Method of coating steel wire with aluminum |
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| 申请号 | US3779056D | 申请日 | 1971-12-28 | 公开(公告)号 | US3779056A | 公开(公告)日 | 1973-12-18 |
| 申请人 | BETHLEHEM STEEL CORP; | 发明人 | BRUGGER J; PADJEN G; HELMAN R; | ||||
| 摘要 | A heavy aluminum coating ranging in thickness from 10 to 15 per cent of the as-coated radius of a wire is provided on steel wire having a nominal diameter of from 0.08 to 0.25 inches by a combination of heating the wire to a temperature within a predetermined range, passing the wire at a predetermined speed related in a substantially inverse ratio to the temperature of the wire through a molten aluminum bath having a predetermined temperature and depth inversely related to each other. The particular operating conditions of the process provide a coating of the desired thickness while operating on a plateau in a curve representing the relationship between the coating thickness and the various combined parameters of the process to provide a readily controllable process of making an easily reproducible, uniform heavy aluminum coating with a very thin interfacial alloy layer on long lengths of ferrous wire. The coated wire is readily redrawable if necessary to attain a desired final gage and strength. | ||||||
| 权利要求 | 1. A method of coating steel wire having an initial diameter of from 0.08 to 0.25 inches with a substantially pure aluminum coating having a thickness of approximately 10 to 15 per cent of the coated wire radius with not more than a very thin iron aluminum alloy layer between the pure aluminum coating and the base metal comprising: a. cleaning the surface of the wire, b. heating the wire to between 980* to 1,060* Fahrenheit within a reducing atmosphere, c. passing the heated wire at a speed of from 70 to 135 feet per minute into a molten aluminum bath below the surface thereof without intermediate contact with oxidizing conditions, said bath being comprised of at least commercially pure alluminum held at a temperature of from approximately 20* to 80* Fahrenheit above the melting point of the molten metal, d. passing said wire through said molten bath for a distance of approximately 0.5 to 4 inches at a speed of from 70 to 135 feet per minute, e. passing the wire from the molten bath, f. maintaining the temperature of the wire as it enters the bath in inverse ratio with respect to the initial wire diameter within the range of approximately 980* to 1,060* Fahrenheit, g. maintaining the distance traveled by the wire through the molten metal bath in direct ratio with respect to the initial diameter of the wire within the range of 0.5 to 4 inches of travel through the molten aluminum bath with a ratio predetermined as to the deeper limit of the molten bath to avoid the initiation of coating slip, and h. maintaining the speed of the wire through the molten aluminum bath within the range of 70 to 135 feet per minute in inverse ratio with respect to the initial diameter of the wire. 2. A method of coating steel wire with a substantially pure aluminum coating according to claim 1 additionally comprising: i. quenching the wire immediately after it passes from said molten bath to solidify at least the surface of the molten coating upon the wire and contacting the wire with a vibration damping means before significant vibration appears in the wire. 3. A method of coating steel wire with aluminum according to claim 2 wherein said vibration damping means is a contacting guide sheave. 4. A method of coating steel wire with aluminum according to claim 2 wherein the wire has an initial fine pearlitic metallurgical structure and additionally comprising: j. drawing said coated wire through a die to reduce the size of the wire and increase its tensile strength. 5. A method of coating steel wire with aluminum according to claim 1 wherein the wire has an initial fine pearlitic metallurgical structure prior to passage through said molten aluminum bath and additionally comprising: j. drawing said coated wire through a reducing die to reduce the size of the wire and increase its tensile strength. 6. A method of coating steel wire with aluminum according to claim 1 wherein the wire has an initial uncoated diameter of 0.145 to 0.22 inches and is coated with an aluminum coating equal to 12 to 14.5 per cent of the coated radius of the wire. 7. A method of coating steel wire with aluminum according to claim 1 wherein the temperature of the wire is controlled within the range of 980* to 1,060* Fahrenheit as it enters the molten aluminum bath in inverse ratio with respect to the initial wire diameter within the range of 0.08 to 0.25 inches with a ratio relationship such that i. a wire having an initial uncoated diameter of 0.08 to 0.15 inches is controlled to have a temperature of between 1,000* and 1,060* Fahrenheit inversely related to the diameter, ii. a wire having an initial uncoated diameter of 0.15 to 0.215 inches is controlled to have a temperature of 980* to 1,040* Fahrenheit inversely related to the diameter, and iii. a wire having an initial uncoated diameter of 0.215 to 0.25 inches is controlled to have a temperature of between 980* to 1,020* Fahrenheit inversely related to the diameter. 8. A method of coating steel wire with aluminum according to claim 7 wherein the distance traveled by the wire through the molten metal bath within a range of 0.5 to 4 inches is controlled in a direct ratio with the initial uncoated wire diameter with a ratio relationship such that i. a wire having a diameter of approximately 0.08 to 0.15 inches will travel through the molten coating bath for approximately 0.5 to 1.5 inches, and ii. a wire having a diameter of approximately 0.15 to 0.25 inches will travel through the molten coating bath for approximately 1.5 to 4 inches. 9. A method of coating steel wire with alumInum according to claim 7 wherein the initial uncoated diameter of the wire is 0.145 to 0.22 inches and the distance traveled by the wire through the molten bath is controlled in a direct ratio with the initial diameter of the wire within a range of 1.5 to 2.5 inches of travel such that the coating applied is equal to 12 to 14.5 per cent of the coated radius of the wire. 10. A method of coating steel wire with aluminum according to claim 8 wherein the speed of the wire through the molten bath within the range of 70 to 135 feet per minute is controlled in inverse ratio with respect to the initial diameter of the wire within the range of 0.08 to 0.25 inches with a ratio relationship such that i. a wire having an initial uncoated diameter of from 0.08 tp 0.15 inchs will have a speed of travel through the molten bath of 100 to 135 feet per minute, ii. a wire having an initial uncoated diameter of from 0.15 to 0.215 inches will have a speed of travel through the molten bath of 72 to 128 feet per minute, and iii. a wire having an initial uncoated diameter of from 0.215 to 0.25 inches will have a speed of travel through the molten bath of from 70 to 100 feet per minute. 11. A method of coating steel wire with aluminum according to claim 8 wherein the initial uncoated diameter of the wire is 0.15 to 0.215 inches and the speed of travel of the wire through the molten bath is controlled within the range of 90 to 120 feet per minute in inverse ratio with respect to the initial diameter of the wire in inches. 12. A method of coating steel wire with aluminum in accordance with claim 10 wherein the wire has an initial fine pearlitic metallurgical structure prior to passage through said molten aluminum bath which remains unchanged after passage of said wire through said bath and additionally comprising: j. drawing said coated wire through a reducing die to reduce the diameter of the wire and increase its tensile strength to specifications. 13. A method of coating steel wire with aluminum according to claim 1 wherein the distance traveled by the wire through the molten metal bath within a range of 0.5 to 4 inches is controlled in a direct ratio with the initial uncoated diameter of the wire being coated with a ratio relationship such that i. a wire having a diameter of approximately 0.08 to 0.15 inches will travel through the molten coating bath for approximately 0.5 to 1.5 inches, and ii. a wire having a diameter of approximately 0.15 to 0.25 inches will travel through the molten coating bath for approximately 1.5 to 4 inches. 14. A method of coating steel wire with aluminum according to claim 13 wherein the speed of the wire through the molten coating bath within the range of 70 to 135 feet per minute is controlled in inverse ratio with respect to the initial diameter of the wire within the range of 0.08 to 0.25 inches with a ratio relationship such that: i. a wire having an initial uncoated diameter of from 0.08 to 0.15 inches will have a transit speed through the molten bath of from 100 to 135 feet per minute in inverse ratio to the initial diameter of the wire, ii. a with having an initial uncoated diameter of from 0.15 to 0.215 inches will have a transit speed through the molten bath of from 72 to 128 feet per minute in inverse ratio to the initial diameter of the wire, and iii. a wire having an initial uncoated diameter of from 0.215 to 0.25 inches will have a transit speed through the molten bath of from 70 to 100 feet per minute in inverse ratio with the initial diameter of the wire. 15. A method of coating steel wire with aluminum according to claim 1 wherein the speed of the wire through the molten coating bath within The range of 70 to 135 feet per minute is controlled in inverse ratio with respect to the initial diameter of the wire within the range of 0.08 to 0.25 inches with a ratio relationship such that i. a wire having an initial uncoated diameter of from 0.08 to 0.15 inches will have a transit speed through the molten bath of from 100 to 135 feet per minute in inverse ratio to the initial diameter of the wire, ii. a wire having an initial uncoated diameter of from 0.15 to 0.215 inches will have a transit speed through the molten bath of from 72 to 128 feet per minute in inverse ratio to the initial diameter of the wire, and iii. a wire having an initial uncoated diameter of from 0.215 to 0.25 inches will have a transit speed through the molten bath of from 70 to 100 feet per minute in inverse ratio with the initial diameter of the wire. 16. A method of coating steel wire with aluminum according to claim 1 wherein the temperature of the wire is controlled within the range of 980* to 1,060* Fahrenheit as it enters the molten aluminum bath in inverse ratio with respect to the initial wire diameter within the range of 0.08 to 0.25 inches with a ratio relationship such that i. a wire having an initial uncoated diameter of 0.08 to 0.15 inches is controlled to have a temperature of between 1,000* and 1,060* Fahrenheit inversely related thereto, ii. a wire having an initial uncoated diameter of 0.15 to 0.215 inches is controlled to have a temperature of 980* to 1,040* degrees inversely related thereto, iii. a wire having an initial uncoated diameter of 0.215 to 0.25 inches is controlled to have a temperature of between 980* to 1,020* Fahrenheit inversely related thereto, and wherein the speed of the wire through the molten coating bath within the range of 70 to 135 feet per minute is controlled in inverse ratio with respect to the initial diameter of the wire within the range of 0.08 to 0.25 inches with a ratio relationship such that i. a wire having an initial uncoated diameter of from 0.08 to 0.15 inches will have a transit speed through the molten bath of from 100 to 135 feet per minute in inverse ratio to the initial diameter of the wire, ii. a wire having an initial uncoated diameter of from 0.15 to 0.215 inches will have a transit speed through the molten bath of from 72 to 128 feet per minute in inverse ratio to the initial diameter of the wire, and iii. a wire having an initial uncoated diameter of from 0.215 to 0.25 inches will have a transit speed through the molten bath of from 70 to 100 feet per minute in inverse ratio to the initial diameter of the wire. 17. A method of coating steel wire with aluminum in accordance with claim 16 wherein the wire has an initial fine pearlitic metallurgical structure prior to passage through said molten aluminum bath, which structure remains unchanged after passage of said wire through said bath and additionally comprising: j. drawing said coated wire through a reducing die to reduce the diameter of the wire and increase its tensile strength to specifications. |
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