier property of electrogalvanized steel sheet but
also improving the coating film adhesion.
[0004]
In recent years, studies have been underway regarding the improvement of the
barrier prope1ty by adding a vanadium element to galvanized layers in
electrogalvanized steel sheets. For example, Non Patent Documents I to 4 describe
teclmiques of electrocrystallizing Zn-V composite oxides on the surface of a copper
sheet which is a negative electrode.
Patent Document 1 describes a technique of forming a V-thickened layer in a
surface layer portion of a plating layer in a zinc-based plated steel sheet.
Patent Document 2 describes a technique regarding a plating layer including
zinc and vanadium and having a plurality of dendrite-shaped arms.
[0005]
Patent Document 3 describes that a plating layer formed on a steel sheet and
including zinc and vanadium has dendrite-shaped crystals in which a vanadium oxide
is present in zinc and describes that, in portions other than the dendrite-shaped crystals,
phases having a higher vanadium content ratio than the dendrite-shaped crystals are
present.
[0006]
Patent Document 4 describes that, in a zinc-based composite electroplated
steel sheet including zinc and a vanadium hydroxide, a vanadium hydroxide is
- 2 -
coprecipitated in zinc.
[Prior Art Document]
[Patent Document]
[0007]
[Patent Document 1] Japanese Unexamined Patent Application, First
Publication No. 2013-185199
[Patent Document 2] Japanese Patent No. 5273316
[Patent Document 3] Japanese Unexamined Patent Application, First
Publication No. 2013-108183
[Patent Document 4] Japanese Unexamined Patent Application, First
Publication No. 2011 · 111633
[Non Patent Document]
[0008]
[Non-Patent Document 1] CAMP-ISIJ Vol. 22 (2009) 933 to 936
[Non-Patent Document 2] Iron and steel Vol. 93 (2007) No. 11, pp. 49 to 54
[Non-Patent Document 3] The Surface Finishing Society of Japan, The
summary of the 1 15th Lectures, 9A-26, pp. 139 and 140
[Non-Patent Document 4] Bulletin of The Iron and Steel Institute of Japan,
Vol. 13, No.4, p. 245, 2008. 4. 1
[Disclosure of the Invention]
[Problems to be Solved by the Invention]
[0009]
However, for surface-treated steel sheets of the related art having a plating
" 3 "
layer including zinc and vanadium on the surface of a steel sheet, there has been a
demand for further improving the barrier property.
In addition, since vanadium (V) is a rare element, there is a desire for platings
having an excellent barrier property which replace zinc-vanadium platings.
The present invention has been made in consideration of the above-described
circumstances, and an object of the present invention is to provide a surface-treated
steel sheet having an excellent barrier property and excellent coating fihn adhesion in
which a plating layer including zinc and vanadium or zirconium is formed on the
surface of a steel sheet.
[Means for Solving the Problem]
[0010]
In order to solve the above-described problems, the present inventors repeated
intensive studies as described below.
That is, the present inventors formed plating layers including zinc and
vanadium or zirconium on the surfaces of steel sheets under a variety of conditions
using an electroplating method and the steel sheets as a negative electrode and
investigated the barrier property and the coating film adhesion.
[0011]
As a result, the present inventors found that it is preferable to form a plating
layer which includes zinc and vanadium and has dendrite-shaped crystals including
metallic zinc and intercrystal filling regions including a hydrated vanadium oxide or a
vanadium hydroxide. The above-described plating layer has intercrystal filling
regions including a hydrated vanadium oxide or a vanadium hydroxide and thus has a
higher corrosion potential and a superior barrier property compared with, for example,
- 4 -
I.,
plated steel sheets formed by providing a galvanized layer instead of this plating layer.
In addition, the present inventors found that, under certain conditions, phases
including a hydrated zirconia oxide or a zirconia hydroxide are formed in the
peripheries of the dendrite-shaped crystals made of metallic zinc. It was clarified that
the plating layer has an equal or better barrier property and excellent coating film
adhesion compared with zinc-vanadium platings, which led to the completion of the
present invention. Individual aspects of the present invention are as described below.
[0012]
(1) A surface-treated steel sheet according to an aspect of the present
invention includes a steel sheet; and a plating layer which is fonned on one surface or
both surfaces of the steel sheet and which includes zinc and one of the group consisting
of vanadium and zirconium; in which the plating layer includes dendrite-shaped
crystals including metallic zinc, and intercrystal filling regions which fill spaces
between the dendrite-shaped crystals and show amorphous diffraction patterns when
electron beam diffraction is carried out, in which when the plating layer includes the
vanadium, the intercrystal filling regions include a hydrated vanadium oxide or a
vanadium hydroxide, and, in which when the plating layer includes zirconium, the
intercrystal filling regions include a hydrated zirconium oxide or a zirconium
hydroxide.
(2) In the surface-treated steel sheet according to (I), a constitution in which,
when the plating layer includes the vanadium, V/Zn which is a molar ratio of the
vanadium to the zinc in the intercrystal filling regions is 0.10 or more and 2.00 or less,
and, in which when the plating layer includes the zirconium, Zr/Zn which is a molar
ratio of the zirconium to the zinc in the intercrystal filling regions is 1.00 or more and
3.00 or less may be employed.
- 5 -
(3) In the surface-treated steel sheet according to (1) or (2), a constitution in
which the plating layer includes the vanadium and surface layers of the dendriteshaped
crystals include a zinc oxide or a zinc hydroxide may be employed.
[0013]
( 4) The surface-treated steel sheet according to any one of (1) to (3) further
includes a base-material plating layer having Zn!V, which is a molar ratio of the zinc to
the vanadium, of 8.00 or more between the steel sheet and the plating layer.
(5) The surface-treated steel sheet according to any one of(!) to (4), finther
incluses an organic resin film having a polyurethane resin and 1% to 20% by mass of
carbon black on a surface of the plating layer.
( 6) A method for manufacturing the surface-treated steel sheet according to
the aspect of the present invention is a method for manufacturing the surface-treated
steel sheet according to any one of(!) to (5), the method including: a base-materialforming
process of forming protrusions and recesses by precipitating a hydrated
vanadium oxide or a vanadium hydroxide on the steel sheet by carrying out an
electroplating at a current density ofO to 18 A/dm2 using a plating bath containing 0.10
to 4.00 mol/1 ofZn2
+ ions and 0.01 to 2.00 mol/1 ofVions or 0.10 to 4.00 mol/1 ofZr
ions; and an upper layer plating process of carrying out an electroplating on the steel
sheet on which the protrusions and the recesses are formed at a current density of 21 to
200 A/dm2 using the plating bath.
[Effects of the Invention]
[0014]
According to the respective aspects, it is possible to provide a surface-treated
steel sheet having an excellent barrier property and excellent coating film adhesion.
" 6 "
[Brief Description of the Drawings]
[00 15]
Fig. 1 is a schematic cross sectional view showing an example of a surfacetreated
steel sheet according to a first embodiment.
Fig. 2 is a schematic cross sectional view showing an example of a surfacetreated
steel sheet according to a second embodiment.
Fig. 3 is a schematic view showing an example of a plating apparatus that is
used to manufacture the surface-treated steel sheet according to the present
embodiment.
Fig. 4A is a schematic view showing the precipitation of a vanadium
compound in a process of manufacturing the surface-treated steel sheet shown in Fig. 1.
Fig. 48 is a schematic view showing the growth of dendrite-shaped crystals in
the process of manufacturing the surface-treated steel sheet shown in Fig. 1.
Fig. 4C is a schematic view showing the generation of hydrogen at front ends
of branch portions of the dendrite-shaped crystals in the process of manufacturing the
surface-treated steel sheet shown in Fig. I.
Fig. 5A is a cross sectional photograph of a plating layer in a surface-treated
steel sheet of Example V4 captured in the entire thickness direction using a
transmission electron microscope (TEM).
Fig. 58 is an enlarged photograph of an interface portion between a steel sheet
and a plating layer in the cross section of Fig. 5A.
Fig. 5C is an enlarged photograph of dendrite-shaped crystals and peripheral
portions thereof in the cross section of Fig. 5A.
Fig. 6 is a scanning electron microscopic (SEM) photograph of the plating
- 7 -
.~,
layer in the surface-treated steel sheet of Example V4.
Fig. 7 is a scanning electron microscopic (SEM) photograph of a plating layer
in a surface-treated steel sheet of Comparative Example x2.
Fig. 8 is a photograph showing electron beam diffraction images of the plating
layer in the surface-treated steel sheet of Example V4.
Fig. 9 is a transmission electron microscopic (TEM) photograph of a plating
layer in a surface-treated steel sheet of Example Z4.
[Embodiments of the Invention]
[0016]
"First embodiment, surface-treated steel sheet I 0"
Hereinafter, a surface-treated steel sheet 10 of a first embodiment when a
plating layer contains vanadium will be described in detail with reference to the
accompanying drawings.
Fig. 1 is a schematic cross sectional view showing an example of the surfacetreated
steel sheet I 0 according to the present embodiment. In the surface-treated
steel sheet I 0 shown in Fig. I, a base-material layer 20, a plating layer 30, and a
surface layer 40 are sequentially formed on each of both surfaces of the steel sheet 1
from the steel sheet 1 side. Fig. 1 shows only the base-material layer 20, the plating
layer 30, and the surface layer 40 fanned on one surface (upper surface) side of the
steel sheet 1 and does not show those on the other surface (lower surface) side.
[0017]
In the present embodiment, the steel sheet I having the plating layer 30
fanned on the surface is not particularly limited. For example, as the steel sheet I,
any types of steel sheets such as an extremely low C-type (a ferrite-dominant structure)
- 8 -
I.,
steel sheet, an Al-k-type (a structure including pearlite in ferrite) steel sheet, a twophase
structure-type (for example, a structure including martensite in ferrite or a
structure including bainite in ferrite) steel sheet, a working-induced transformationtype
(a structure including residual austenite in ferrite) steel sheet, or a fine ctystal-type
(a ferrite-dominant structure) steel sheet may be used.
[0018]
The base-material layer 20 may be provided between the steel sheet I and the
plating layer 30 as shown in Fig. I. The base-material layer 20 is provided as
necessary in order to improve the adhesion between the steel sheet 1 and the plating
layer 30. In the present embodiment, the base-material layer 20 which has a thickness
of 1 to 300 nm and is made of crystals including nickel is preferably provided.
[0019]
As shown in Fig. I, the plating layer 30 has dendrite-shaped crystals 31 and
intercrystal filling regions 32 which are disposed between the dendrite-shaped crystals
31 and shows amorphous diffraction patterns when electron beam diffraction is carried
out.
In the present invention, "being amorphous" means that, when electron beam
diffraction is carried out on each layer in the cross sectional direction using a
transmission electron microscope (TEM), diffraction patterns attributed to crystal
structures are not obtained.
[0020]
The intercrystal filling region 32 includes a hydrated vanadium oxide or a
vanadium hydroxide. The intercrystal filling region 32 preferably includes a
vanadium hydroxide since the coating film adhesion is improved.
In addition, the intercrystal filling region 32 preferably includes zinc. When
- 9 -
I.,
the interctystal filling region 32 includes zinc, the corrosion resistance improves.
[0021]
When the intercrystal filling region 32 includes a hydrated vanadium oxide or
a vanadium hydroxide and zinc, the molar ratio (V/Zn) of vanadium to zinc in the
intercrystal filling region 32 is preferably 0.10 or more and 2.00 or less. When the
molar ratio (V /Zn) is in the above-described range, and the intercrystal filling regions
show amorphous diffraction patterns when electron beam diffraction is carried out,
excellent corrosion resistance (barrier property) and coating film adhesion can be
obtained. When the molar ratio (V/Zn) of vanadium to zinc in the intercrystal filling
region 32 is less than 0.1 0, there are cases in which amorphous diffraction patterns
cannot be stably obtained, and the corrosion resistance deteriorates. On the other
hand, when the molar ratio exceeds 2.00, the sacrificial protection property of platings
deteriorates.
[0022]
As shown in Fig. 1, a plurality of the dendrite-shaped crystals 31 is formed in
the plating layer 30. The shapes of the plurality of dendrite-shaped crystals 31 may
be different from one another, or some of them may have the same shape. The shape
of each of the dendrite-shaped crystals 3lmay be a needle shape or a rod shape. In
addition, the respective dendrite-shaped crystals 31 may be ctystals which extend
linearly in the length direction or extend in a curved manner. The cross sectional
shapes of the respective dendrite-shaped crystals 31 are not particularly limited, and
examples thereof include a circular shape, an elliptical shape, a polyhedral shape, and
the like. In addition, the cross sectional shapes of the respective dendrite-shaped
crystals 31 may be even or uneven in the length direction. In addition, the outer
circumference dimensions of the respective dendrite-shaped crystals 31 may be even or
- 10 -
uneven in the length direction.
[0023]
In the surface-treated steel sheet 10 of the present embodiment, the respective
dendrite-shaped crystals 31 have an inside 3a of the dendrite-shaped crystal and a
surface layer 3b formed on the surface of the dendrite-shaped crystal31 as shown in
Fig. I. The inside 3a of the dendrite-shaped crystal 31 grows from the steel sheet I
side toward the outside and has a plurality of branch portions. The surface layer 3b is
formed in a substantially uniform thickness so as to cover the surface of the inside 3a
of the dendrite-shaped crystal 31.
[0024]
The dendrite-shaped crystal 31 having the inside 3a of the dendrite-shaped
crystal 31 and the surface layer 3b which is shown in Fig. 1 preferably has a maximum
length of 4.0 J.lm or less and a maximum cross sectional width of0.5 ~1111 or less.
When the maximum length and the maximum width of the dendrite-shaped crystal 31
are in the above-described ranges, the plating layer 30 has fme dendrite-shaped crystals
31 and becomes dense. Therefore, the barrier action of the plating layer 30 improves
and a superior barrier property can be obtained. In order to further improve the
barrier property, the maximum length of the dendrite-shaped crystal 31 is more
preferably 3.0 11m or less. In addition, the maximum cross sectional width of the
dendrite-shaped crystal 31 is more preferably 0.4 ~1111 or less.
[0025]
In the present embodiment, "the maximum length of the dendrite-shaped
crystal 31" is obtained by observing a cross section of the plating layer using a
scanning electron microscope (SEM), measuring the maximum lengths of 50 dendriteshaped
crystals 31, and computing the average value thereof.
- 11 -
In addition, "the maximum cross sectional width of the dendrite-shaped
crystal31" is obtained by observing a cross section of the plating layer using a
transmission electron microscope (TEM), measuring the maximum widths of 50
dendrite-shaped crystals 31, and computing the average value thereof.
[0026]
The inside 3a of the dendrite-shaped crystal31 preferably includes metallic
zmc. In addition to the metallic zinc, the inside 3a of the dendrite-shaped crystal31
may include other metal components having a higher precipitation potential than zinc
such as nickel.
In addition, the surface layer 3b preferably includes crystals including a zinc
oxide or a zinc hydroxide. The surface layer 3b more preferably includes the crystals
of a zinc oxide. The thickness of the surface layer 3b is preferably 0.1 to 500 nm.
[0027]
In addition, as shown in Fig. I, the inside 3a of the dendrite-shaped crystal31
may include granular crystals 3c. The granular crystal 3c includes zinc and nickel.
The grain diameters of the granular crystals 3c are preferably 0.1 to 500 nm. When
the grain diameters of the granular crystals 3c are in the above-described range,
superior coating film adhesion can be obtained.
[0028]
In the surface-treated steel sheet 10 of the present embodiment, Zn!V which is
the molar ratio of zinc to vanadium included in the plating layer 30 is preferably 0.50
or more and less than 8.00. When Zn!V is 0.50 or more and less than 8.00, vanadium
being included provides a superior barrier function, which is preferable.
[0029]
In the surface-treated steel sheet 10, a base-material plating layer (not shown)
- 12 -
containing zinc may be formed between the steel sheet 1 and the plating layer 30
(between the base-material layer 20 and the plating layer 30 when the base-material
layer 20 is formed). This is because the base-material plating layer (not shown) being
formed provides an excellent corrosion resistance improvement effect which is
attributed to the sacrificial protection by zinc.
The base-material plating layer (not shown) may include zinc and vanadium
and may have Zn/V, which is the molar ratio of the zinc to the vanadium, of 8.00 or
more. In addition, the base-material plating layer (not shown) may also be
constituted of zinc alone.
[0030]
As an upper layer of the plating layer 30, an upper layer plating layer (not
shown) containing zinc may be fom1ed. The upper layer plating layer (not shown)
being formed provides an excellent corrosion resistance improvement effect which is
attributed to the sacrificial protection by zinc, which is preferable.
The upper layer plating layer (not shown) may also be constituted of zinc
alone. h1 addition, the upper layer plating layer (not shown) includes zinc and
vanadium and may have Zn/V, which is the molar ratio of the zinc to the vanadium, of
8.00 or more.
[0031]
The base-material plating layer (not shown) can be formed between the steel
sheet I and the plating layer 30 (between the base-material layer 20 and the plating
layer 30 when the base-material layer 20 is formed) by controlling the current density
for electroplating and the adjusting the molar ratio of zinc to vanadium.
The upper layer plating layer (not shown) can be formed on the plating layer
30 using the same method for the base-material plating layer (not shown).
- 13 -
[0032]
The molar ratio (alb) of the amount of zinc (a) included in the insides 3a of
the dendrite-shaped crystals 31 to the total of the amounts of zinc (b) included in the
intercrystal filling regions 32 and the surface layers 3b of the dendrite-shaped crystals
31 is preferably in a range ofO.IO or more and 3.00 or less.
When the molar ratio (alb) is 0.10 or more, the sacrificial protection action of
the metallic zinc in the dendrite-shaped crystals 31 can be effectively obtained when
flaws are generated on the surface of the plating layer 30, and a superior ban-ier
property can be obtained. In order to more effectively obtain the sacrificial protection
action of the metallic zinc in the dendrite-shaped crystals 3 I, the molar ratio (alb) is
more preferably set to 0.20 or more.
In addition, when the molar ratio (alb) is 3.00 or less, the barrier property
improvement action of the steel sheet I which is attributed to the zinc oxide or the zinc
hydroxide in the surface layers of the dendrite-shaped crystals 31 which does not easily
transmit the air or water can be effectively obtained, and a superior barrier prope1ty can
be obtained. In order to more effectively obtain the barrier property improvement
action of the surface layers 3 b of the dendrite-shaped crystals 31, the mo Jar ratio (alb)
is more preferably 0.25 or less.
[0033]
In addition, the molar ratio (NB) of the total (A) of the amount of zinc
included in the dendrite-shaped crystals 3 I and the amount of zinc .included in the
surface layers 3b of the dendrite-shaped crystals 31 to the amount of vanadium (B)
included in the interc1ystal filling regions 32 is preferably 0.05 or more and 6.00 or
less. When the molar ratio (NB) is 0.05 or more, the sacrificial protection action of
the metallic zinc in the dendrite-shaped crystals 3 I and the barrier property
-14
I.,
improvement action of the zinc oxide or the zinc hydroxide in the surface layers 3b of
the dendrite-shaped crystals 31 are effectively obtained, and a superior barrier property
can be obtained.
In order to more effectively obtain the sacrificial protection action of the
dendrite-shaped crystals 31 and the barrier property improvement action of the surface
layers 3b of the dendrite-shaped crystals 31, the molar ratio (A/B) is more preferably
0.10 or more. In addition, when the molar ratio (AlB) is 6.00 or less, an effect of
improving the barrier property by the corrosion potential set to a positive potential by
containing vanadium is more effectively showed. In order to further improve the
barrier property improvement action of vanadium being included, the molar ratio (A/B)
is more preferably 5.00 or less and more preferably 4.50 or less.
[0034]
In the present embodiment, the amount of vanadium in the plating layer 30 is
preferably 1% by mass to 20% by mass. When the amount of vanadium in the plating
layer 30 is 1% by mass or more, a superior barrier property can be obtained. The
amount of vanadium in the plating layer 30 is more preferably 4% by mass or more in
order to further improve the barrier property and the coating film adhesion. When the
amount of vanadium in the plating layer 30 is 20% by mass or less, the amount in the
dendrite-shaped crystals 31 and the surface layers 3 b of the dendrite-shaped ctystals 31
become relatively great, and the sacrificial protection action of the dendrite-shaped
crystals 3 I and the barrier property improvement action of the surface layers 3b of the
dendrite-shaped crystals 31 can be effectively obtained.
The amount of vanadium in the plating layer 30 is more preferably 15% by
mass or less in order to ensure the amount in the dendrite-shaped crystals 3 I and the
surface layers 3b of the dendrite-shaped crystals 31.
- I5 -
I '
[0035]
The adhered amount of the plating layer 30 is preferably 1 g/m2 or more and
more preferably 3 g/m2 or more in order to improve the barrier property. In addition,
the adhered amount of the plating layer 30 is preferably 90 g/m2 or less, more
preferably 50 g/m2 or less, and stillmore preferably 15 g/m2 or less. When the
adhered amount of the plating layer 30 is 15 g/m2 or less, the amount of metal being
precipitated is smaller compared with that in electrogalvanizing of the related art
(generally, approximately 20 g/m2
), and the adhered amount is economically excellent
from the viewpoint of metal costs or electric power costs for forming the plating layer
30.
[0036]
In the surface-treated steel sheet 10 of the present embodiment, the natural
immersion potential (corrosion potential) when the plating layer 30 is immersed in a
5% aqueous NaCI solution at 25°C as a working electrode is preferably -0.8 V or more.
The corrosion potential is preferably 0.2 V or more higher (positive) than those of
plated steel sheets (the corrosion potentials are approximately -1.0 V) formed by
providing a galvanized layer instead ofthe plating layer 30. In order to further
improve the barrier property, the corrosion potential is more preferably -0.7 V or more.
[0037]
As shown in Fig. 1, the surface layer 40 made of one or more films is formed
on the surface of the plating layer 30. The surface layer 40 is provided as necessaty.
The surface layer 40 being formed improves the corrosion resistance.
One or more films fanning the surface layer 40 preferably c.ontain an organic
resin (R).
[0038]
- 16 -
The organic resin (R) in the film is not particularly limited, and examples
thereof include polyurethane resins.
As the organic resin (R) in the film, one or more organic resins (not modified)
may be mixed and used, or one or more organic resins obtained by modifYing at least
one organic resin in the presence of at least one different organic resin may be mixed
and used.
[0039]
Examples of the polyurethane resin that is used as the organic resin (R)
include resins obtained by reacting a polyol compound and a polyisocyanate
compound and then elongating chains using a chain elongation agent.
The pol yo! compound that is used as a raw material of the polyurethane resin
is not particularly limited as long as the polyol compound has two or more hydroxyl
groups per molecule, and examples thereof include ethylene glycol, propylene glycol,
diethylene glycol, 1,6-hexanediol, neopentyl glycol, triethylene glycol, glycerin,
trimethylolethane, trimethylolpropane, polycarbonate polyol, polyester polyol,
polyether polyols such as bisphenol hydroxypropyl ether, polyesteramide polyol, aery!
polyol, polyurethane polyol, and mixtures thereof.
[0040]
As the polyisocyanate compound that is used as a raw material of the
polyurethane resin, compounds having two or more isocyanate groups per molecule are
used, and examples thereof include aliphatic isocyanates such as hexamethylene
diisocyanate (HOI), alicyclic diisocyanates such as isophorone isocyanate (IPDI),
aromatic diisocyanates such as torylene diisocyanate (TDI), aromatic aliphatic
diisocyanates such as diphenylmethane diisocyanate (MDI), and mixtures thereof.
[0041]
- 17 -
I '
As the chain elongation agent that is used to manufacture the polyurethane
resin, compounds having one or more active hydrogen atoms per in the molecule can
be used, and examples thereof include aliphatic polyamines such as ethylenediamine,
propylenediamine, hexamethylenedimnine, diethylenetriamine, dipropylenetriamine,
triethylenetetramine, and tetraethylenepentamine, aromatic polyamines such as
torylenediamine, xylylenedimaine, and diaminodiphenylmethane, alicyclic polyamines
such as diaminocyclohxylmethane, pyperazine, 2,5-dimethylpyperazine, and
isophorodiamine, hydrozines such as hydrazine, succinic dihydrazide, adipic
dihydrazide, and phthalic dihydrazide, alkanoleamines such as hydroxyethyl
diethylenetriamine, 2-[(2-aminoethyl)amino]ethanol and 3-aminopropanediol, and the
like. These compounds that are used as the chain elongation agent can be used singly,
or two or more compounds can be used as a mixture.
[0042]
In addition, the polyurethane resin that is used as the organic resin (R) may be
a polyurethane resin obtained by heating a raw material solution including a blocked
isocyanate compound and the polyol compound to a temperature at which a block
agent is dissociated and reacting regenerated isocyanate groups and the polyol
component of the polyol compound in the raw material solution.
The blocked isocyanate compound is a compound that regenerates isocyanate
groups when heated to a temperature or higher at which the block agent is dissociated.
As the blocked isocyanate compound, it is possible to use, for example, compounds
obtained by masking the isocyanate groups in the polyisocyante compound with a
well-known block agent of the related art. As the block agent, it is possible to use, for
example, dimethylpyrazole (DMP}, methyl ethyl ketone oxime, and the like.
[0043]
- 18 -
I.,
One or more films forming the surface layer 40 preferably include, in addition
to the organic resin (R), one or more raw materials selected from a phosphoric acid
compound (P), an organic silicon compound (W), carbon black (C), a fluoro metal
complex compound (F), and polyethylene wax (Q).
[0044]
The phosphoric acid compound (P) in the film is more preferably a compound
that emits phosphate ions in the film. When the phosphoric acid compound (P) is a
compound (P) that emits phosphate ions in the film, when a coating composition for
forming the films during the formation of the films is brought into contact with the
plating layer 30 or phosphate ions derived from the phosphoric acid compound are
eluted fi:om the films after the fonnation of the films, the phosphoric acid compound
(P) and a vanadium oxide present on the surface of the plating layer 30 react with each
other, and a poorly-soluble phosphoric acid-vanadium-based film is formed on the
surface of the plating layer 30. Therefore, the white rust resistance can be
significantly improved.
[0045]
When the phosphoric acid compound (P) is a insoluble compound that does
not emit phosphate ions in the environment, the phosphoric acid compound (P) in the
film inhibits the migration of corrosion factors such as water and oxygen, and thus an
excellent barrier property can be obtained.
[0046]
As the phosphoric acid compound (P) in the film, it is possible to use, for
example, phosphoric acids such as orthophosphoric acid, metaphosphoric acid,
pyrophosphoric acid, triphosphoric acid, and tetraphosphoric acid or ammonium
dihydrogen phosphate. These phosphoric acid compounds (P) may be used singly, or
- 19 -
I . I
two or more phosphoric acid compounds may be jointly used.
[0047]
The amount of the phosphoric acid compound (P) in the film is preferably 1%
to 20% by mass, more preferably 6% to 18% by mass, and most preferably 10% to
15% by mass in terms of phosphate ions. When the concentration of phosphate ions
in the film is 1% by mass or more, an excellent barrier property can be obtained. In
addition, when the concentration of phosphate ions in the film is 20% by mass or less,
the swelling of coating film caused by the elution of phosphoric acid can be prevented.
[0048]
When the phosphoric acid compound (P) is included in the film, a barrier
layer (not shown) including vanadium in the plating layer 30 and the phosphoric acid
compound in the films and having an excellent barrier property against corrosion
factors (water, oxygen, and the like) is formed on the surface of the steel sheet I. As
a result, compared with a case in which the surface layer 40 is not formed on the
surface of the plating layer 30, the white rust resistance is excellent, and an effect of
delaying the generation of red rust can be obtained, and thus the barrier property
significantly improves.
[0049]
Examples of the organic silicon compound (W) in the film include hydrolysis
condensates of silane coupling agents and the like.
Examples of silane coupling agents that are used to generate the organic
silicon compound (W) in the film include 3-glycidoxypropyl trimethoxysilane, 3-
aminopropyl triethoxysilane. The silane coupling agents may be used singly or two
or more silane coupling agents may be jointly used.
[0050]
- 20-.:
The organic silicon compound (W) in the film is preferably a compound
obtained from a reaction between a silane coupling agent (WI) containing an amino
group and a silane coupling agent (W2) containing an epoxy group. In this case,
dense films having a high crosslinking density are formed from a reaction between the
amino group and the epoxy group and a reaction between alkoxysilyl groups that are
respectively included in the silane coupling agent (Wl) and the silane coupling agent
(W2) or partial hydrolysis products thereof. As a result, the barrier property, flaw
resistance, and contamination resistance of the surface-treated steel sheet further
1m prove.
[0051]
Examples of the silane coupling agent (Wl) containing an amino group
include 3-aminopropyltriethoxysilane. Examples of the silane coupling agent (W2)
containing an epoxy group include 3-glycidoxypropyltrimethoxysilane.
[0052]
The molar ratio {(Wl)/(W2)} of the silane coupling agent (Wl) containing an
amino group to the silane coupling agent (W2) containing an epoxy group is preferably
0.5 or more and 2.5 or less and more preferably 0. 7 or more and 1.6 or less. When
the molar ratio { (Wl )I(W2)} is 0.5 or more, a sufficient film production property can
be obtained, and thus the barrier property improves. In addition, when the molar ratio
is 2.5 or less, a sufficient water resistance can be obtained, and thus an excellent barrier
property can be obtained.
[0053]
The number-average molecular weight of the organic silicon compound (W)
in the film is, for example, preferably I ,000 or more and I 0,000 or less and more
preferably 2,000 or more and I 0,000 or less. When the number-average molecular
- 21 -
i " I
weight of the organic silicon compound (W) is 1,000 or more, the film becomes
excellent in tenns of the water resistance, and the alkali resistance and the barrier
property become more favorable" On the other hand, when the number-average
molecular weight of the organic silicon compound (W) is 10,000 or less, it is possible
to stably dissolve or disperse the organic silicon compound (W) in aqueous media
which contain water as a main component, and there are cases in which the storage
stability degrades.
[0054]
As the method for measuring the number-average molecular weight of the
organic silicon compound (W), direct measurement by means of time of flight mass
spectrometry (TOF-MS) may be used, or conversion measurement by means of
chromatography may be used.
[0055]
The mass ratio (RIW) of the organic resin (R) to the organic silicon compound
(W) in the film is preferably 1.0 to 3.0. When R1W is 1.0 or more, cohesion failure
does not easily occur in the film during working, and the working adhesion becomes
favorable. In addition, when RIW is 3.0 or less, the effect of the inclusion of the
organic silicon compound (W) can be sufficiently obtained, and films having high
hardness can be obtained.
[0056]
The organic silicon compound (W) can be manufactured using, for example, a
method in which the above-described silane coupling agent is dissolved or dispersed in
water and is stirred at a predetennined temperature for a predetermined period of time,
thereby obtaining hydrolysis condensates.
[0057]
- 22 -
The film containing the organic silicon compound (W) can be formed by, for
example, manufacturing an aqueous liquid or alcohol-based liquid containing the
organic silicon compound (W) as a raw material ofthe coating composition for
forming the film and applying and drying the coating composition including the liquid
on the plating layer.
The aqueous liquid or alcohol-based liquid containing the organic silicon
compound (W) can be manufactured using, for example, a method in which the organic
silicon compound such as the hydrolysis condensate of the silane coupling agent is
dissolved or dispersed in water, thereby obtaining aqueous liquids, a method in which
the organic silicon compound such as the hydrolysis condensate of the silane coupling
agent is dissolved in an alcohol-based organic solvent such as methanol, ethanol, or
isopropanol, thereby obtaining alcohol-based liquids, or the like.
[0058]
When the aqueous liquid or alcohol-based liquid containing the organic
silicon compound (W) is manufactured, in addition to the organic silicon compound
(W) and water or the alcohol-based organic solvent, acids, alkalis, organic solvents,
surfactants, and the like may be added thereto in order to dissolve or disperse the silane
coupling agent or the hydrolysis condensate thereof in the aqueous liquid or alcoholbased
liquid. Particularly, the pH of the aqueous liquid or alcohol-based liquid is
preferably adjusted to 3 to 6 by adding organic acids in addition to water or the
alcohol-based organic solvent from the viewpoint of the storage stability ofthe
aqueous liquid or alcohol-based liquid.
[0059]
The solid content concentration of the organic silicon compound (W) in the
aqueous liquid or alcohol-based liquid of the organic silicon compound (W) is
- 23 -
preferably 25% by mass or less. When the solid content concentration of the organic
silicon compound (W) is 25% by mass or less, the storage stability of the aqueous
liquid or alcohol-based liquid becomes favorable.
[0060]
In the film, the carbon black (C) is preferably included as a coloring pigment.
When the carbon black is included in the film, fine unevenness present on the surface
of the plating layer is covered, a beautiful black external appearance is obtained, and
excellent designability can be obtained.
[0061]
Examples of the carbon black (C) in the film include well-known carbon
blacks such as furnace black, keljenblack, acetylene black, and channel black. In
·addition, as the carbon black (C) in the film, carbon black on which a well-known
ozone treatment, plasma treatment, or liquid-phase oxidation treatment is carried out
may be used.
[0062]
The particle diameters of the carbon black (C) in the film are not particularly
limited as long as there are no problems with the dispersibility in the coating
composition for forming the film, the qualities of coating films, and the coatability.
When dispersed in water-based solvents, the carbon black coheres together in the
process of dispersing the carbon black. Therefore, generally, it is difficult to disperse
the carbon black in water-based solvents while maintaining the primary particle
diameters. Therefore, the carbon black in the coating composition for forming the
film is present in a form of secondary particles having larger particle diameters than
the primary particle diameters. Therefore, the carbon black in the film fonned using
the coating composition is, similar to those in the coating composition, present in a
- 24 -
form of secondary particles.
[0063]
As the carbon black that is used as the raw material of the film, for example,
carbon black having primmy patiicle diameters of 10 11111 to 120 11111 can be used.
When the designability and barrier prope1iy of the film are taken into account, the
particle diameters of the carbon black in the film are preferably 10 nm to 50 nm.
In order to secure the designability and barrier property of the film, the
particle diameters of the carbon black in a form of secondary particles which is
dispersed in the film are impmiant. The average particle diameter of the carbon black
in the film is preferably 20 nm to 300 nm.
[0064]
The amount of the carbon black (C) in the film is, for example, preferably 1%
to 20% by mass, more preferably 3% to 15% by mass, and most preferably set to 5% to
13% by mass. When the amount of the carbon black (C) in the film is I% by mass or
more, an even black external appearance can be obtained. In addition, when the
amount of the carbon black (C) in the film is 20% by mass or less, it is possible to
ensure the amount of raw materials other than the carbon black (C) in the film, and
thus an excellent barrier property can be obtained.
[0065]
In the film, the fluoro metal complex compound (F) may be included. The
fluoro metal complex compound (F) acts as a cross linking agent in the film and
improves the cohesive force of the film. The fluoro metal complex compound (F) is
not particularly limited, and a fluoro metal complex compound having titanium is
preferably used fi·om the viewpoint of the barrier prope1iy. Examples of the fluoro
metal complex compound (F) include hexafluorotitanic acid.
- 25 -
[0066]
In the film, the polyethylene wax (Q) may be included. The polyethylene
wax (Q) is capable of improving the flaw resistance of the film. Therefore, when the
polyethylene wax (Q) is included in the film, the lubricity of the surface-treated steel
sheet enhances, the friction resistance attributed to the contact between, for example,
the steel sheet and a press die decreases, and it is possible to prevent damages in
worked portions of the steel sheet and scratches being generated during the handling of
the steel sheet.
[0067]
The polyethylene wax (Q) in the film is not particularly limited, and wellknown
lubricants can be used. Specifically, as the polyethylene wax (Q), polyolefin
resin-based lubricants are preferably used.
[0068]
The polyolefin resin-based lubricants that are used as the polyethylene wax
(Q) are not particularly limited, and examples thereof include hydrocarbon-based wax
such as polyethylene.
[0069]
The amount of the polyethylene wax (Q) in the fihn is preferably 0.5% by
mass or more and 10% by mass or less and more preferably 1% by mass or more and
5% by mass or less in the film. When the amount ofthe polyethylene wax (Q) is
0.5% by mass or more, a flaw resistance improvement effect can be obtained. When
the amount of the polyethylene wax (Q) is 10% by mass or less, it is possible to ensure
the amount of raw materials other than the polyethylene wax (Q) in the film, and thus
an excellent barrier property can be obtained.
[0070]
- 26 -
"Method for manufacturing surface-treated steel sheet 1 0"
Next, a method for manufacturing the surface-treated steel sheet I 0 will be
described.
A method for manufacturing the surface-treated steel sheet of the present
embodiment includes a base-material-forming process of fom1ing protrusions and
recesses by precipitating a hydrated vanadium oxide or a vanadium hydroxide on the
steel sheet I by carrying out an electroplating at a current density ofO to 18 A/dnl
using a plating bath containing 0.10 to 4.00 mol/1 ofZr2
+ ions and 0.01 to 2.00 moll! of
V ions or 0.10 to 4.00 mol/! ofZr ions and an upper layer plating process of carrying
out an electroplating on the steel sheet 1 on which the protrusions and the recesses are
formed at a current density of21 to 200 A/dnl using the plating bath. The abovedescribed
base-material-forming process is a factor that affects V/Zn which is the
molar ratio of the vanadium to the zinc in the above-described intercrystal filling
regions in the plating layer. When the current density in the base-material-forming
process exceeds 18 A/dm2
, V/Zn which is the molar ratio of vanadium to zinc in the
intercrystal filling regions reaches less than 0.10.
[0071]
In the present embodiment, a pretreatment is carried out on both surfaces of
the steel sheet 1 forming the plating layer 30 as necessary. As the pretreatment, it is
preferable to provide I to 300 nm-thick nickel platings on both surfaces of the steel
sheet 1 and fonn the base-material layers 20.
Next, the plating layer 30 is formed on one surface or both surfaces of the
steel sheet I. The present embodiment will be described using a method in which the
plating layers 30 are formed on both surfaces of the steel sheet I by means of
electroplating using a plating apparatus shown in Fig. 3 as an example.
:: 27
[0072]
Fig. 3 is a schematic view showing an example of the plating apparatus. In
the present embodiment, out of rolls 4a, 4b, 5a, and 5b, the rolls 4a and 4b disposed
above the steel sheet 1 function as connection portions (conductors) that electrically
connect a power supply (not shown) and the steel sheet I. The steel sheet I is
electrically connected to the rolls 4a and 4b and acts as a negative electrode. When
electroplating is carried out, a plurality of the plating apparatuses shown in Fig. 3 is
arranged in series and used. The base-material-forming process is carried out in the
plating apparatus shown in Fig. 3 or in a region surrounded by the rolls 4a and Sa and
the intennediate branching paths 2d and 2fin Fig. 3. In addition, the upper layer
plating process is carried out in the plating apparatus shown in Fig. 3 or in a region
surrounded by the intem1ediate branching paths 2d and 2f and the rolls 4b and 5b in
Fig. 3.
[0073]
A plating tank 21 has an upper portion tank 21 a disposed above the steel sheet
1 and a lower portion tank 21b disposed below the steel sheet I.
As shown in Fig. 3, at locations adjacent to the steel sheet I in the upper
portion tank 21 a and the lower portion tank 2lb, a plurality of positive electrodes 3
made of platinum or the like is disposed at predetermined intervals from the steel sheet
I. The respective positive electrodes 3 are disposed so that the surfaces of the
positive electrodes facing the steel sheet I become substantially parallel to the surface
of the steel sheet I. The respective positive electrodes 3 are electrically connected to
the power supply (not shown) using non-shown connection members.
[0074]
The upper portion tank 2la and the lower portion tank 21 bare filled with a
- 28 -
plating bath 2. As shown in Fig. 3, the steel sheet I migrating with the surface
direction set to be substantially horizontal is disposed between the upper portion tank
21a and the lower portion tank 2lb of the plating tank 21. In addition, the steel sheet
1 being passed through the plating tank 21 in an arrow direction using the rolls 4a, 4b,
Sa, and Sb is in a state of being immersed in the plating bath 2 in the upper portion tank
21a and the lower portion tank 2lb. Therefore, in the present embodiment, the steel
sheet I is transported using the rolls 4a, 4b, Sa, and Sb, and the steel sheet 1 is migrated
in the plating bath 2, whereby the plating bath 2 falls into a fluid state in which the
plating bath 2 is relatively fluid with respect to the steel sheet 1.
[007S]
As shown in Fig. 3, in the upper portion tank 21a, an upper portion supply
pipe 2a that supplies the plating bath 2 to the upper portion tank 21a is provided so as
to penetrate through the upper surface of the upper portion tank 21a. The upper
portion supply pipe 2a is branched into a plurality of outer circumferential branching
paths 2c and the plurality of intermediate branching paths 2d (only one path is shown
in Fig. 3) in the upper portion tank 21a. The plurality of intermediate branching paths
2d is disposed along the width direction of the steel sheet I between the positive
electrodes 3 adjacent to each other in a plan view. The intermediate branching path
2d includes an opening portion that supplies the plating bath 2 toward between the
positive electrodes 3 on both sides and the steel sheet 1. The plurality of outer
circumferential branching paths 2c is disposed along the width direction of the steel
sheet 1 between the positive electrode 3 and the rolls 4a and 4b in a plan view. The
outer circumferential branching path 2c includes an opening portion that supplies the
plating bath 2 toward between the positive electrode 3 and the steel sheet I.
[0076]
- 29 -
In the upper portion tank 2la, a discharge opening (not shown) that discharges
the plating bath 2 is provided and is connected to the upper portion supply pipe 2a
through a pipe including a pump (not shown). Therefore, in the upper portion tank
2la, the plating bath 2 which has been supplied from the upper portion supply pipe 2a
and been discharged from the discharging opening turns into the plating bath 2 in a
fluid state in which the plating bath is again supplied from the upper portion supply
pipe 2a through the pipe using the pump and is circulated.
[0077]
In the lower portion tank 2lb, a lower portion supply pipe 2b that supplies the
plating bath 2 to the lower portion tank 2lb is provided so as to penetrate through the
lower surface of the lower portion tank 21b. The lower portion supply pipe 2b is
branched into a plurality of outer circumferential branching paths 2e and the plurality
of intennediate branching paths 2f (only one path is shown in Fig. 3) in the lower
portion tank 21 b. The plurality of intermediate branching paths 2f is disposed along
the width direction of the steel sheet 1 between the positive electrodes 3 adjacent to
each other in a plan view. The intermediate branching path 2f includes an opening
portion that supplies the plating bath 2 toward between the positive electrodes 3 on
both sides and the steel sheet I. The plurality of outer circumferential branching
paths 2e is disposed along the width direction of the steel sheet 1 between the positive
electrode 3 and the rolls Sa and 5b in a plan view. The outer circumferential
branching path 2e includes an opening portion that supplies the plating bath 2 toward
between the positive electrode 3 and the steel sheet 1.
[0078]
In the lower portion tank 21 b, a discharge opening (not shown) that discharges
the plating bath 2 is provided and is connected to the lower portion supply pipe 2b
- 30 -
through a pipe including a pump (not shown). Therefore, in the lower portion tank
21 b, the plating bath 2 which has been supplied from the lower portion supply pipe 2b
and been discharged from the discharging opening turns into the plating bath 2 in a
fluid state in which the plating bath is again supplied from the lower portion supply
pipe 2b through the pipe using the pump and is circulated.
[0079]
When the electric conduction time in the base-material-forming process is
adjusted to O.OS seconds to 8.00 seconds, the intercrystal filling regions 32 stably show
amorphous diffraction patterns.
[0080]
In the present embodiment, it is assumed that the plating layer 30 is formed on
the surface of the steel sheet I. through a mechanism described below. Fig. 4A to Fig.
4C are schematic views showing the state of the surface of the steel sheet I in the
process of manufacturing the surface-treated steel sheet 10 shown in Fig. 1.
In the plating apparatus shown in Fig. 3, the steel sheet I having a nickel
plating layer (base-material layer) 20a formed on the surface sequentially comes into
contact with the plating bath 2 from a portion that has passed through between the rolls
4a and Sa, and plating is initiated at a current density of 18 A/dm2 or less.
That is, the rolls 4a and Sa are rolls for electric conduction and are also
referred to as conductor rolls. The steel sheet and a plating liquid come into contact
with each other after passing through between these conductor rolls 4a and Sa.
[0081]
In the present embodiment, on the surface (solid-liquid interface) of the steel
sheet I on which the nickel plating layer 20a is formed which has passed through the
rolls 4a and Sa, before the precipitation of zinc, a vanadium compound 6 including a
- 31 -
hydrated vanadium oxide or a vanadium hydroxide is precipitated as shown in Fig. 4A,
and the base-material-forming process in which protrusions and recesses are fom1ed is
initiated.
This is assumed to be because, at the current density of 18 A/dm2 or less,
vanadium having a high precipitation potential is reduced and precipitated, but zinc
having a low precipitation potential is not precipitated. Meanwhile, in the basematerial-
fanning process, the vanadium compound 6 including a hydrated vanadium
oxide or a vanadium hydroxide is precipitated. This base-material is different from
the above-described base-material layer 20. This base-material is incorporated into
the plating layer 30 in the end.
[0082]
In the base-material-fonning process, when the precipitation of the vanadium
compound 6 on the surface of the steel sheet 1 is initiated, a plurality of currentconcentrating
portions 61 is formed on the surface of the steel sheet 1 as shown in Fig.
4A The current-concentrating portions 61 can be assumed as portions which are
made of portions in which the vanadium compound 6 is not or slightly precipitated on
the surface of the steel sheet 1 and allow electric currents to easily flow.
[0083]
When the current density is set to 21 A/dm2 or more, the potential reaches the
precipitation potential ofZn, and the reduction and precipitation reaction of zinc is
initiated. The current-concentrating portions 61 act as the starting points, as shown in
Fig. 4B, the dendrite-shaped crystals 3a including metallic zinc grow, and the upper
layer plating process is initiated. When the dendrite-shaped crystals 3a grow, it is
assumed that it becomes easier for the crystals to grow at the front end sections of the
dendrite-shaped crystals 3a.
- 32 -
[0084]
In the upper portion plating process, electric currents further concentrate at the
front ends of a plurality of branching portions branched from the dendrite-shaped
crystals 3a as the dendrite-shaped crystals 3a grow, and, as shown in Fig. 4C, it is
assumed that hydrogen 62 is generated at the solid-liquid interfaces between the front
ends of the branching portions and the plating bath 2.
[0085]
The hydrogen 62 generated in the above-described mrumer increases the pH
of the solid-liquid interfaces between the surfaces of the dendrite-shaped crystals 3a
and the plating bath 2. As a result, it is assumed that crystals including a zinc oxide
or a zinc hydroxide are precipitated so as to cover the surfaces of the dendrite-shaped
crystals 31 and the dendrite-shaped crystals 31 having the surface layer 3b shown in
Fig. I are fonned. In addition, it is assumed that, as the pH of the plating bath 2
increases, amorphous substances including a hydrated vanadium oxide or a vanadium
hydroxide are precipitated between the dendrite-shaped crystals 3 I adjacent to each
other, and the intercrystal filling regions 32 shown in Fig. 1 are formed.
[0086]
In the present embodiment, as described above, in the base-material-forming
process, the electric conduction time is controlled to a range of 0.05 to 8.00 seconds.
Therefore, before the precipitation of zinc on the surface of the steel sheet I, the
precipitation of the vanadium compound 6 is initiated, and the plurality of currentconcentrating
pmtions 61 is formed on the surface of the steel sheet I. As a result, it
is assumed that, through the above-described mechanism, the dendrite-shaped crystals
31 are obtained, and the intercrystal filling regions 32 showing amorphous diffraction
patterns when electron beam diffraction is carried out are obtained. The migration
- 3J -
time of the steel sheet 1 passing through the interval Dis more preferably in a range of
1.00 to 6.00 seconds.
[0087]
When the electric conduction time in the base-material-forming process is
shorter than 0.05 seconds, the precipitation amount ofthe vanadium compound 6
precipitated before the precipitation of zinc on the surface of the steel sheet I is
insufficient. Therefore, it becomes difficult for the dendrite-shaped crystals 3 I made
of metallic zinc to grow in the current -concentrating pmtions 6 I formed on the surface
of the steel sheet I. In addition, the intercrystal filling regions 32 including a
hydrated vanadium oxide or a vanadium hydroxide are not obtained or the amorphous
diffraction patterns become unstable even when the interc1ystal filling regions 32 are
obtained.
When the electric conduction time in the base-material-forming process
exceeds 8.00 seconds, the precipitation amount of the vanadium compound 6
precipitated before the precipitation of zinc on the surface of the steel sheet I becomes
too great, and thus the number of the current -concentrating portions 61 formed on the
surface of the steel sheet 1 becomes smaller or zero. Therefore, it becomes difficult
for the dendrite-shaped crystals 3 I made of metallic zinc to grow, and the dendriteshaped
crystals 31 and the intercrystal filling regions 32 are not obtained or the
amorphous diffraction patterns become unstable even when the intercrystal filling
regions 32 are obtained.
[0088]
In the present embodiment, in the base-material-forming process,
electroplating is preferably carried out under a condition in which the current density
reaches 0 to 18 A/dm2
, and electroplating is more preferably carried out under a
- 34 -
i I
condition in which the current density reaches 2 to 15 Ndm2
• When the current
density is set to 18 Ndm2 or less in the base-material-forming process, the molar ratio
(V/Zn) of vanadium to zinc in the intercrystal filling regions 32 reaches 0.10 or more
and 2.00 or less, the intercrystal filling regions 32 show amorphous diffi"action patterns
when electron beam diffi"action is carried out, and consequently, the barrier property
and the coating film adhesion can be improved. On the other hand, when the current
density is not in the above-described range in the base-material-forming process, the
intercrystal filling regions 32 are not formed or the amorphous diffiaction patterns
become unstable even when the intercrystal filling regions 32 are obtained.
In addition, in the upper layer plating process, electroplating is preferably
carried out under conditions in which the current density reaches 21 to 200 Ndm2
•
When the current density is set to 21 Ndm2 or more, it is possible to sufficiently
generate the hydrogen 62 in the solid-liquid interfaces between the front ends of the
branching portions of the dendrite-shaped crystals 31 and the plating bath 2.
Therefore, the precipitation amount ofthe hydrated vanadium oxide or the vanadium
hydroxide in the intercrystal filling regions 32 increases. Therefore, it is possible to
fonn the plating layer 30 in which the amount of vanadium is great and the barrier
properties are excellent. In addition, when the current density exceeds 200 Ndm2
,
plating structures become coarse or cracks are likely to be generated, and thus there is
a concern that the adhesion between the plating layer 30 and the steel sheet I may
degrade.
[0089]
The average flow rate of the plating bath 2 in the plating tank 21 during
plating is preferably in a range of20 to 300m/min and more preferably in a range of
40 to 200m/min. When the average flow rate of the plating bath 2 is in a range of20
- 35 -
to 300m/min, it is possible to prevent the generation of cracks in the plating layer 30
and supply ions to the surface of the steel sheet I from the plating bath 2 without any
hindrance.
[0090]
As the plating bath 2, a plating bath including a V compound and a Zn
compound is used. Meanwhile, to the plating bath 2, in addition to the V compound
and the Zn compound, a pH adjuster, metal compounds other than the V compound and
the Zn compound, and additives may be added as necessary.
Examples of the pH adjuster include H2S04, NaOH, and the like.
Examples of the additives include Na2S04 and the like which stabilize the
electric conductivity of the plating bath 2.
[0091]
Examples of other metal compounds include nickel compounds such as
NiS04 · 6H20 and the like. When the plating bath 2 includes a nickel compound, the
concentration orNe+ in the plating bath 2 is preferably O.Olmol/1 or more. ln such a
case, the plating layer 30 including a sufficient amount of nickel can be formed. The
plating layer 30 including nickel is capable of providing excellent plating adhesion,
which is preferable.
[0092]
Examples of the Zn compound that is used in the plating bath 2 include
metallic Zn, ZnS04·?H20, ZnC03, and the like. These Zn compounds may be used
singly or two or more zinc compounds may be jointly used.
In addition, examples of the V compound that is used in the plating bath 2
include ammonium (V) metavanadate, potassium (V) metavanadate, sodium (V)
metavanadate, VO(CsH102)2 (vanadyl acetylacetonate (IV)), VOS04·SH20 (vanadyl
- 36 -
sulfate (IV)), and the like. These V compounds may be used singly or two or more
vanadium compounds may be jointly used.
[0093]
As the plating bath 2, a plating bath including Zn2+ and V02+ is preferably
used.
When the plating bath 2 includes Zn2+, the concentration of Zn2+ is preferably
0.10 to 4.00 mol/! and more preferably 0.35 to 2.00 mol/!.
When the plating bath 2 includes V02+, the concentration ofV02+ in the
plating bath 2 is preferably O.Olmol/1 or more and less than 2.00 mol/!. When the
plating bath 2 including V02+ in the above-described range is used, it is possible to
easily form the plating layer 30 in which the amount of vanadium is great and the
barrier property is excellent. When the amount ofV02+ in the plating bath 2 is below
the above-described range, it becomes difficult to ensure the amount of vanadium in
the plating layer 30. In addition, when the amount ofV02+ in the plating bath 2 is
above the above-described range, a large amount of expensive vanadium is used in the
plating bath 2, which becomes economically disadvantageous.
[0094]
In addition, as the plating bath 2, a plating bath including 0.10 mol/! or more
ofNa +in the plating bath 2 is preferably used. In this case, it is possible to enhance
the electric conductivity of the plating bath 2 and easily form the plating layer 30 in the
present embodiment.
[0095]
The temperature of the plating bath 2 is not particularly limited, but is
preferably in a range of 40°C to 60°C in order to easily and efficiently form the plating
layer 30 in the present embodiment.
- 37 -
In addition, the pH of the plating bath 2 is preferably in a range of 1 to 5 and
more preferably in a range of I .5 to 4 in order to easily form the plating layer 30 in the
present embodiment.
[0096]
In the present embodiment, after the formation ofthe plating layer 30, the
surface layer 40 is preferably formed on the plating layer 30 as necessary by applying a
treatment agent that improves a barrier property, fingerprint resistance, flaw resistance,
lubricity, designability, and the like.
Through the above-described process, the surface-treated steel sheet 10 shown
in Fig. I can be obtained.
[0097]
"Second embodiment, surface-treated steel sheet 21 0"
Hereinafter, a surface-treated steel sheet 2 I 0 of a second embodiment when a
plating layer 230 contains zirconium will be described.
The surface-treated steel sheet 210 of the present embodiment includes a steel
sheet 201 and a plating layer 230 formed on one surface or both surfaces of the steel
sheet. The plating layer 230 includes zinc and zirconium. In addition, the plating
layer 230 has dendrite-shaped ctystals 23 I including metallic zinc and intercrystal
filling regions 232 including one or both of a hydrated zirconium oxide and a
zirconium hydroxide. Hereinafter, the surface-treated steel sheet 210 will be
described in detail.
[0098]
The steel sheet 201 is the same as the steel sheet 1 in the first embodiment and
thus will not be described.
[0099]
" 38 "
i I
As described above, the plating layer 230 has the dendrite-shaped crystals 231
including metallic zinc and the intercrystal filling regions 232 including one or both of
a hydrated zirconium oxide and a zirconium hydroxide.
The dendrite-shaped ctystal 231 is a dendrite-shaped crystal phase including
metallic zinc, and the intercrystal filling region 232 includes one or both of a hydrated
zirconium oxide and a zirconium hydroxide, is formed in the peripheries of the
dendrite-shaped crystal 231, and has an amorphous pattern in electron beam diffraction.
The plating layer 230 has an aspect in which the dendrite-shaped crystals 231
are precipitated earlier, and then the intercrystal filling regions 232 are precipitated in
the peripheries of the dendrite-shaped crystals 231.
[0100]
As described above, the dendrite-shaped crystal 31 in the first embodiment
has the inside 3a and the surface layer 3b. As described above, the inside 3a of the
dendrite-shaped crystal 31 preferably includes metallic zinc and may include other
metal components such as nickel. On the other hand, the surface layer 3b of the
dendrite-shaped ctystal 31 preferably includes a zinc oxide or a zinc hydroxide and
more preferably include crystals of a hydrated zinc oxide. Meanwhile, the dendriteshaped
crystal 231 in the present embodiment does not have any insides and any
surface layers.
The dendrite-shaped crystal 231 may be formed of metallic zinc alone and
may include, in addition to metallic zinc, other metal components having a higher
precipitation potential than zinc such as nickel. In addition, the dendrite-shaped
crystals 231 grow from the steel sheet 201 side toward the plating layer 230 surface
side along the thickness direction of the plating layer 230 and have a structure of being
branched toward the surface of the plating layer 230. When the dendrite-shaped
- 39
ij
crystals 231 include metallic zinc, it is possible to impart a sacrificial protection
property to the plating layer 230.
[0101]
The intercrystal filling region 232 may include a zinc oxide in addition to one
or both of the hydrated zirconium oxide and the zirconium hydroxide. When the
intercrystal filling regions 232 include the above-described substances, it is possible to
impart a barrier property to the plating layer 230. In addition, since the intercrystal
filling regions 232 include the hydrated oxide or the hydroxide as a main body, it is
possible to ensure coating film adhesion when coating films are formed in the
intercrystal filling regions 232.
The intercrystal filling regions 232 show amorphous diffraction patterns when
electron beam diffraction is carried out.
[0102]
When the intercrystal filling region 232 includes the hydrated zirconium oxide
or the zirconium hydroxide and a zinc oxide, the molar ratio (Zr/Zn) of zirconium to
zinc in the intercrystal filling regions 232 is preferably 1.00 or more and 3.00 or less.
When the molar ratio (Zr/Zn) is in the above-described range, and the intercrystal
filling regions 232 show amorphous diffraction patterns when electron beam
diffi·action is carried out, arr excellent corrosion resistarrce (barrier property) and
excellent coating film adhesion can be obtained.
[0103]
On the plating layer 230, an amorphous layer 250 showing amorphous
diffraction patterns when electron beam diffraction is carried out may be formed.
The amorphous layer 250 is assumed to be a layer that is first formed during
the formation of the plating layer 230. That is, it is assumed that the amorphous layer
- 40 -
250 is first formed on the steel sheet 201 and then the plating layer 230 including the
dendrite-shaped crystals 231 and the intercrystal filling regions 232 grows between the
steel sheet 201 and the amorphous layer 250.
[0104]
The amorphous layer 250 is a layer including zirconium oxide as a main body
and may include a small amount of zinc. The amorphous layer 250 shows a barrier
property when formed on the plating layer 230.
[0105]
After the formation of the plating layer 230, the steel sheet 201 having the
plating layer 230 is immersed in an acidic solution, whereby the amorphous layer 250
can be removed. Through the above-described process, the amorphous layer 250 may
be removed from the surface-treated steel sheet 20 I.
When the amorphous layer 250 is removed, the plating layer 230 is exposed.
The surface of the plating layer 230 has a higher surface roughness than the amorphous
layer 250 and superior coating film adhesion compared with a case in which the
amorphous layer 250 is formed.
[0106]
The adhered amount of the plating layer 230 is preferably I g/m2 or more and
preferably 3 gjm2 or more in order to improve the barrier property. In addition, the
adhered amount of the plating layer 230 is preferably 60 gjm2 or less, more preferably
40 gjm2 or less, and stillmore preferably 20 gjm2 or less. When the adhered amount
of the plating layer 230 is 20 gjm2 or less, the amount of metal being precipitated is
smaller compared with that in electrogalvanizing of the related art (generally,
approximately 20 g/m2
). In addition, when the adhered amount is too large, it
becomes easy for cracks to be generated in the plating layer 230.
- 41 -
[0107]
The thickness of the plating layer 230 is preferably in a range of0.5 to 40 fUll,
more preferably in a range of 1.0 to 20 fllll, and still more preferably in a range of 2.0
to 15 fUll. When the thickness of the plating layer 230 is the lower limit or more, the
barrier property can be improved. In addition, when the thickness of the plating layer
230 is the upper limit or less, it becomes difficult for cracks to be generated in the
plating layer 230. The thickness of the plating layer 230 can be controlled by
adjusting the amount of electric power that is conducted dnring electroplating.
[0108]
The thickness of the amorphous layer 250 is preferably in a range of0.20 to
2.00 f!m, more preferably in a range of0.30 to 1.50 f!m, and still more preferably in a
range of0.50 to LOO f!m. When the thickness of the amorphous layer 250 is the
upper limit or more, it is possible to impart the barrier property to the plating layer 230.
In addition, when the thickness of the amorphous layer 250 is the lower limit or less, it
is possible to ensnre the barrier property by preventing the generation of cracks. The
thickness of the amorphous layer 250 can be controlled by adjusting the concentration
ofZr in the plating bath during electroplating. That is, as the concentration ofZr in
the plating bath during electroplating increases, it is possible to increase the thickness
of the amorphous layer 250.
[0109]
The plating layer 230 is made of, in terms of the average concentration, Zr: 3
to 40 atm%, Zn: 3 to 40 atm%, residual oxygen, and impurities. When the
concentration ofZr in the plating layer 230 is 3 atm% or more, it is possible to enhance
the barrier property. In addition, when the concentration of Zr in the plating layer 230
is 40 atm% or less, it is possible to ensure the barrier property by preventing the
- 42 -
generation of cracks in the plating layer 230. In addition, when the concentration of
Zn in the plating layer 230 is 3 atm% or more, it is possible to impart a sacrificial
protection effect to the plating layer 230. In addition, when the concentration of Zn in
the plating layer 230 is 40 atm% or less, it is possible to relatively ensure the amount
ofZr and improve the barrier property of the plating layer 230.
[0 II 0]
The dendrite-shaped crystal 231 includes metallic Zn as described above and
may additionally include Ni and the like.
For the dendrite-shaped crystals 231, diffraction patterns attributed to the
crystal structures can be obtained when electron beam diffraction is carried out on a
cross section of the plating layer 230 using a transmission electron microscope (TEM).
[Olll]
The intercrystal filling region 232 is made of, in terms of the average
concentration, Zr: 10 to 80 atm%, Zn: 3 to 40 atm%, residual oxygen, and impurities.
When the concentration of Zr in the intercrystal filling region 232 is 10 atm% or more,
it is possible to enhance the barrier property. In addition, when the concentration of
Zr in the intercrystal filling region 232 is 80 atm% or less, it is possible to ensure the
barrier property by preventing the generation of cracks in the plating layer 230. In
addition, when the concentration of Zn in the intercrystal filling region 232 is 3 atm%
or more, it is possible to enhance the barrier property. In addition, when the
concentration of Zn in the intercrystal filling region 232 is 40 atm% or less, it is
possible to relatively ensure the amount ofZr and improve the barrier property of the
plating layer 230.
[0112]
The amorphous layer 250 is made of, in terms of the average concentration,
- 43 -
Zr: 10 to 60 atm%, Zn: 0 to 15 atm%, residual oxygen, and impurities. When the
concentration ofZr in the amorphous layer 250 is 10 atm% or more, it is possible to
enhance the barrier property. In addition, when the concentration of Zr in the
amorphous layer 250 is 60 atm% or less, it is possible to ensure the barrier property by
preventing the generation of cracks. The amorphous layer 250 may include a small
amount of Zn or no Zn.
[0113]
Similar to the first embodiment, a base-material layer 220 may be formed
between the steel sheet 201 and the plating layer 230.
[0114]
Similar to the first embodiment, a surface layer 240 may be formed on the
plating layer 230 (the amorphous layer 250 when the amorphous layer 250 is formed).
[0115]
The surface-treated steel sheet 210 of the present embodiment has an L * value,
which represent the brightness, of 40 or less and has a black external appearance.
The black external appearance makes the surface-treated steel sheet available in a
variety of fields. When the L *value exceeds 40, it is difficult to use the steel sheet as
a material having a black external appearance. Particularly, when the concentration
of Zr in the plating layer 230 is set to 5% by mass or more, it is possible to reliably set
to the L * value to 40 or less.
[0116]
In addition, regarding the surface-treated steel sheet 210 of the present
embodiment, an example in which the plating layer 230 is formed on the steel sheet
20 I has been described, but the present embodiment is not limited thereto, and the
plating layer 230 in the present embodiment may be formed on galvanized layers in
-44 -
electro galvanized steel sheets, hot -dip galvanized steel sheets, and galvannealed steel
sheets. That is, a second galvanized layer (not shown) containing zinc may be further
formed between the steel sheet 201 and the plating layer 230. When the second
galvanized layer (not shown) is further formed, the corrosion resistance of the surfacetreated
steel sheet 210 can be further improved. For example, even when corrosive
substances pass through the plating layer 230, a sacrificial protection effect can be sho
wed due to the second galvanized layer (not shown), and the corrosion resistance of the
surface-treated steel sheet 210 can be improved.
[0117]
"Method for manufacturing surface-treated steel sheet 21 0"
Next, a method for manufacturing the surface-treated steel sheet 210 will be
described. The method for manufacturing the surface-treated steel sheet 210 and the
method for manufacturing the surface-treated steel sheet I according to the first
embodiment are different from each other only in terms of the composition of the
plating bath and are the same as each other in terms of the other facts.
[0118]
Similar to the first embodiment, the method for manufacturing the surfacetreated
steel sheet 210 has the base-material-forming process and the upper layer
plating process. In the base-material-forming process and the upper layer plating
process, the same plating bath is used, and a plating bath including a Zr compound
(Zr02l and a Zn compound (Zn2l is used.
The Zr compound is preferably a compound that forms Zr02
+ ions in the
plating bath, and examples thereof include soluble salts such as zirconium nitrate oxide,
zirconium sulfate oxide, and zirconium nitrate chloride oxide. These Zr compounds
may be used singly or two or more Zr compounds may be jointly used.
- 45 -
I I
[0119]
The plating bath preferably includes 0.10 to 4.00 moll! of Zn2
+ and more
preferably includes 0.50 to 2.00 moll! of Zn2+ In addition, the plating bath preferably
includes 0.10 to 4.00 mol/! ofZr02+ and more preferably includes 0.50 to 2.00 moll! of
Zr02+. When a plating bath including Zr02+ in the above-described range is used, it
is possible to easily form the plating layer 230 having a high amount ofZr and an
excellent barrier property. When the amount of Zr02
+ in the plating bath is below the
above-described range, it becomes difficult to ensure the amount of Zr in the plating
layer 230. In addition, when the amount of Zr02+ in the plating bath is above the
above-described range, a large amount of Zr is used in the plating bath 2, which
becomes economically disadvantageous.
[0120]
To the plating bath, in addition to the Zr compound and the Zn compound, a
pH adjuster, metal compounds other than the Zr compound and the Zn compound,
additives, and the like may be added as necessary.
[0121]
The current densities in the base-material-forming process and the upper layer
plating process are the same as those in the first embodiment and thus will not be
described.
[0122]
"Other examples"
The present invention is not limited to the above-described embodiments.
The present embodiment has been described using a case in which the plating
layers are fonned on both surfaces of the steel sheet as an example, but the plating
layer may be formed only on one surface of the steel sheet.
- 46 -
I I
In addition, it is preferable that the base-material layer is formed between the
steel sheet and the plating layer, but the base-material layer may not be formed. In
addition, when the plating layers are formed on both surfaces of the steel sheet, the
base-material layer may be formed only between one surface of the steel sheet and the
plating layer.
[0123]
In the present embodiment, a case in which the plating layer includes
vanadium and a case in which the plating layer includes zirconium have been
separately described, but these embodiments may be included at the same time.
[0124]
In addition, the present embodiment has been described using a case in which
the surface layer is fanned on the surface of the plating layer as an example, but the
surface layer may not be fanned. The surface-treated steel sheet of the present
embodiment has an excellent barrier property, and thus the surface layer for improving
the barrier property may not be formed on the surface of the plating layer. In addition,
when the plating layers are formed on both surfaces ofthe steel sheet, the surface layer
may be formed on the surface of the plating layer only on one surface.
[0125]
In addition, the present embodiment has been described using a case in which
the surface-treated steel sheet is manufactured using the plating apparatus shown in Fig.
3 as an example, but the plating apparatus for manufacturing the surface-treated steel
sheet is not limited to the plating apparatus shown in Fig. 3. For example, in the
plating apparatus shown in Fig. 3, four positive electrodes 3 are disposed, but the
number of the positive electrodes 3 is not limited. In addition, the sizes and shapes of
the plating tank 21, the steel sheet I, and the positive electrode 3, the dispositions and
- 47 -
shapes of the upper pmtion supply pipe 2a and the lower pmtion supply pipe 2b are not
particularly limited and can be appropriately determined depending on the applications
and the like of the surface-treated steel sheet I 0.
Example I
[0126]
"Test results of vanadium-containing surface-treated steel sheet"
A surface-treated steel sheet having plating layers including vanadium on both
surfaces of a steel sheet was produced using the plating apparatus shown in Fig. 3 and
a method described below and was evaluated.
A plating bath in a fluid state was prepared by circulating a plating bath
having a plating bath composition, a temperature, and a pH shown in Table I at a
relative average flow rate of I 00 m/min.
- 48 -
[0127]
[Table 1]
Plating bath composition (molll) Plating batb temperature Plating bath pH
Zu2+ V(VH)+{V02+) Na+ Ni2 .. ("C)
Bath (Zn-V) 1.0 0.8 L3 0.1 50 2.2
Bath (Zn) 1.0 - - - 50 1.0
[0128]
As the steel sheet, a 0.5 mm-thick SPCD steel sheet which is a drawing
quality cold-rolled steel sheet defined by JIS 0 3141 was used.
A pretreatment (nickel plating) was carried out on the steel sheet, and the steel
sheet was used as a negative electrode.
In the pretreatment, first, as a plating bath for the nickel plating, ion exchange
water, dense sulfuric acid, and NiS04·6H20 were mixed together, thereby adjusting a
plating bath having a concentration ofNi2
+ of 60 giL and a pH at 60°C of2.0. In
addition, the steel sheet was immersed in the plating bath, and an electrolytic treatment
was carried out using the steel sheet as a negative electrode and a platinum electrode as
a positive electrode so that the adhered amount ofNi reached 200 mglnl.
In a base-material-forming process and an upper layer plating process,
individual electric conduction times were set to times shown in Table 2 and Table 3,
and a plating layer was formed using an electroplating method.
- 49 -
[0129]
[Table 2]
Base-material-forming process Upper layer plating process
Example Plating bat1t
(Seconds) Current density
(Seconds)
Current density
A/dm2 A/dnl
VI Bath (Zn-V) 8 10 3 100
V2 Bath (Zn-V) 4 10 3 100
V3 Bath (Zn-V) 2 10 3 100
V4 Bath (Zn-V) I 10 3 100
V5 Bath (Zn-V) 0.5 10 3 100
V6 Bath (Zn-V) 0.2 10 3 100
V7 Bath (Zn-V) 0.05 10 3 100
V8 Bath (Zn-V) I 18 3 100
V9 Bath (Zn-V) I 5 3 100
VlO Bath (Zn-V) 4 18 3 100
VII Bath (Zn-V) 4 14 3 100
Vl2 Bath (Zn-V) 4 5 3 100
Vl3 Bath (Zn-V) 4 0 3 100
Vl4 Bath (Zn-V) I 10 6 100
Vl5 Bath (Zn-V) I 10 12 100
Vl6 Bath (Zn-V) I 10 3 150
Vl7 Bath (Zn-V) I 10 3 50
Vl8 Bath (Zn-V) I 10 3 100
Vl9 Bath (Zn-V) I 10 3 100
V20 Bath (Zn-V) I 10 3 100
[0130]
[Table 3]
Comparati\'C
Base-matcrial-fonning process Upper layer plating process
Example Plating bath
(Seconds)
Current density
(Seconds)
Current density
Aldm2 A/dm2
XI Bath (Zn-V) 0 - 15 21
X2 Bath (Zn-V) 4 25 3 100
X3 Bath (Zn-V) I 25 3 100
X4 Bath (Zn-V) 0 - 18 18
X5 Bath (Zn-V) 0 - 3 100
X6 Bath (Zn) I 10 12 100
X7 Bath (Zn-V) 12 10 3 100
[0131]
Meanwhile, in the plating bath composition shown in Table I, ZnS04 · ?H20
was used as a Zn compound, VOS04 · SH20 was used as a V compound, and
furthermore, Na2S04 and, as another metal compound, NiS04·6H20 were used as
necessary. The amounts thereof were adjusted so as to obtain the concentrations of
I I
[0132]
The plating layers of examples and comparative examples obtained as
described above were observed using a field-emission transmission electron
microscope (FE-TEM) (manufactured by JEOL Ltd. (JED-2100F)).
[0133]
Fig. SA to Fig. 5C are the transmission electron microscopic (TEM)
photographs of a plating layer in a surface-treated steel sheet of Example V4. Fig. SA
is a cross sectional photograph in the entire thickness direction of the plating layer 30
fanned on the steel sheet 1, Fig. 58 is an enlarged photograph of an interface portion
between the steel sheet and the plating layer in the cross section of Fig. SA, and Fig.
5C is an enlarged photograph of dendrite-shaped crystals and peripheral portions
thereof in the cross section of Fig. SA.
[0134]
In Fig. 58, a reference symbol 51 indicates a base-material layer, and a
reference symbol 52 indicates an intercrystal filling region in the vicinity of an
interface between the steel sheet and the plating layer. In addition, in Fig. 5C, a
reference symbol 53 indicates a dendrite-shaped crystal, a reference symbol 54 ·
indicates an interctystal filling region, and a reference symbol 55 indicates a surface
layer fanned on the surface of the dendrite-shaped crystal.
[0135]
As shown in Fig. SA to Fig. 5C, in the surface-treated steel sheet of Example
V4, dendrite-shaped crystals, intercrystal filling regions, and the surface layers of the
dendrite-shaped crystals were formed in the plating layer.
[0136]
- 51 -
Similar to Example V4, the plating layers in the surface-treated steel sheets of
Examples VI to V3 and V5 to V20 were observed using TEM. As a result, dendriteshaped
crystals, intercrystal filling regions, and the surface layers of the dendriteshaped
crystals were formed in the plating layers.
[0137]
The plating layer in the surface-treated steel sheet of Example V4 was
observed using a scanning electron microscope (SEM: A-4300SE manufactured by
Hitachi, Ltd.) in a cross section direction. The plating layer was observed after a gold
film was deposited on the surface of the plating layer in order to facilitate the
observation of the surface shape of the plating layer.
Fig. 6 is a scanning electron microscopic (SEM) photograph of the plating
layer in the surface-treated steel sheet of Example V4. In Fig. 6, a reference symbol
56 indicates a dendrite-shaped crystal, a reference symbol 57 indicates an intercrystal
filling region disposed between dendrite-shaped crystals, and a reference symbol 58
indicates a surface layer covering the surface of the dendrite-shaped crystal.
Meanwhile, in the photograph shown in Fig. 6, white portions on the surface of the
plating layer are the gold film deposited to observe the plating layer.
[0138]
Similar to the plating layer in Example V4, in the plating layers in the surfacetreated
steel sheets of Examples VI to V3 and V5 to V20, dendrite-shaped crystals,
intercrystal filling regions, and the surface layers of the dendrite-shaped crystals were
formed.
[0139]
Similar to Example V4, the plating layers in the surface-treated steel sheets of
Comparative Example xl to Comparative Example x7 were observed using SEM.
- 52 -
i I
Fig. 7 is a scanning electron microscopic (SEM) photograph of the plating layer in the
surface-treated steel sheet of Comparative Example x2. As shown in Fig. 7, the
plating layer in Comparative Examples x2 was a single phase made of a dendriteshaped
c1ystal.
[0140]
For the plating layers in Examples VI to Example V20, elements in the
dendrite-shaped crystals, the intercrystal filling regions, and the surface layers of the
dendrite-shaped crystals were each analyzed using an energy dispersive X -ray analyzer
(EDS) (manufactured by JEOL (JED-2300T)). In addition, elements (composition) in
the dendrite-shaped crystals, elements (composition) in the intercrystal filling regions,
the amount of vanadium, the amount of zinc, and elements (composition) in the surface
layers of the dendrite-shaped crystals were investigated.
In addition, the molar ratio (V/Zn) of the amount of vanadium to the amount
of zinc in the intercrystal filling regions was computed using the results of the element
analyses.
[0141]
For the plating layers in Comparative Example xl to Comparative Example
x7 as well, elements in the dendrite-shaped crystals, the intercrystal filling regions, and
the surface layers of the dendrite-shaped crystals were analyzed in the same mmmer as
in Example VI to Example V20.
The results are shown in Table 4 and Table 5.
- 53 -
·mrwrmr!Wi
[0142]
[Table 4]
(A) Dendrite-shaped crystal (B) Intcrcrystal filling region
(C) Surface layer of dendrite~
shaped cryst:ll Lower layer plating
Exnmplo
Presence or a Ptcscneo or V/Zn molar Presence or Presence or a Adhered
bscncc
Composition
absence
Composition
ratio absence
Composition
bsenee
Composition amount (g/m~)
V1 Present Zn (hexagonal) Present Zn, V, 0 (amorphous) 0.20 Present ZoO ( cryst:ll) Absent - -
V2 Present Zn (hexagonal) Present Zn, V, 0 (amorphous) 1.20' Present ZnO (crystal) Absent - -
V3 Present Zn (hexagonal) Present Zn, V, 0 (amorphous) 0.80 Present ZnO (crystal) Absent - -
V4 Present Zn (hexagonal) Present Zn. V. 0 (amorphous) 0.60 Present ZnO (crystal) Absent - -
V5 Present Zn (hexagonal) Present Zn. V, 0 (amorphous) 0.40 Present ZoO (crystal) Abscnt - -
V6 Present Zn (hexogonol) Present Zn, V, 0 (amorphous) 0.30 Present ZnO (cryst:ll) Absent - -
V7 Present Zn (hexagonal) Present Zn, V, 0 (amorphous) 0.20 Present ZnO (crystal) Absent - -
V8 Present Zn (hexagonal) Present Zn. V, 0 (amorphous) 0.70 Present ZnO (crystal) Absent - -
V9 Present Zn (hexogonal) Present Zn. V, 0 (amorphous) 0.50 Present ZnO (crystal) Absent - -
V10 Present Zn (hexogonal) Present Zn, V. 0 (amorphous) 0.30 Present ZnO (cryst:ll) Absent - -
Vll Present Zn (hexagonal) Present Zn. V. 0 (amorphous) 0.80 Present ZnO (cryst:ll) Absent - -
V12 Present Zn (hexagonal) Present Zn, V, 0 (amorphous) 0.90 Present ZnO (crystal) Absent - -
V13 Present Zn (hcx:~.gonal) Present Zn, V, 0 (runorphous) 0.15 Present ZoO (crystal) Absent - -
V14 Present Zn (hexagonal) Present Zn, V, 0 (amorphous) 0.70 Present ZoO (crystal) Absent - -
VIS Present Zn (hexagon:~.!) Present Zn, V, 0 (amorphous) 0.80 Present ZnO (crystal) Absent - -
V16 Present Zn (hexagonal) Present Zn, V. 0 (amorphous) 0.70 Present ZnO (crystal) Absent - -
V17 Present Zn (hexagonal) Present Zn, V, 0 (amorphous) 0.40 Present ZoO (cryst:ll) Absent - -
V18 Present Zn (hexagonal) Present Zn. V. 0 (amorphous) 0.60 Present ZnO ( cryst:ll) Present Zn 3
V19 Present Zn (hexagonal) Present Zn. V, 0 (amorphous) 0.60 Present ZnO (crystal) Present Zn 10
V20 Present Zn (hcxogonol) Present Zn. V. 0 (amorphous) 0.60 Present ZnO (crystal) Present Zn 20
------
- 54 -
[0143]
[Table 5]
(A) Dcndritc~shapcd crystal (B) Intcrcrystal filling region (C) Surfncc layer of dcndritcM ComparatiYe shaped crys!