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An examination of the corrosion resistance of zinc-magnesium and zinc-aluminium-magnesium coated steels. / Chris Weirman

Swansea University Author: Chris Weirman

Abstract

This project has investigated the development of the optimum combination levels andprocessing conditions for zinc and magnesium coatings deposited by a Physical VapourDeposition (PVD) process under investigation by Tata Steel Europe Ltd.Temperatures in the range of 100°C to 350°C and times ranges of...

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Published: 2011
Institution: Swansea University
Degree level: Doctoral
Degree name: EngD
URI: https://cronfa.swan.ac.uk/Record/cronfa43111
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spelling 2018-09-03T10:34:41.5775434 v2 43111 2018-08-02 An examination of the corrosion resistance of zinc-magnesium and zinc-aluminium-magnesium coated steels. 518160df73809f7d82664cefb5e13a73 NULL Chris Weirman Chris Weirman true true 2018-08-02 This project has investigated the development of the optimum combination levels andprocessing conditions for zinc and magnesium coatings deposited by a Physical VapourDeposition (PVD) process under investigation by Tata Steel Europe Ltd.Temperatures in the range of 100°C to 350°C and times ranges of 2-10 hours and 30 -300 seconds were investigated and the coatings characterised by optical microscopy,scanning electron microscopy (SEM) with energy dispersive x-ray analysis, (EDX), alsoknown as electron probe microanalysis (EPMA), glow discharge optical emissionspectrophotometry (GDOES) and x-ray diffraction (XRD), and examined for corrosionresistance using the scanning vibrating electrode technique (SVET) and acceleratedweathering cabinet tests; prohesion and salt spray.The work has shown that the initial zinc magnesium coatings prepared via the developingTata Steel Europe PVD process did not perform as well as the current and developing hotdipped zinc-aluminium or zinc-aluminium-magnesium alloys in continuously submergedsodium chloride solutions.In support of this work, and to contrast the coatings prepared via the PVD process theproject investigated changes to the coating composition and substrate gauge of a range ofconventionally prepared hot dip galvanised samples. This part of the project has lookedat variations in the alloying additions to zinc using magnesium in the range of 0-2wt%and aluminium in the range of 0-5wt%.Changing coating composition and/or changing processing conditions produced coatingswith dendrites per mm2 (dendrite number) ranging from 350 to 7600. Primary zinc% hasalso been found to vary in the range of 29% to 95% and the relative corrosion rates havebeen found to vary between 49% and 477% that of benchmark samples of conventionalhot-dip galvanised steel of 275g/m2.Conventional and more recently developed coatings have been studied in mildly alkalineenvironments by immersion mass loss and SVET testing, as part of a study to investigateif Tata Steel Europe can substitute a lower coating weight, newly developed MagiZincmetallic coating into construction industry in the UK. It was found that both conventionaland the new alloy chemistries were seen to have sufficient coating weight after the 28days, the total cement curing time, to allow the substitution. E-Thesis Metallurgy 31 12 2011 2011-12-31 COLLEGE NANME Engineering COLLEGE CODE Swansea University Doctoral EngD 2018-09-03T10:34:41.5775434 2018-08-02T16:24:31.3034091 College of Engineering Engineering Chris Weirman NULL 1 0043111-02082018162547.pdf 10821503.pdf 2018-08-02T16:25:47.4800000 Output 27892011 application/pdf E-Thesis true 2018-08-02T16:25:47.4800000 false
title An examination of the corrosion resistance of zinc-magnesium and zinc-aluminium-magnesium coated steels.
spellingShingle An examination of the corrosion resistance of zinc-magnesium and zinc-aluminium-magnesium coated steels.
Chris Weirman
title_short An examination of the corrosion resistance of zinc-magnesium and zinc-aluminium-magnesium coated steels.
title_full An examination of the corrosion resistance of zinc-magnesium and zinc-aluminium-magnesium coated steels.
title_fullStr An examination of the corrosion resistance of zinc-magnesium and zinc-aluminium-magnesium coated steels.
title_full_unstemmed An examination of the corrosion resistance of zinc-magnesium and zinc-aluminium-magnesium coated steels.
title_sort An examination of the corrosion resistance of zinc-magnesium and zinc-aluminium-magnesium coated steels.
author_id_str_mv 518160df73809f7d82664cefb5e13a73
author_id_fullname_str_mv 518160df73809f7d82664cefb5e13a73_***_Chris Weirman
author Chris Weirman
author2 Chris Weirman
format E-Thesis
publishDate 2011
institution Swansea University
college_str College of Engineering
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hierarchy_top_id collegeofengineering
hierarchy_top_title College of Engineering
hierarchy_parent_id collegeofengineering
hierarchy_parent_title College of Engineering
department_str Engineering{{{_:::_}}}College of Engineering{{{_:::_}}}Engineering
document_store_str 1
active_str 0
description This project has investigated the development of the optimum combination levels andprocessing conditions for zinc and magnesium coatings deposited by a Physical VapourDeposition (PVD) process under investigation by Tata Steel Europe Ltd.Temperatures in the range of 100°C to 350°C and times ranges of 2-10 hours and 30 -300 seconds were investigated and the coatings characterised by optical microscopy,scanning electron microscopy (SEM) with energy dispersive x-ray analysis, (EDX), alsoknown as electron probe microanalysis (EPMA), glow discharge optical emissionspectrophotometry (GDOES) and x-ray diffraction (XRD), and examined for corrosionresistance using the scanning vibrating electrode technique (SVET) and acceleratedweathering cabinet tests; prohesion and salt spray.The work has shown that the initial zinc magnesium coatings prepared via the developingTata Steel Europe PVD process did not perform as well as the current and developing hotdipped zinc-aluminium or zinc-aluminium-magnesium alloys in continuously submergedsodium chloride solutions.In support of this work, and to contrast the coatings prepared via the PVD process theproject investigated changes to the coating composition and substrate gauge of a range ofconventionally prepared hot dip galvanised samples. This part of the project has lookedat variations in the alloying additions to zinc using magnesium in the range of 0-2wt%and aluminium in the range of 0-5wt%.Changing coating composition and/or changing processing conditions produced coatingswith dendrites per mm2 (dendrite number) ranging from 350 to 7600. Primary zinc% hasalso been found to vary in the range of 29% to 95% and the relative corrosion rates havebeen found to vary between 49% and 477% that of benchmark samples of conventionalhot-dip galvanised steel of 275g/m2.Conventional and more recently developed coatings have been studied in mildly alkalineenvironments by immersion mass loss and SVET testing, as part of a study to investigateif Tata Steel Europe can substitute a lower coating weight, newly developed MagiZincmetallic coating into construction industry in the UK. It was found that both conventionaland the new alloy chemistries were seen to have sufficient coating weight after the 28days, the total cement curing time, to allow the substitution.
published_date 2011-12-31T04:10:49Z
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