Zn-1.5%Al-1.5%Mg镀层汽车板质量评价
Quality evaluation of Zn-1.5%Al-1.5%Mg coated automotive sheets
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摘要: 基于某热镀锌产线生产的镀层成分为Zn-1.5%Al-1.5%Mg锌铝镁镀层CR3钢板(CR3-ZM70钢板)和纯锌镀层CR3钢板(CR3-Z70钢板),对其镀层物相进行了分析,并对其冲压成形性能、焊接性能、涂装性能、胶接和耐蚀服役性能进行了实验分析,评价了锌铝镁镀层钢板替代纯锌镀层钢板应用于汽车车身的可行性。结果表明:锌铝镁镀层由纯锌相、锌镁二元相和锌铝镁三元相组成,各物相晶粒尺寸均不大于50 μm,远小于纯锌镀层的物相;锌铝镁镀层因添加了Al、Mg元素,具有更多的表面氧化物。锌铝镁镀层纳米硬度较纯锌镀层高33%以上。CR3-ZM70钢板表面摩擦因数较CR3-Z70钢板小27%,多次摩擦实验后,CR3-ZM70钢板表面摩擦因数更稳定;CR3-ZM70钢板冲压脱落量较CR3-Z70钢板少72%;CR3-ZM70钢板和CR3-Z70钢板焊接电流窗口宽度相近,焊核尺寸无明显差异;CR3-ZM70钢板电泳漆膜各项性能指标均能达到CR3-Z70钢板水平,两者磷化膜晶粒尺寸均不大于10 μm;CR3-ZM70钢板部分减震胶和点焊胶达不到CR3-Z70钢板内聚断裂水平;在同等中性盐雾实验条件下,CR3-ZM70钢板的耐蚀性能是CR3-Z70钢板的3倍,在电泳后裸露基板的循环腐蚀实验中,CR3-ZM70钢板的耐蚀性能也明显优于CR3-Z70钢板。由实验结果可以得出:锌铝镁镀层钢板的冲压成形性能、耐腐蚀服役性能优于纯锌镀层钢板,焊接性能、涂装性能与纯锌镀层钢板相近,但其胶接应用性能较纯锌镀层钢板差,具备替换纯锌镀层钢板应用于汽车车身的条件,但无法完全等效替代。Abstract: Based on a hot-dip galvanized CR3 sheet with a Zn-1.5%Al-1.5%Mg zinc-aluminum-magnesium coating (CR3-ZM70) and a pure zinc-coated CR3 sheet (CR3-Z70), the coating phasesare analyzed and the forming performance, weldability, paintability, adhesion properties, and corrosion resistance in service are experimentally analyzed. The feasibility of replacing pure zinc-coated sheets with Zn-Al-Mg-coated sheets in automotive body applications is assessed. The results demonstrate that the Zn-Al-Mg coating consists of pure zinc, zinc-magnesium binary, and zinc-aluminum-magnesium ternary phases, with all phase grain sizes 50 μm or small and significantly smaller than those of the pure zinc coating. The addition of Al and Mg increases surface oxide formation on the Zn-Al-Mg coating. Its nano-hardness exceeds that of pure zinc coating by over 33%. The surface friction coefficient of CR3-ZM70 is 27% lower than CR3-Z70, and it exhibits better friction stability after repeated tests. CR3-ZM70 shows 72% less stamping scale-off compared to CR3-Z70. The welding current window width and nugget size are comparable between the two coatings. Both achieve equivalent electrocoating performance, with phosphating film grain sizes 10 μm or small. However, CR3-ZM70 exhibits lower cohesive fracture performance in some structural adhesives and spot welding pastes. Under identical neutral salt spray conditions, CR3-ZM70 demonstrates three times the corrosion resistance of CR3-Z70, with significantly better cyclic corrosion resistance in post-electrocoating exposed substrate tests. The experimental results confirm that Zn-Al-Mg-coated sheets outperform pure zinc-coated sheets in forming performance and corrosion resistance, while showing comparable weldability and paintability. However, their adhesion property is inferior to that of pure zinc-coated sheets. Thus, Zn-Al-Mg coatings are viable substitutes for automotive body applications but cannot fully replace pure zinc coatings.
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