U.S. patent application number 10/854451 was filed with the patent office on 2004-10-28 for corrosion-resistant fuel tank.
This patent application is currently assigned to The Louis Berkman Company, a corporation of Ohio. Invention is credited to Carey, Jay F. II, Hesske, Nicholas R., Zamanzadeh, Mehrooz.
Application Number | 20040213916 10/854451 |
Document ID | / |
Family ID | 29718734 |
Filed Date | 2004-10-28 |
United States Patent
Application |
20040213916 |
Kind Code |
A1 |
Carey, Jay F. II ; et
al. |
October 28, 2004 |
Corrosion-resistant fuel tank
Abstract
A corrosion-resistant coated brass metal coated with a corrosion
resistant alloy. The corrosion resistant alloy is a tin metal alloy
or a tin and zinc metal alloy. The corrosion resistant metal alloy
may also include one or more metal additives to improve the coating
process and/or to alter the properties of the tin or tin and zinc
metal alloy.
Inventors: |
Carey, Jay F. II;
(Follansbee, WV) ; Zamanzadeh, Mehrooz;
(Pittsburgh, PA) ; Hesske, Nicholas R.; (Weirton,
WV) |
Correspondence
Address: |
FAY, SHARPE, FAGAN, MINNICH & McKEE
Seventh Floor
1100 Superior Avenue
Cleveland
OH
44114-2579
US
|
Assignee: |
The Louis Berkman Company, a
corporation of Ohio
|
Family ID: |
29718734 |
Appl. No.: |
10/854451 |
Filed: |
May 26, 2004 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
10854451 |
May 26, 2004 |
|
|
|
10434641 |
May 9, 2003 |
|
|
|
10434641 |
May 9, 2003 |
|
|
|
10144148 |
May 10, 2002 |
|
|
|
6652990 |
|
|
|
|
10144148 |
May 10, 2002 |
|
|
|
09634828 |
Aug 9, 2000 |
|
|
|
09634828 |
Aug 9, 2000 |
|
|
|
08929623 |
Sep 15, 1997 |
|
|
|
08929623 |
Sep 15, 1997 |
|
|
|
08604074 |
Feb 20, 1996 |
|
|
|
5667849 |
|
|
|
|
08604074 |
Feb 20, 1996 |
|
|
|
08551456 |
Nov 1, 1995 |
|
|
|
5616424 |
|
|
|
|
08551456 |
Nov 1, 1995 |
|
|
|
08402925 |
Mar 13, 1995 |
|
|
|
5491036 |
|
|
|
|
08402925 |
Mar 13, 1995 |
|
|
|
08165085 |
Dec 10, 1993 |
|
|
|
5397652 |
|
|
|
|
08165085 |
Dec 10, 1993 |
|
|
|
08000101 |
Jan 4, 1993 |
|
|
|
08000101 |
Jan 4, 1993 |
|
|
|
07858662 |
Mar 27, 1992 |
|
|
|
5314758 |
|
|
|
|
10434641 |
|
|
|
|
10144148 |
May 10, 2002 |
|
|
|
6652990 |
|
|
|
|
10144148 |
May 10, 2002 |
|
|
|
09634828 |
Aug 9, 2000 |
|
|
|
09634828 |
Aug 9, 2000 |
|
|
|
08929623 |
Sep 15, 1997 |
|
|
|
08929623 |
Sep 15, 1997 |
|
|
|
08604074 |
Feb 20, 1996 |
|
|
|
5667849 |
|
|
|
|
08604074 |
Feb 20, 1996 |
|
|
|
08551456 |
Nov 1, 1995 |
|
|
|
5616424 |
|
|
|
|
08551456 |
Nov 1, 1995 |
|
|
|
08402925 |
Mar 13, 1995 |
|
|
|
5491036 |
|
|
|
|
08402925 |
Mar 13, 1995 |
|
|
|
08260333 |
Jun 15, 1994 |
|
|
|
5429882 |
|
|
|
|
08260333 |
Jun 15, 1994 |
|
|
|
08209400 |
Mar 14, 1994 |
|
|
|
08209400 |
Mar 14, 1994 |
|
|
|
08175523 |
Dec 30, 1993 |
|
|
|
5401586 |
|
|
|
|
08175523 |
Dec 30, 1993 |
|
|
|
08154376 |
Nov 17, 1993 |
|
|
|
08154376 |
Nov 17, 1993 |
|
|
|
08042649 |
Apr 5, 1993 |
|
|
|
10434641 |
|
|
|
|
10144148 |
May 10, 2002 |
|
|
|
6652990 |
|
|
|
|
10144148 |
May 10, 2002 |
|
|
|
09634828 |
Aug 9, 2000 |
|
|
|
09634828 |
Aug 9, 2000 |
|
|
|
08929623 |
Sep 15, 1997 |
|
|
|
08929623 |
Sep 15, 1997 |
|
|
|
08604074 |
Feb 20, 1996 |
|
|
|
5667849 |
|
|
|
|
08604074 |
Feb 20, 1996 |
|
|
|
08551456 |
Nov 1, 1995 |
|
|
|
5616424 |
|
|
|
|
08551456 |
Nov 1, 1995 |
|
|
|
08402925 |
Mar 13, 1995 |
|
|
|
5491036 |
|
|
|
|
08402925 |
Mar 13, 1995 |
|
|
|
08341365 |
Nov 17, 1994 |
|
|
|
5489490 |
|
|
|
|
08341365 |
Nov 17, 1994 |
|
|
|
08175523 |
Dec 30, 1993 |
|
|
|
5401586 |
|
|
|
|
08175523 |
Dec 30, 1993 |
|
|
|
08154376 |
Nov 17, 1993 |
|
|
|
08154376 |
Nov 17, 1993 |
|
|
|
08042649 |
Apr 5, 1993 |
|
|
|
10434641 |
|
|
|
|
10144148 |
May 10, 2002 |
|
|
|
6652990 |
|
|
|
|
10144148 |
May 10, 2002 |
|
|
|
09634828 |
Aug 9, 2000 |
|
|
|
09634828 |
Aug 9, 2000 |
|
|
|
08929623 |
Sep 15, 1997 |
|
|
|
08929623 |
Sep 15, 1997 |
|
|
|
08604074 |
Feb 20, 1996 |
|
|
|
5667849 |
|
|
|
|
08604074 |
Feb 20, 1996 |
|
|
|
08551456 |
Nov 1, 1995 |
|
|
|
5616424 |
|
|
|
|
08551456 |
Nov 1, 1995 |
|
|
|
08402925 |
Mar 13, 1995 |
|
|
|
5491036 |
|
|
|
|
08402925 |
Mar 13, 1995 |
|
|
|
08347261 |
Nov 30, 1994 |
|
|
|
5491035 |
|
|
|
|
08347261 |
Nov 30, 1994 |
|
|
|
08175523 |
Dec 30, 1993 |
|
|
|
5401586 |
|
|
|
|
08175523 |
Dec 30, 1993 |
|
|
|
08154376 |
Nov 17, 1993 |
|
|
|
08154376 |
Nov 17, 1993 |
|
|
|
08042649 |
Apr 5, 1993 |
|
|
|
10434641 |
|
|
|
|
10144148 |
May 10, 2002 |
|
|
|
6652990 |
|
|
|
|
10144148 |
May 10, 2002 |
|
|
|
09634828 |
Aug 9, 2000 |
|
|
|
09634828 |
Aug 9, 2000 |
|
|
|
08929623 |
Sep 15, 1997 |
|
|
|
08929623 |
Sep 15, 1997 |
|
|
|
08604074 |
Feb 20, 1996 |
|
|
|
5667849 |
|
|
|
|
08604074 |
Feb 20, 1996 |
|
|
|
08551456 |
Nov 1, 1995 |
|
|
|
5616424 |
|
|
|
|
08551456 |
Nov 1, 1995 |
|
|
|
08402925 |
Mar 13, 1995 |
|
|
|
5491036 |
|
|
|
|
08402925 |
Mar 13, 1995 |
|
|
|
08175523 |
Dec 30, 1993 |
|
|
|
5401586 |
|
|
|
|
08175523 |
Dec 30, 1993 |
|
|
|
08154376 |
Nov 17, 1993 |
|
|
|
08154376 |
Nov 17, 1993 |
|
|
|
08042649 |
Apr 5, 1993 |
|
|
|
10434641 |
|
|
|
|
10144148 |
May 10, 2002 |
|
|
|
6652990 |
|
|
|
|
10144148 |
May 10, 2002 |
|
|
|
09634828 |
Aug 9, 2000 |
|
|
|
09634828 |
Aug 9, 2000 |
|
|
|
08929623 |
Sep 15, 1997 |
|
|
|
08929623 |
Sep 15, 1997 |
|
|
|
08604074 |
Feb 20, 1996 |
|
|
|
5667849 |
|
|
|
|
08604074 |
Feb 20, 1996 |
|
|
|
08551456 |
Nov 1, 1995 |
|
|
|
5616424 |
|
|
|
|
08551456 |
Nov 1, 1995 |
|
|
|
08402925 |
Mar 13, 1995 |
|
|
|
5491036 |
|
|
|
|
08402925 |
Mar 13, 1995 |
|
|
|
08373533 |
Jan 17, 1995 |
|
|
|
5455122 |
|
|
|
|
08373533 |
Jan 17, 1995 |
|
|
|
08254875 |
Jun 6, 1994 |
|
|
|
08254875 |
Jun 6, 1994 |
|
|
|
08209400 |
Mar 14, 1994 |
|
|
|
08209400 |
Mar 14, 1994 |
|
|
|
08175523 |
Dec 30, 1993 |
|
|
|
5401586 |
|
|
|
|
08175523 |
Dec 30, 1993 |
|
|
|
08154376 |
Nov 17, 1993 |
|
|
|
08154376 |
Nov 17, 1993 |
|
|
|
08042649 |
Apr 5, 1993 |
|
|
|
10434641 |
|
|
|
|
10144148 |
May 10, 2002 |
|
|
|
6652990 |
|
|
|
|
10144148 |
May 10, 2002 |
|
|
|
09634828 |
Aug 9, 2000 |
|
|
|
09634828 |
Aug 9, 2000 |
|
|
|
08929623 |
Sep 15, 1997 |
|
|
|
08929623 |
Sep 15, 1997 |
|
|
|
08604074 |
Feb 20, 1996 |
|
|
|
5667849 |
|
|
|
|
08604074 |
Feb 20, 1996 |
|
|
|
08551456 |
Nov 1, 1995 |
|
|
|
5616424 |
|
|
|
|
08551456 |
Nov 1, 1995 |
|
|
|
08402925 |
Mar 13, 1995 |
|
|
|
5491036 |
|
|
|
|
08402925 |
Mar 13, 1995 |
|
|
|
08338337 |
Nov 14, 1994 |
|
|
|
08338337 |
Nov 14, 1994 |
|
|
|
08229097 |
Apr 18, 1994 |
|
|
|
5395702 |
|
|
|
|
08229097 |
Apr 18, 1994 |
|
|
|
08000101 |
Jan 4, 1993 |
|
|
|
08000101 |
Jan 4, 1993 |
|
|
|
07858662 |
Mar 27, 1992 |
|
|
|
5314758 |
|
|
|
|
10434641 |
|
|
|
|
10144148 |
May 10, 2002 |
|
|
|
6652990 |
|
|
|
|
10144148 |
May 10, 2002 |
|
|
|
09634828 |
Aug 9, 2000 |
|
|
|
09634828 |
Aug 9, 2000 |
|
|
|
08929623 |
Sep 15, 1997 |
|
|
|
08929623 |
Sep 15, 1997 |
|
|
|
08604078 |
Feb 20, 1996 |
|
|
|
5695822 |
|
|
|
|
08604078 |
Feb 20, 1996 |
|
|
|
08438042 |
May 8, 1995 |
|
|
|
5597656 |
|
|
|
|
08438042 |
May 8, 1995 |
|
|
|
08338386 |
Nov 14, 1994 |
|
|
|
5470667 |
|
|
|
|
08338386 |
Nov 14, 1994 |
|
|
|
08175523 |
Dec 30, 1993 |
|
|
|
5401586 |
|
|
|
|
08175523 |
Dec 30, 1993 |
|
|
|
08154376 |
Nov 17, 1993 |
|
|
|
08154376 |
Nov 17, 1993 |
|
|
|
08042649 |
Apr 5, 1993 |
|
|
|
10434641 |
|
|
|
|
10144148 |
May 10, 2002 |
|
|
|
6652990 |
|
|
|
|
10144148 |
May 10, 2002 |
|
|
|
09634828 |
Aug 9, 2000 |
|
|
|
09634828 |
Aug 9, 2000 |
|
|
|
08929623 |
Sep 15, 1997 |
|
|
|
08929623 |
Sep 15, 1997 |
|
|
|
08604078 |
Feb 20, 1996 |
|
|
|
5695822 |
|
|
|
|
08604078 |
Feb 20, 1996 |
|
|
|
08438042 |
May 8, 1995 |
|
|
|
5597656 |
|
|
|
|
08438042 |
May 8, 1995 |
|
|
|
08260333 |
Jun 15, 1994 |
|
|
|
5429882 |
|
|
|
|
08260333 |
Jun 15, 1994 |
|
|
|
08209400 |
Mar 14, 1994 |
|
|
|
08209400 |
Mar 14, 1994 |
|
|
|
08175523 |
Dec 30, 1993 |
|
|
|
5401586 |
|
|
|
|
08175523 |
Dec 30, 1993 |
|
|
|
08154376 |
Nov 17, 1993 |
|
|
|
08154376 |
Nov 17, 1993 |
|
|
|
08042649 |
Apr 5, 1993 |
|
|
|
10434641 |
|
|
|
|
10144148 |
May 10, 2002 |
|
|
|
6652990 |
|
|
|
|
10144148 |
May 10, 2002 |
|
|
|
09634828 |
Aug 9, 2000 |
|
|
|
09634828 |
Aug 9, 2000 |
|
|
|
08929623 |
Sep 15, 1997 |
|
|
|
08929623 |
Sep 15, 1997 |
|
|
|
08604078 |
Feb 20, 1996 |
|
|
|
5695822 |
|
|
|
|
08604078 |
Feb 20, 1996 |
|
|
|
08438042 |
May 8, 1995 |
|
|
|
5597656 |
|
|
|
|
08438042 |
May 8, 1995 |
|
|
|
08341365 |
Nov 17, 1994 |
|
|
|
5489490 |
|
|
|
|
08341365 |
Nov 17, 1994 |
|
|
|
08175523 |
Dec 30, 1993 |
|
|
|
5401586 |
|
|
|
|
08175523 |
Dec 30, 1993 |
|
|
|
08154376 |
Nov 17, 1993 |
|
|
|
08154376 |
Nov 17, 1993 |
|
|
|
08042649 |
Apr 5, 1993 |
|
|
|
10434641 |
|
|
|
|
09634828 |
Aug 9, 2000 |
|
|
|
09634828 |
Aug 9, 2000 |
|
|
|
08929623 |
Sep 15, 1997 |
|
|
|
08929623 |
Sep 15, 1997 |
|
|
|
08604078 |
Feb 20, 1996 |
|
|
|
5695822 |
|
|
|
|
08604078 |
Feb 20, 1996 |
|
|
|
08438042 |
May 8, 1995 |
|
|
|
5597656 |
|
|
|
|
08438042 |
May 8, 1995 |
|
|
|
08347261 |
Nov 30, 1994 |
|
|
|
5491035 |
|
|
|
|
08347261 |
Nov 30, 1994 |
|
|
|
08175523 |
Dec 30, 1993 |
|
|
|
5401586 |
|
|
|
|
08175523 |
Dec 30, 1993 |
|
|
|
08154376 |
Nov 17, 1993 |
|
|
|
08154376 |
Nov 17, 1993 |
|
|
|
08042649 |
Apr 5, 1993 |
|
|
|
10434641 |
|
|
|
|
10144148 |
May 10, 2002 |
|
|
|
6652990 |
|
|
|
|
10144148 |
May 10, 2002 |
|
|
|
09634828 |
Aug 9, 2000 |
|
|
|
09634828 |
Aug 9, 2000 |
|
|
|
08980985 |
Oct 20, 1997 |
|
|
|
08980985 |
Oct 20, 1997 |
|
|
|
08636179 |
Apr 22, 1996 |
|
|
|
08636179 |
Apr 22, 1996 |
|
|
|
08551456 |
Nov 1, 1995 |
|
|
|
5616424 |
|
|
|
|
08551456 |
Nov 1, 1995 |
|
|
|
08402925 |
Mar 13, 1995 |
|
|
|
5491036 |
|
|
|
|
08402925 |
Mar 13, 1995 |
|
|
|
08380372 |
Jan 30, 1995 |
|
|
|
5480731 |
|
|
|
|
08380372 |
Jan 30, 1995 |
|
|
|
08153026 |
Nov 17, 1993 |
|
|
|
5395703 |
|
|
|
|
08153026 |
Nov 17, 1993 |
|
|
|
07858662 |
Mar 27, 1992 |
|
|
|
5314758 |
|
|
|
|
10434641 |
|
|
|
|
10144148 |
May 10, 2002 |
|
|
|
6652990 |
|
|
|
|
10144148 |
May 10, 2002 |
|
|
|
09634828 |
Aug 9, 2000 |
|
|
|
09634828 |
Aug 9, 2000 |
|
|
|
09071316 |
May 1, 1998 |
|
|
|
6080497 |
|
|
|
|
09071316 |
May 1, 1998 |
|
|
|
08929623 |
Sep 15, 1997 |
|
|
|
08929623 |
Sep 15, 1997 |
|
|
|
08604074 |
Feb 20, 1996 |
|
|
|
5667849 |
|
|
|
|
08604074 |
Feb 20, 1996 |
|
|
|
08551456 |
Nov 1, 1995 |
|
|
|
5616424 |
|
|
|
|
08551456 |
Nov 1, 1995 |
|
|
|
08402925 |
Mar 13, 1995 |
|
|
|
5491036 |
|
|
|
|
08402925 |
Mar 13, 1995 |
|
|
|
08165085 |
Dec 10, 1993 |
|
|
|
5397652 |
|
|
|
|
08165085 |
Dec 10, 1993 |
|
|
|
08000101 |
Jan 4, 1993 |
|
|
|
08000101 |
Jan 4, 1993 |
|
|
|
07967407 |
Oct 26, 1992 |
|
|
|
07967407 |
Oct 26, 1992 |
|
|
|
07913209 |
Jul 15, 1992 |
|
|
|
07913209 |
Jul 15, 1992 |
|
|
|
07858662 |
Mar 27, 1992 |
|
|
|
5314758 |
|
|
|
|
10434641 |
|
|
|
|
10144148 |
May 10, 2002 |
|
|
|
6652990 |
|
|
|
|
10144148 |
May 10, 2002 |
|
|
|
09634828 |
Aug 9, 2000 |
|
|
|
09634828 |
Aug 9, 2000 |
|
|
|
09100578 |
Jun 19, 1998 |
|
|
|
09100578 |
Jun 19, 1998 |
|
|
|
08929623 |
Sep 15, 1997 |
|
|
|
08929623 |
Sep 15, 1997 |
|
|
|
08604074 |
Feb 20, 1996 |
|
|
|
5667849 |
|
|
|
|
08604074 |
Feb 20, 1996 |
|
|
|
08551456 |
Nov 1, 1995 |
|
|
|
5616424 |
|
|
|
|
08551456 |
Nov 1, 1995 |
|
|
|
08402925 |
Mar 13, 1995 |
|
|
|
5491036 |
|
|
|
|
08402925 |
Mar 13, 1995 |
|
|
|
08380372 |
Jan 30, 1995 |
|
|
|
5480731 |
|
|
|
|
08380372 |
Jan 30, 1995 |
|
|
|
08153026 |
Nov 17, 1993 |
|
|
|
5395703 |
|
|
|
|
08153026 |
Nov 17, 1993 |
|
|
|
07858662 |
Mar 27, 1992 |
|
|
|
5314758 |
|
|
|
|
10434641 |
|
|
|
|
10144148 |
May 10, 2002 |
|
|
|
6652990 |
|
|
|
|
10144148 |
May 10, 2002 |
|
|
|
09634828 |
Aug 9, 2000 |
|
|
|
09634828 |
Aug 9, 2000 |
|
|
|
09131219 |
Aug 7, 1998 |
|
|
|
09131219 |
Aug 7, 1998 |
|
|
|
08929623 |
Sep 15, 1997 |
|
|
|
08929623 |
Sep 15, 1997 |
|
|
|
08604074 |
Feb 20, 1996 |
|
|
|
5667849 |
|
|
|
|
08604074 |
Feb 20, 1996 |
|
|
|
08551456 |
Nov 1, 1995 |
|
|
|
5616424 |
|
|
|
|
08551456 |
Nov 1, 1995 |
|
|
|
08402925 |
Mar 13, 1995 |
|
|
|
5491036 |
|
|
|
|
08402925 |
Mar 13, 1995 |
|
|
|
08380372 |
Jan 30, 1995 |
|
|
|
5480731 |
|
|
|
|
08380372 |
Jan 30, 1995 |
|
|
|
08153026 |
Nov 17, 1993 |
|
|
|
5395703 |
|
|
|
|
08153026 |
Nov 17, 1993 |
|
|
|
07858662 |
Mar 27, 1992 |
|
|
|
5314758 |
|
|
|
|
10434641 |
|
|
|
|
10144148 |
May 10, 2002 |
|
|
|
6652990 |
|
|
|
|
10144148 |
May 10, 2002 |
|
|
|
09634828 |
Aug 9, 2000 |
|
|
|
09634828 |
Aug 9, 2000 |
|
|
|
09161573 |
Sep 28, 1998 |
|
|
|
09161573 |
Sep 28, 1998 |
|
|
|
08929623 |
Sep 15, 1997 |
|
|
|
08929623 |
Sep 15, 1997 |
|
|
|
08604074 |
Feb 20, 1996 |
|
|
|
5667849 |
|
|
|
|
08604074 |
Feb 20, 1996 |
|
|
|
08551456 |
Nov 1, 1995 |
|
|
|
5616424 |
|
|
|
|
08551456 |
Nov 1, 1995 |
|
|
|
08402925 |
Mar 13, 1995 |
|
|
|
5491036 |
|
|
|
|
08402925 |
Mar 13, 1995 |
|
|
|
08380372 |
Jan 30, 1995 |
|
|
|
5480731 |
|
|
|
|
08380372 |
Jan 30, 1995 |
|
|
|
08153026 |
Nov 17, 1993 |
|
|
|
5395703 |
|
|
|
|
08153026 |
Nov 17, 1993 |
|
|
|
07858662 |
Mar 27, 1992 |
|
|
|
5314758 |
|
|
|
|
10434641 |
|
|
|
|
10144148 |
May 10, 2002 |
|
|
|
6652990 |
|
|
|
|
10144148 |
May 10, 2002 |
|
|
|
09634828 |
Aug 9, 2000 |
|
|
|
09634828 |
Aug 9, 2000 |
|
|
|
09161580 |
Sep 28, 1998 |
|
|
|
09161580 |
Sep 28, 1998 |
|
|
|
08929623 |
Sep 15, 1997 |
|
|
|
08929623 |
Sep 15, 1997 |
|
|
|
08604074 |
Feb 20, 1996 |
|
|
|
5667849 |
|
|
|
|
08604074 |
Feb 20, 1996 |
|
|
|
08551456 |
Nov 1, 1995 |
|
|
|
5616424 |
|
|
|
|
08551456 |
Nov 1, 1995 |
|
|
|
08402925 |
Mar 13, 1995 |
|
|
|
5491036 |
|
|
|
|
08402925 |
Mar 13, 1995 |
|
|
|
08380372 |
Jan 30, 1995 |
|
|
|
5480731 |
|
|
|
|
08380372 |
Jan 30, 1995 |
|
|
|
08153026 |
Nov 17, 1993 |
|
|
|
5395703 |
|
|
|
|
08153026 |
Nov 17, 1993 |
|
|
|
07858662 |
Mar 27, 1992 |
|
|
|
5314758 |
|
|
|
|
10434641 |
|
|
|
|
10144148 |
May 10, 2002 |
|
|
|
6652990 |
|
|
|
|
10144148 |
May 10, 2002 |
|
|
|
09634828 |
Aug 9, 2000 |
|
|
|
09634828 |
Aug 9, 2000 |
|
|
|
09420165 |
Oct 18, 1999 |
|
|
|
09420165 |
Oct 18, 1999 |
|
|
|
08929623 |
Sep 15, 1997 |
|
|
|
08929623 |
Sep 15, 1997 |
|
|
|
08604074 |
Feb 20, 1996 |
|
|
|
5667849 |
|
|
|
|
08604074 |
Feb 20, 1996 |
|
|
|
08551456 |
Nov 1, 1995 |
|
|
|
5616424 |
|
|
|
|
08551456 |
Nov 1, 1995 |
|
|
|
08402925 |
Mar 13, 1995 |
|
|
|
5491036 |
|
|
|
|
08402925 |
Mar 13, 1995 |
|
|
|
08380372 |
Jan 30, 1995 |
|
|
|
5480731 |
|
|
|
|
08380372 |
Jan 30, 1995 |
|
|
|
08153026 |
Nov 17, 1993 |
|
|
|
5395703 |
|
|
|
|
08153026 |
Nov 17, 1993 |
|
|
|
07858662 |
Mar 27, 1992 |
|
|
|
5314758 |
|
|
|
|
10434641 |
|
|
|
|
10144148 |
May 10, 2002 |
|
|
|
6652990 |
|
|
|
|
10144148 |
May 10, 2002 |
|
|
|
09634828 |
Aug 9, 2000 |
|
|
|
09634828 |
Aug 9, 2000 |
|
|
|
09420165 |
Oct 18, 1999 |
|
|
|
09420165 |
Oct 18, 1999 |
|
|
|
09161580 |
Sep 28, 1998 |
|
|
|
09161580 |
Sep 28, 1998 |
|
|
|
08929623 |
Sep 15, 1997 |
|
|
|
08929623 |
Sep 15, 1997 |
|
|
|
08604074 |
Feb 20, 1996 |
|
|
|
5667849 |
|
|
|
|
08604074 |
Feb 20, 1996 |
|
|
|
08551456 |
Nov 1, 1995 |
|
|
|
5616424 |
|
|
|
|
08551456 |
Nov 1, 1995 |
|
|
|
08402925 |
Mar 13, 1995 |
|
|
|
5491036 |
|
|
|
|
08402925 |
Mar 13, 1995 |
|
|
|
08373533 |
Jan 17, 1995 |
|
|
|
5455122 |
|
|
|
|
08373533 |
Jan 17, 1995 |
|
|
|
08254875 |
Jun 6, 1994 |
|
|
|
08254875 |
Jun 6, 1994 |
|
|
|
08209400 |
Mar 14, 1994 |
|
|
|
08209400 |
Mar 14, 1994 |
|
|
|
08154376 |
Nov 17, 1993 |
|
|
|
08154376 |
Nov 17, 1993 |
|
|
|
08042649 |
Apr 5, 1993 |
|
|
|
10434641 |
|
|
|
|
10144148 |
May 10, 2002 |
|
|
|
-- |
Apr 5, 1993 |
|
|
|
Current U.S.
Class: |
427/433 ;
148/533; 428/647; 428/648; 428/658; 428/659; 428/939 |
Current CPC
Class: |
C23C 28/025 20130101;
C23C 28/021 20130101; Y10S 428/939 20130101; C23C 28/023 20130101;
B32B 15/011 20130101; C23C 2/40 20130101; B32B 15/013 20130101;
Y10T 428/12937 20150115; C22C 30/06 20130101; C22C 18/00 20130101;
Y10T 428/12799 20150115; B32B 15/01 20130101; B23K 35/262 20130101;
C22C 13/00 20130101; C23C 26/00 20130101; Y10T 428/12708 20150115;
C22C 30/00 20130101; C23C 2/08 20130101; B32B 15/015 20130101; C23C
30/00 20130101; B23K 35/282 20130101; C22C 30/04 20130101; Y10T
428/12715 20150115; Y10T 428/12722 20150115; C23C 2/02 20130101;
C23C 2/06 20130101; Y10T 428/12792 20150115; C23C 2/28
20130101 |
Class at
Publication: |
427/433 ;
428/648; 428/647; 428/658; 428/659; 428/939; 148/533 |
International
Class: |
B32B 015/01 |
Claims
1-7. Canceled
8. A method of forming a corrosion-resistant metal strip that is
adapted for use in the at least partial formation of a petroleum
receptacle comprising: a) providing a carbon steel metal strip
having a top and bottom surface, said carbon steel strip having an
average thickness of less than about 5080 microns; b) coating the
top and bottom surface of said carbon steel metal strip with a
corrosion-resistant tin-zinc alloy by a hot dip process, said
corrosion-resistant tin-zinc alloy forming a multi-phase alloy upon
cooling which resists corrosion by petroleum products, said
corrosion-resistant tin-zinc alloy comprising tin, zinc and metal
additive, at least about 95 weight percent of said
corrosion-resistant tin-zinc alloy comprised of tin and zinc, said
zinc content of said corrosion-resistant tin-zinc alloy being up to
about 30 weight percent, said metal additive including an effective
amount of at least one metal to positively affect at least one
physical or chemical property of said tin-zinc alloy, said metal
additive including a metal selected from the group consisting of
chromium, copper, lead, magnesium, manganese, molybdenum, nickel,
silicon, titanium and mixtures thereof; and, c) controlling a
coating thickness of said corrosion-resistant tin-zinc alloy on
said top and bottom surface of said carbon steel strip such that
the average coating thickness on each surface of said carbon steel
strip is up to about 1270 microns.
9. The method as defined in claim 8, including the step of plating
a nickel layer on said top and bottom surface of said carbon steel
metal strip prior to said corrosion-resistant tin-zinc alloy being
applied to said carbon steel metal strip, said nickel layer having
an average thickness on each side of said carbon steel metal strip
of up to about 3 microns, said coating thickness of said
corrosion-resistant tin-zinc alloy being greater than the thickness
of said plated nickel layer.
10. The method as defined in claim 8, including the step of forming
a heat created intermetallic layer between said carbon steel strip
and said corrosion-resistant tin-zinc alloy, said heat created
intermetallic layer having an average thickness of less than about
3 microns, said heat created intermetallic layer including iron,
tin and zinc.
11. The method as defined in claim 9, including the step of forming
a heat created intermetallic layer between said carbon steel strip
and said corrosion-resistant tin-zinc alloy, said heat created
intermetallic layer having an average thickness of less than about
3 microns, said heat created intermetallic layer including iron,
tin and zinc.
12. The method as defined in claim 10, wherein said heat created
intermetallic layer includes at least one additional metal selected
from the group consisting of aluminum, lead, magnesium, manganese,
nickel, titanium and mixtures thereof.
13. The method as defined in claim 11, wherein said heat created
intermetallic layer includes at least one additional metal selected
from the group consisting of aluminum, lead, magnesium, manganese,
nickel, titanium and mixtures thereof.
14. The method as defined in claim 8, wherein said
corrosion-resistant tin-zinc alloy includes magnesium.
15. The method as defined in claim 8, wherein said
corrosion-resistant tin-zinc alloy includes aluminum.
16. The method as defined in claim 8, wherein said
corrosion-resistant tin-zinc alloy includes manganese.
17. The method as defined in claim 8, wherein said
corrosion-resistant tin-zinc alloy includes lead.
18. The method as defined in claim 8, wherein said
corrosion-resistant tin-zinc alloy includes copper.
19. The method as defined in claim 8, wherein said
corrosion-resistant tin-zinc alloy includes chromium.
20. The method as defined in claim 8, wherein said
corrosion-resistant tin-zinc alloy includes molybdenum.
21. The method as defined in claim 8, wherein said
corrosion-resistant tin-zinc alloy includes nickel.
22. The method as defined in claim 8, wherein said
corrosion-resistant tin-zinc alloy includes silicon.
23. The method as defined in claim 8, wherein said
corrosion-resistant tin-zinc alloy includes titanium.
24. The method as defined in claim 8, including the step of at
least partially forming said coated carbon steel metal strip into a
shell member of a petroleum receptacle.
25. The method as defined in claim 8, wherein said hot dip process
includes at least partially immersing said carbon steel strip into
a molten bath of corrosion-resistant tin-zinc alloy.
26. The method as defined in claim 8, including the step of
controlling the cooling rate of said hot dip coating to regulate
the crystal size formation in the corrosion-resistant tin-zinc
alloy.
27. A method of forming a corrosion-resistant metal strip that is
adapted for use in the at least partial formation of a petroleum
receptacle comprising: a) providing a metal strip having a top and
bottom surface, said carbon steel strip having an average thickness
of about 127-5080 microns; b) coating the top and bottom surface of
said metal strip with a corrosion-resistant tin-zinc alloy by a hot
dip process to form a heat created intermetallic layer between said
surfaces of said metal strip and said corrosion-resistant tin-zinc
alloy, said corrosion-resistant tin-zinc alloy forming a multi
phase alloy upon cooling which resists corrosion by petroleum
products, at least about 90 weight percent of said
corrosion-resistant tin-zinc alloy comprised of tin and zinc, said
zinc content of said corrosion-resistant tin-zinc alloy being up to
about 30 weight percent, said heat created intermetallic layer
having an average thickness of less than 10 microns and including
iron, nickel, tin and zinc; and, c) controlling a coating thickness
of said corrosion-resistant tin-zinc alloy on said top and bottom
surface of said carbon steel strip such that the average coating
thickness on each surface of said carbon steel strip is about
2.5-1270 microns.
28. The method as defined in claim 27, wherein said heat created
intermetallic layer includes at least one additional metal selected
from the group consisting of aluminum, copper, lead, magnesium,
manganese, silicon, titanium and mixtures thereof.
29. The method as defined in claim 27, wherein said
corrosion-resistant tin-zinc alloy includes at least an effective
amount of at least one metal additive to positively affect the
mechanical properties of said corrosion-resistant tin-zinc alloy,
the chemical properties of said corrosion-resistant tin-zinc alloy
and combinations thereof, said at least one metal additive selected
from the group consisting of aluminum, chromium, copper, lead,
magnesium, manganese, molybdenum, nickel, silicon, titanium and
mixtures thereof.
30. The method as defined in claim 28, wherein said
corrosion-resistant tin-zinc alloy includes at least an effective
amount of at least one metal additive to positively affect the
mechanical properties of said corrosion-resistant tin-zinc alloy,
the chemical properties of said corrosion-resistant tin-zinc alloy
and combinations thereof, said at least one metal additive selected
from the group consisting of aluminum, chromium, copper, lead,
magnesium, manganese, molybdenum, nickel, silicon, titanium and
mixtures thereof.
31. The method as defined in claim 27, including the step ofplating
a nickel layer on said top and bottom surface of said carbon steel
metal strip prior to said corrosion-resistant tin-zinc alloy being
applied to said carbon steel metal strip, said nickel layer having
an average thickness on each side of said carbon steel metal strip
of up to about 3 microns, said coating thickness of said
corrosion-resistant tin-zinc alloy being greater than the thickness
of said plated nickel layer.
32. The method as defined in claim 30, including the step ofplating
a nickel layer on said top and bottom surface of said carbon steel
metal strip prior to said corrosion-resistant tin-zinc alloy being
applied to said carbon steel metal strip, said nickel layer having
an average thickness on each side of said carbon steel metal strip
of up to about 3 microns, said coating thickness of said
corrosion-resistant tin-zinc alloy being greater than the thickness
of said plated nickel layer.
33. The method as defined in claim 27, including the step of
forming a heat created intermetallic layer between said carbon
steel strip and said corrosion-resistant tin-zinc alloy, said heat
created intermetallic layer having an average thickness of less
than about 3 microns, said heat created intermetallic layer
including iron, tin and zinc.
34. The method as defined in claim 31, including the step of
forming a heat created intermetallic layer between said carbon
steel strip and said corrosion-resistant tin-zinc alloy, said heat
created intermetallic layer having an average thickness of less
than about 3 microns, said heat created intermetallic layer
including iron, tin and zinc.
35. The method as defined in claim 27, wherein said
corrosion-resistant tin-zinc alloy includes magnesium.
36. The method as defined in claim 27, wherein said
corrosion-resistant tin-zinc alloy includes aluminum.
37. The method as defined in claim 27, wherein said
corrosion-resistant tin-zinc alloy includes manganese.
38. The method as defined in claim 27, wherein said
corrosion-resistant tin-zinc alloy includes lead.
39. The method as defined in claim 27, wherein said
corrosion-resistant tin-zinc alloy includes copper.
40. The method as defined in claim 27, wherein said
corrosion-resistant tin-zinc alloy includes chromium.
41. The method as defined in claim 27, wherein said
corrosion-resistant tin-zinc alloy includes molybdenum.
42. The method as defined in claim 27, wherein said
corrosion-resistant tin-zinc alloy includes nickel.
43. The method as defined in claim 27, wherein said
corrosion-resistant tin-zinc alloy includes silicon.
44. The method as defined in claim 27, wherein said
corrosion-resistant tin-zinc alloy includes titanium.
45. The method as defined in claim 27, including the step of at
least partially forming said coated metal strip into a shell member
of a petroleum receptacle.
46. The method as defined in claim 27, wherein said hot dip process
includes at least partially immersing said metal strip into a
molten bath of corrosion-resistant tin-zinc alloy.
47. The method as defined in claim 27, wherein said metal strip is
a carbon steel strip.
48. The method as defined in claim 27, including the step of
controlling the cooling rate of said hot dip coating to regulate
the crystal size formation in the corrosion-resistant tin-zinc
alloy.
Description
[0001] This patent application is a continuation of Ser. No.
10/434,641 filed May 9, 2003, which in turn is a continuation of
Ser. No. 10/144,148 filed May 10, 2002, which in turn is
continuation of Ser. No. 09/634,828 filed Aug. 9, 2000, which in
turn is a continuation-in-part of Ser. No. 08/929,623 filed Sep.
15, 1997, now abandoned, which in turn is a continuation-in-part of
Ser. No. 08/604,074 filed Feb. 20, 1996, now U.S. Pat. No.
5,667,849, which in turn is a divisional of Ser. No. 08/551,456
filed Nov. 1, 1995, now U.S. Pat. No. 5,616,424, which in turn is a
divisional of Ser. No. 08/402,925 filed Mar. 13, 1995, now U.S.
Pat. No.5,491,036, which in turn is a continuation-in-part of Ser.
No. 08/165,085 filed Dec. 10, 1993, now U.S. Pat. No. 5,397,652,
which in turn is a continuation-in-part of Ser. No. 08/000,101
filed Jan. 4, 1993, now abandoned, which in turn is a
continuation-in-part of Ser. No. 07/858,662 filed Mar. 27, 1992,
now U.S. Pat. No. 5,314,758.
[0002] This patent application is also a continuation of Ser. No.
10/434,641 filed May 9, 2003, which in turn is a continuation of
Ser. No. 10/144,148 filed May 10, 2002, which in turn is
continuation of Ser. No. 09/634,828 filed Aug. 9, 2000, which in
turn is a continuation-in-part of Ser. No.08/929,623 filed Sep. 15,
1997, now abandoned, which in turn is a continuation-in-part of
Ser. No. 08/604,074 filed Feb. 20, 1996, now U.S. Pat. No.
5,667,849, which in turn is a divisional of Ser. No. 08/551,456
filed Nov. 1, 1995, now U.S. Pat. No. 5,616,424, which in turn is a
divisional of Ser. No. 08/402,925 filed Mar. 13, 1995, now U.S.
Pat. No. 5,491,036, which in turn is a continuation-in-part of Ser.
No. 08/260,333 filed Jun. 15, 1994, now U.S. Pat. No. 5,429,882,
which in turn is a continuation-in-part of Ser. No. 08/209,400
filed Mar. 14, 1994, now abandoned, which in turn is a
continuation-in-part of Ser. No. 08/175,523 filed Dec. 30, 1993,
now U.S. Pat. No. 5,401,586, which in turn is a
continuation-in-part of Ser. No. 08/154,376 filed Nov. 17, 1993,
now abandoned, which in turn is a continuation of Ser. No.
08/042,649 filed Apr. 5, 1993, now abandoned.
[0003] This patent application is further a continuation of Ser.
No. 10/434,641 filed May 9, 2003, which in turn is a continuation
of Ser. No. 10/144,148 filed May 10, 2002, which in turn is
continuation of Ser. No. 09/634,828 filed Aug. 9, 2000, which in
turn is a continuation-in-part of Ser. No. 08/929,623 filed Sep.
15, 1997, now abandoned, which in turn is a continuation-in-part of
Ser. No. 08/604,074 filed Feb. 20, 1996, now U.S. Pat. No.
5,667,849, which in turn is a divisional of Ser. No. 08/551,456
filed Nov. 1, 1995, now U.S. Pat. No. 5,616,424, which in turn is a
divisional of Ser. No. 08/402,925 filed Mar. 13, 1995, now U.S.
Pat. No. 5,491,036, which in turn is a continuation-in-part of Ser.
No. 08/341,365 filed Nov. 17, 1994, now U.S. Pat. No. 5,489,490,
which in turn is a continuation-in-part of Ser. No. 08/175,523
filed Dec. 30,1993, now U.S. Pat. No. 5,401,586, which in turn is a
continuation-in-part of Ser. No. 08/154,376 filed Nov. 17, 1993,
now abandoned, which in turn is a continuation of Ser. No.
08/042,649 filed Apr. 5, 1993, now abandoned.
[0004] This patent application is still further a continuation of
Ser. No. 10/434,641 filed May 9, 2003, which in turn is a
continuation of Ser. No. 10/144,148 filed May 10, 2002, which in
turn is continuation of Ser. No. 09/634,828 filed Aug. 9, 2000,
which in turn is a continuation-in-part of Ser. No. 08/929,623
filed Sep. 15, 1997, now abandoned, which in turn is a
continuation-in-part of Ser. No. 08/604,074 filed Feb. 20, 1996,
now U.S. Pat. No. 5,667,849, which in turn is a divisional of Ser.
No. 08/551,456 filed Nov. 1, 1995, now U.S. Pat. No. 5,616,424,
which in turn is a divisional of Ser. No. 08/402,925 filed Mar. 13,
1995, now U.S. Pat. No. 5,491,036, which in turn is a
continuation-in-part of Ser. No. 08/347,261 filed Nov. 30, 1994,
now U.S. Pat. No. 5,491,035, which in turn is a
continuation-in-part of Ser. No. 08/175,523 filed Dec. 30, 1993,
now U.S. Pat. No. 5,401,586, which in turn is a
continuation-in-part of Ser. No. 08/154,376 filed Nov. 17, 1993,
now abandoned, which in turn is a continuation of Ser. No.
08/042,649 filed Apr. 5, 1993, now abandoned.
[0005] This patent application is yet further a continuation of
Ser. No. 10/434,641 filed May 9, 2003, which in turn is a
continuation of Ser. No. 10/144,148 filed May 10, 2002, which in
turn is continuation of Ser. No. 09/634,828 filed Aug. 9, 2000,
which in turn is a continuation-in-part of Ser. No. 08/929,623
filed Sep. 15, 1997, now abandoned, which in turn is a
continuation-in-part of Ser. No. 08/604,074 filed Feb. 20, 1996,
now U.S. Pat. No. 5,667,849, which in turn is a divisional of Ser.
No. 08/551,456 filed Nov. 1, 1995, now U.S. Pat. No. 5,616,424,
which in turn is a divisional of Ser. No. 08/402,925 filed Mar. 13,
1995, now U.S. Pat. No. 5,491,036, which in turn is a
continuation-in-part of Ser. No. 08/175,523 filed Dec. 30, 1993,
now U.S. Pat. No. 5,401,586, which in turn is a
continuation-in-part of Ser. No. 08/154,376 filed Nov. 17, 1993,
now abandoned, which in turn is a continuation of Ser. No.
08/042,649 filed Apr. 5, 1993, now abandoned.
[0006] This patent application is also a continuation of Ser. No.
10/434,641 filed May 9, 2003, which in turn is a continuation of
Ser. No. 10/144,148 filed May 10, 2002, which in turn is
continuation of Ser. No. 09/634,828 filed Aug. 9, 2000, which in
turn is a continuation-in-part of Ser. No. 08/929,623 filed Sep.
15, 1997, now abandoned, which in turn is a continuation-in-part of
Ser. No. 08/604,074 filed Feb. 20, 1996, now U.S. Pat. No.
5,667,849, which in turn is a divisional of Ser. No. 08/551,456
filed Nov. 1, 1995, now U.S. Pat. No. 5,616,424, which in turn is a
divisional of Ser. No. 08/402,925 filed Mar. 13, 1995, now U.S.
Pat. No. 5,491,036, which in turn is a continuation-in-part of Ser.
No. 08/373,533 filed Jan. 17, 1995, now U.S. Pat. No. 5,455,122,
which in turn is a continuation of Ser. No. 08/254,875 filed Jun.
6, 1994, now abandoned, which in turn is a divisional of Ser. No.
08/209,400 filed Mar. 14, 1994, now abandoned, which in turn is a
continuation-in-part of Ser. No. 08/175,523 filed Dec. 30, 1993,
now U.S. Pat. No. 5,401,586, which in turn is a
continuation-in-part of Ser. No. 08/154,376 filed Nov. 17, 1993,
now abandoned, which in turn is a continuation of Ser. No.
08/042,649 filed Apr. 5, 1993, now abandoned.
[0007] This patent application is further a continuation of Ser.
No. 10/434,641 filed May 9, 2003, which in turn is a continuation
of Ser. No. 10/144,148 filed May 10, 2002, which in turn is
continuation of Ser. No. 09/634,828 filed Aug. 9, 2000, which in
turn is a continuation-in-part of Ser. No. 08/929,623 filed Sep.
15, 1997, now abandoned, which in turn is a continuation-in-part of
Ser. No. 08/604,074 filed Feb. 20, 1996, now U.S. Pat. No.
5,667,849, which in turn is a divisional of Ser. No. 08/551,456
filed Nov. 1, 1995, now U.S. Pat. No. 5,616,424, which in turn is a
divisional of Ser. No. 08/402,925 filed Mar. 13, 1995, now U.S.
Pat. No. 5,491,036, which in turn is a continuation-in-part of Ser.
No. 08/338,337 filed Nov. 14, 1994, now abandoned, which in turn is
a divisional of 08/229,097 filed Apr. 18, 1994, now U.S. Pat. No.
5,395,702, which in turn is a continuation of Ser. No. 08/000,101
filed Jan. 4, 1993, now abandoned, which in turn is a
continuation-in-part of Ser. No. 07/858,662 filed Mar. 27, 1992,
now U.S. Pat. No. 5,314,758.
[0008] This patent application is yet further a continuation of
Ser. No. 10/434,641 filed May 9, 2003, which in turn is a
continuation of Ser. No. 10/144,148 filed May 10, 2002, which in
turn is continuation of Ser. No. 09/634,828 filed Aug. 9, 2000,
which in turn is a continuation-in-part of Ser. No. 08/929,623
filed Sep. 15, 1997, now abandoned, which in turn is a
continuation-in-part of Ser. No. 08/604,078 filed Feb. 20, 1996,
now U.S. Pat. No. 5,695,822, which in turn is a divisional of Ser.
No. 08/438,042 filed May 8, 1995, now U.S. Pat. No. 5,597,656,
which in turn is a continuation-in-part of Ser. No. 08/338,386
filed Nov. 14, 1994, now U.S. Pat. No. 5,470,667, which in turn is
a continuation of Ser. No. 08/175,523 filed Dec. 30, 1993, now U.S.
Pat. No. 5,401,586, which in turn is a continuation-in-part of Ser.
No. 08/154,376 filed Nov. 17, 1993, now abandoned, which in turn is
a continuation of Ser. No. 08/042,649 filed Apr. 5, 1993, now
abandoned.
[0009] This patent application is also a continuation of Ser. No.
10/434,641 filed May 9, 2003, which in turn is a continuation of
Ser. No. 10/144,148 filed May 10, 2002, which in turn is
continuation of Ser. No. 09/634,828 filed Aug. 9, 2000, which in
turn is a continuation-in-part of Ser. No. 08/929,623 filed Sep.
15, 1997, now abandoned, which in turn is a continuation-in-part of
Ser. No. 08/604,078 filed Feb. 20, 1996, now U.S. Pat. No.
5,695,822, which in turn is a divisional of Ser. No. 08/438,042
filed May 8, 1995, now U.S. Pat. No. 5,597,656, which in turn is a
continuation-in-part of Ser. No. 08/260,333 filed Jun. 15, 1994,
now U.S. Pat. No. 5,429,882, which in turn is a
continuation-in-part of Ser. No. 08/209,400 filed Mar. 14, 1994,
now abandoned, which in turn is a continuation-in-part of Ser. No.
08/175,523 filed Dec. 30, 1993, now U.S. Pat. No. 5,401,586, which
in turn is a continuation-in-part of Ser. No. 08/154,376 filed Nov.
17, 1993, now abandoned, which in turn is a continuation of Ser.
No. 08/042,649 filed Apr. 5, 1993, now abandoned.
[0010] This patent application is further a continuation of Ser.
No. 10/434,641 filed May 9, 2003, which in turn is a continuation
of Ser. No. 10/144,148 filed May 10, 2002, which in turn is
continuation of Ser. No. 09/634,828 filed Aug. 9, 2000, which in
turn is a continuation-in-part of Ser. No. 08/929,623 filed Sep.
15, 1997, now abandoned, which in turn is a continuation-in-part of
Ser. No. 08/604,078 filed Feb. 20, 1996, now U.S. Pat. No.
5,695,822, which in turn is a divisional of Ser. No. 08/438,042
filed May 8, 1995, now U.S. Pat. No. 5,597,656, which in turn
5,489,490, which in turn is a continuation-in-part of Ser. No.
08/175,523 filed Dec. 30, 1993, now U.S. Pat. No. 5,401,586, which
in turn is continuation-in-part of Ser. No. 08/154,376, filed Nov.
17, 1993, now abandoned, which in turn is a continuation of Ser.
No. 08/042,649 filed Apr. 5, 1993, now abandoned.
[0011] This patent application is yet further a continuation of
Ser. No. 10/434,641 filed May 9, 2003, which in turn is a
continuation of Ser. No. 09/634,828 filed Aug. 9, 2000, which in
turn is a continuation-in-part of Ser. No. 08/929,623 filed Sep.
15, 1997, now abandoned, which in turn is a continuation-in-part of
Ser. No. 08/604,078 filed Feb. 20, 1996, now U.S. Pat. No.
5,695,822, which in turn is a divisional of Ser. No. 08/438,042
filed May 8, 1995, now U.S. Pat. No. 5,597,656, which in turn is a
continuation-in-part of Ser. No. 08/347,261 filed Nov. 30, 1994,
now U.S. Pat. No. 5,491,035, which in turn is a
continuation-in-part of Ser. No. 08/175,523, filed Dec. 30, 1993,
now U.S. Pat. No. 5,401,586, which in turn is a
continuation-in-part of Ser. No. 08/042,649 filed Apr. 5, 1993, now
abandoned.
[0012] This patent application is further a continuation of Ser.
No. 10/434,641 filed May 9, 2003, which in turn is a continuation
of Ser. No. 10/144,148 filed May 10, 2002, which in turn is
continuation of Ser. No. 09/634,828 filed Aug. 9, 2000, which in
turn is a continuation-in-part of Ser. No. 08/980,985 filed Oct.
20, 1997, now abandoned, which in turn is a continuation of Ser.
No. 08/636,179 filed Apr. 22, 1996, now abandoned, which in turn is
a continuation-in-part of Ser. No. 08/551,456 filed Nov. 1, 1995,
now U.S. Pat. No. 5,616,424, which in turn is a divisional of Ser.
No. 08/402,925 filed Mar. 13, 1995, now U.S. Pat. No. 5,491,036,
which in turn is a continuation-in-part of Ser. No. 08/380,372
filed Jan. 30, 1995, now U.S. Pat. No. 5,480,731, which is in turn
a continuation of Ser. No. 08/153,026 filed Nov. 17, 1992, now U.S.
Pat. No. 5,395,703, which in turn is a divisional of Ser. No.
07/858,662 filed Mar. 27, 1992, now U.S. Pat. No. 5,314,758.
[0013] This patent application is still further a continuation of
Ser. No. 10/434,641 filed May 9, 2003, which in turn is a
continuation of Ser. No. 10/144,148 filed May 10, 2002, which in
turn is continuation of Ser. No. 09/634,828 filed Aug. 9, 2000,
which in turn is a continuation-in-part of Ser. No. 09/071,316
filed May 1, 1998, now U.S. Pat. No. 6,080,497, which in turn is a
continuation-in-part of Ser. No. 08/929,623 filed Sep. 15, 1997,
now abandoned, which in turn is a continuation-in-part of Ser. No.
08/604,074 filed Feb. 20, 1996, now U.S. Pat. No. 5,667,849, which
in turn is a divisional of Ser. No. 08/551,456 filed Nov. 1, 1995,
now U.S. Pat. No. 5,616,424, which in turn is a divisional of Ser.
No. 08/402,925 filed Mar. 13, 1995, now U.S. Pat. No. 5,491,036,
which in turn is a continuation-in-part of Ser. No. 08/165,085
filed Dec. 10, 1993, now U.S. Pat. No. 5,401,586, which in turn is
a continuation-in-part of Ser. No. 08/000,101 filed Jan. 4, 1993,
now abandoned, which in turn is a continuation-in-part of Ser. No.
07/967,407 filed Oct. 26, 1992, now abandoned, which in turn is a
continuation-in-part of Ser. No. 07/913,209 filed Jul. 15, 1992,
now abandoned, which in turn is a continuation-in-part of Ser. No.
07/858,662 filed Mar. 27, 1992, now U.S. Pat. No. 5,314,758.
[0014] This patent application is yet further a continuation of
Ser. No. 10/434,641 filed May 9, 2003, which in turn is a
continuation of Ser. No. 10/144,148 filed May 10, 2002, which in
turn is continuation of Ser. No. 09/634,828 filed Aug. 9, 2000,
which in turn is a continuation-in-part of Ser. No. 09/100,578
filed Jun. 19, 1998, now abandoned, which in turn is a
continuation-in-part of Ser. No. 80/929,623, filed Sep. 15, 1997,
now abandoned, which in turn is a continuation-in-part of Ser. No.
08/604,074 filed Feb. 20, 1996, now U.S. Pat. No. 5,667,849, which
in turn is a divisional of Ser. No. 08/551,456 filed Nov. 1, 1995,
now U.S. Pat. No. 5,616,424, which in turn is a divisional of Ser.
No. 08/402,925 filed Mar. 13, 1995, now U.S. Pat. No. 5,491,036,
which in turn is a continuation-in-part of Ser. No. 08/380,372
filed Jan. 30, 1995, now U.S. Pat. No. 5,480,731, which is in turn
a continuation of Ser. No. 08/153,026 filed Nov. 17, 1993, now U.S.
Pat. No. 5,395,703, which in turn is a divisional of Ser. No.
07/858,662 filed Mar. 27, 1992, now U.S. Pat. No. 5,314,758.
[0015] This patent application is also a continuation of Ser. No.
10/434,641 filed May 9, 2003, which in turn is a continuation of
Ser. No. 10/144,148 filed May 10, 2002, which in turn is
continuation of Ser. No. 09/634,828 filed Aug. 9, 2000, which in
turn is a continuation-in-part of Ser. No. 09/131,219 filed Aug. 7,
1998, now abandoned, which in turn is a continuation-in-part of
Ser. No. 08/929,623 filed Sep. 15, 1997, now abandoned, which in
turn is a continuation-in-part of Ser. No. 08/604,074 filed Feb.
20, 1996, now U.S. Pat. No. 5,667,849, which in turn is a
divisional of Ser. No. 08/551,456 filed Nov. 1, 1995, now U.S. Pat.
No. 5,616,424, which in turn is a divisional of Ser. No. 08/402,925
filed Mar. 13, 1995, now U.S. Pat. No. 5,491,036, which in turn is
a continuation-in-part of Ser. No. 08/380,372 filed Jan. 30, 1995,
now U.S. Pat. No. 5,480,731, which is in turn a continuation of
Ser. No. 08/153,026 filed Nov. 17, 1993, now U.S. Pat. No.
5,395,703, which in turn is a divisional of Ser. No. 07/858,662
filed Mar. 27, 1992, now U.S. Pat. No. 5,314,758.
[0016] This patent application is further a continuation of Ser.
No. 10/434,641 filed May 9, 2003, which in turn is a continuation
of Ser. No. 10/144,148 filed May 10, 2002, which in turn is
continuation of Ser. No. 09/634,828 filed Aug. 9, 2000, which in
turn is a continuation-in-part of Ser. No. 09/161,573 filed Sep.
28, 1998, now abandoned, which in turn is a continuation-in-part of
Ser. No. 08/929,623 filed Sep. 15, 1997, now abandoned, which in
turn is a continuation-in-part of Ser. No. 08/604,074 filed Feb.
20, 1996, now U.S. Pat. No. 5,667,849, which in turn is a
divisional of Ser. No. 08/551,456 filed Nov. 1, 1995, now U.S. Pat.
No. 5,616,424, which in turn is a divisional of Ser. No. 08/402,925
filed Mar. 13, 1995, now U.S. Pat. No. 5,491,036, which in turn is
a continuation-in-part of Ser. No. 08/380,372 filed Jan. 30, 1995,
now U.S. Pat. No. 5,480,731, which is in turn a continuation of
Ser. No. 08/153,026 filed Nov. 17, 1993, now U.S. Pat. No.
5,395,703, which in turn is a divisional of Ser. No. 07/858,662
filed Mar. 27, 1992, now U.S. Pat. No. 5,314,758.
[0017] This patent application is still further a continuation of
Ser. No. 10/434,641 filed May 9, 2003, which in turn is a
continuation of Ser. No. 10/144,148 filed May 10, 2002, which in
turn is continuation of Ser. No. 09/634,828 filed Aug. 9, 2000,
which in turn is a continuation-in-part of Ser. No. 09/161,580
filed Sep. 28, 1998, now abandoned, which in turn is a
continuation-in-part of Ser. No. 08/929,623 filed Sep. 15, 1997,
now abandoned, which in turn is a continuation-in-part of Ser. No.
08/604,074 filed Feb. 20, 1996, now U.S. Pat. No. 5,667,849, which
in turn is a divisional of Ser. No. 08/551,456 filed Nov. 1, 1995,
now U.S. Pat. No. 5,616,424, which in turn is a divisional of Ser.
No. 08/402,925 filed Mar. 13, 1995, now U.S. Pat. No. 5,491,036,
which in turn is a continuation-in-part of Ser. No. 08/380,372
filed Jan. 30, 1995, now U.S. Pat. No. 5,480,731, which is in turn
a continuation of Ser. No. 08/153,026 filed Nov. 17, 1993, now U.S.
Pat. No. 5,395,703, which in turn is a divisional of Ser. No.
07/858,662 filed Mar. 27, 1992, now U.S. Pat. No. 5,314,758.
[0018] This patent application is yet further a continuation of
Ser. No. 10/434,641 filed May 9, 2003, which in turn is a
continuation of Ser. No. 10/144,148 filed May 10, 2002, which in
turn is continuation of Ser. No. 09/634,828 filed Aug. 9, 2000,
which in turn is a continuation-in-part of Ser. No. 09/420,165
filed Oct. 18, 1999, now abandoned, which in turn is a
continuation-in-part of Ser. No. 08/929,623 filed Sep. 15, 1997,
now abandoned, which in turn is a continuation-in-part of Ser. No.
08/604,074 filed Feb. 20, 1996, now U.S. Pat. No. 5,667,849, which
in turn is a divisional of Ser. No. 08/551,456 filed Nov. 1, 1995,
now U.S. Pat. No. 5,616,424, which in turn is a divisional of Ser.
No. 08/402,925 filed Mar. 13, 1995, now U.S. Pat. No. 5,491,036,
which in turn is a continuation-in-part of Ser. No. 08/380,372
filed Jan. 30, 1995, now U.S. Pat. No. 5,480,731, which is in turn
a continuation of Ser. No. 08/153,026 filed Nov. 17, 1993, now U.S.
Pat. No. 5,395,703, which in turn is a divisional of Ser. No.
07/858,662 filed Mar. 27, 1992, now U.S. Pat. No. 5,314,758.
[0019] This patent application is also a continuation of Ser. No.
10/434,641 filed May 9, 2003, which in turn is a continuation of
Ser. No. 10/144,148 filed May 10, 2002, which in turn is
continuation of Ser. No. 09/634,828 filed Aug. 9, 2000, now
abandoned, which in turn is a continuation-in-part of Ser. No.
09/420,165 filed Oct. 18, 1999, now abandoned, which in turn is a
continuation-in-part of Ser. No. 09/161,580 filed Sep. 28, 1998,
now abandoned, which in turn is a continuation-in-part Ser. No.
08/929,623 filed Sep. 15, 1997, now abandoned, which in turn is a
continuation-in-part of Ser. No. 08/604,074 filed Feb. 20, 1996,
now U.S. Pat. No. 5,667,849, which in turn is a divisional of Ser.
No. 08/551,456 filed Nov. 1, 1995, now U.S. Pat. No. 5,616,424,
which in turn is a divisional of Ser. No. 08/402,925 filed Mar. 13,
1995, now U.S. Pat. No. 5,491,036, which in turn is a
continuation-in-part of Ser. No. 08/373,533 filed Jan. 17, 1995,
now U.S. Pat. No. 5,455,122, which in turn is a continuation of
Ser. No. 08/254,875 filed Jun. 6, 1994, now abandoned, which in
turn is a divisional of Ser. No. 08/209,400 filed Mar. 14, 1994,
now abandoned, which in turn is a continuation-in-part of Ser. No.
08/154,376 filed Nov. 17, 1993, now abandoned, which in turn is a
continuation of Ser. No. 08/042,649 filed Apr. 5, 1993, now
abandoned.
[0020] This patent application is also a continuation of Ser. No.
10/434,641 filed May 9, 2003, which in turn is a continuation of
Ser. No. 10/144,148 filed May 10, 2002, which in turn is
continuation of Ser. No. 09/634,828 filed Aug. 9, 2000, now
abandoned, which in turn is a continuation-in-part of Ser. No.
08/929,623 filed Sep. 15, 1997, now abandoned, which in turn is a
continuation-in-part of Ser. No. 08/604,074 filed Feb. 20, 1996,
now U.S. Pat. No. 5,667,849, which in turn is a divisional of Ser.
No. 08/551,456 filed Nov. 1, 1995, now U.S. Pat. No. 5,616,424,
which in turn is a divisional of Ser. No. 08/402,925 filed Mar. 13,
1995, now U.S. Pat. No. 5,491,036, which in turn is a
continuation-in-part of Ser. No. 08/373,533 filed Jan. 17, 1995,
now U.S. Pat. No. 5,455,122, which in turn is a continuation of
Ser. No. 08/254,875 filed Jun. 6, 1994, now abandoned, which in
turn is a divisional of Ser. No. 08/209,400 filed Mar. 14, 1994,
now abandoned, which in turn is a continuation-in-part of Ser. No.
08/154,376 filed Nov. 17, 1993, now abandoned, which in turn is a
continuation of Ser. No. 08/042,649 filed Apr. 5, 1993, now
abandoned.
[0021] This patent application is also a continuation of Ser. No.
10/434,641 filed May 9, 2003, which in turn is a continuation of
Ser. No. 10/144,148 filed May 10, 2002, which in turn is
continuation of Ser. No. 09/634,828 filed Aug. 9, 2000, now
abandoned, which in turn is a continuation-in-part of Ser. No.
08/929,623 filed Sep. 15, 1997, now abandoned, which in turn is a
continuation-in-part of Ser. No. 08/604,074 filed Feb. 20, 1996,
now U.S. Pat. No. 5,667,849, which in turn is a divisional of Ser.
No. 08/551,456 filed Nov. 1, 1995, now U.S. Pat. No. 5,616,424,
which in turn is a divisional of Ser. No. 08/402,925 filed Mar. 13,
1995, now U.S. Pat. No. 5,491,036, which in turn is a
continuation-in-part of Ser. No. 08/347,261 filed Nov. 30, 1994,
now U.S. Pat. No. 5,491,035, which in turn is a
continuation-in-part of Ser. No. 08/254,875 filed Jun. 6, 1994, now
abandoned, which in turn is a divisional of Ser. No. 08/209,400
filed Mar. 14, 1994, now abandoned, which in turn is a
continuation-in-part of Ser. No. 08/154,376 filed Nov. 17, 1993,
now abandoned, which in turn is a continuation of Ser. No.
08/042,649 filed Apr. 5, 1993, now abandoned.
[0022] The present invention relates to the art of
corrosion-resistant metal materials and more particularly to a
corrosion resistant alloy or coated base metal which is coated with
a corrosion resistant alloy, which alloy is environmentally
friendly, and has a long life.
INCORPORATION BY REFERENCE
[0023] As background material so that the specification need not
specify in detail what is known in the art, U.S. Pat. Nos.
4,934,120; 4,982,543; 4,987,716; 4,934,120; 5,001,881; 5,022,203;
5,259,166; and 5,301,474 are incorporated herein by reference to
illustrate metal roofing systems of the type to which this
invention can be used. U.S. Pat. No. 5,455,122 is incorporated
herein by reference to illustrate petroleum receptacles of the type
to which this invention can be used. U.S. Pat. No. 5,203,985 is
incorporated herein by reference to illustrate a prior art
electroplating process which can be used to coat the coated base
metal. U.S. Pat. Nos. 5,296,300; 5,314,758; 5,354,624; 5,395,702;
5,395,703; 5,397,652; 5,401,586; 5,429,882; 5,455,122; 5,470,667;
5,480,731; 5,489,490; 5,491,035; 5,491,036; 5,492,772; 5,520,964;
5,597,656; 5,616,424; 5,667,849, 5,695,822; and 6,080,497 and U.S.
patent application Ser. No. 07/913,209, filed Jul. 15, 1992; Ser.
No. 08/042,649, filed Apr. 5, 1993; Ser. No. 08/929,623, filed Sep.
15, 1997; Ser. No. 08/980,985, filed Oct. 20, 1997; Ser. No.
09/100,578, filed Jun. 19, 1998; Ser. No. 09/131,219, filed Aug. 7,
1998; Ser. No. 09/161,573, filed Sep. 28, 1998; Ser. No.
09/161,580, filed Set. 28, 1998; and Ser. No. 09/420,165, filed
Oct. 18, 1999 are incorporated herein by reference to illustrate
various processes that can be used to coat, treat and use the
coated base metal.
BACKGROUND OF THE INVENTION
[0024] The present invention relates to the art of
corrosion-resistant metal materials such as a corrosion-resistant
metal made of a corrosion-resistant metal alloy or a base metal
which is coated with a corrosion resistant metal alloy, which
corrosion-resistant metal materials can be used in a wide variety
of applications such as, but not limited to, architectural or
building materials such as roofing materials, siding materials,
window frames, sheet metal, metal plates and the like; truck and
automotive products such as, but not limited to, gasoline tanks,
filter casings, body molding, body parts and the like; household
products such as, but not limited to, appliance housings,
electrical housings, light fixtures and the like; marine products
such as, but not limited to, boat hulls, boat masts, dock system
components; and/or other types of metal materials such as, but not
limited to, tools, machinery, wires, cables, electrodes, solder and
the like. The invention also relates to various metal alloy
compositions or metal coating alloy compositions based upon metal
alloys of tin and metal alloys of tin and zinc, and several novel
methods and processes used therein for forming the metal alloy
compositions or base metals coated with the metal alloy materials,
such as but not limited to, wire or solder forming, metal strip
forming, and coated metal forming by a plating process and/or a
hot-dip process (i.e plating of metal alloy and subsequent flow
heating, immersion in molten metal alloy, metal spraying of metal
alloy, and/or roller coating of metal alloy), pretreatment of the
base metal prior to metal alloy coating, applying an intermediate
barrier metal layer prior to metal alloy coating, post-treating the
metal alloy or coated base metal, and/or forming the metal alloy or
coated base metal into a variety of different articles.
[0025] Over the last several years, there has been a trend in the
industry to produce products which are higher in quality, are
environmentally friendly, and are safe for use by humans, animals,
and/or plants. This push for quality, safety and environmental
friendliness is very apparent in the automotive industry wherein
both consumer groups and environmental organizations are constantly
lobbying for safer, higher-quality vehicles that are more fuel
efficient and less detrimental to the environment. Recycling old
vehicles has been one answer to resolving the environmental issues
associated with vehicles which have run out their useful life.
Automotive salvage markets have developed for these vehicles. The
vehicles are partially dismantled and sold as scrap metal wherein
the metal is melted down and reformed into various parts. Because
of the environmentally-un-friendly nature of lead, the gasoline
tanks of vehicles must be removed prior to the recycling of the
vehicle. Gasoline tanks are commonly made of carbon or stainless
steel that are coated with a terne alloy.
[0026] Terne or terne alloy is a term commonly used to describe a
metal alloy containing about 80% lead and the balance tin. The
terne alloy is conventionally applied to a base metal by immersing
the base metal into a molten bath of terne metal by a continuous or
batch process.
[0027] Although terne coated metals have excellent
corrosion-resistant properties and have been used in various
applications, terne coated materials have been questioned due to
environmental concerns based on the high lead content of the alloy.
Environmental and public safety laws have been proposed and/or
passed prohibiting or penalizing the user of materials containing a
significant portion of lead. As a result, these terne coated gas
tanks must be disposed of in dumping yards or landfills. Not only
does the terne coated gasoline tank take up space in the landfills,
but there is a concern with the lead leaching from the terne
coating into the landfill site and potentially contaminating the
surrounding area and underground water reservoirs. Plastic gasoline
tanks have been used as an alternative to terne coated materials,
but with limited success. Although the use of plastic tanks
eliminates the environmental concerns associated with lead, the
plastic in-of-itself is a non-environmentally-friendly compound
which does not readily degrade and therefore must be disposed of in
a landfill. The plastic used to make the gasoline tanks is usually
not the type that can be recycled. Plastics have also been found to
be less reliable than metal gasoline tanks with respect to
durability and safety. Plastic gasoline tanks have a tendency to
rupture upon impact, such as from a car accident, whereas a metal
gasoline tank tends to absorb much of the shock on impact by
bending and slightly deforming. Furthermore, the plastic gasoline
tanks are more susceptible to being punctured from roadside debris
since the plastic skin is not as strong or malleable as the skin of
a metal gasoline tank. Plastic gasoline tanks also require new
materials, special tools and new assembly methods to fix and
install the gasoline tanks due to the nature of plastic and its
physical properties. These additional costs and shortcomings of
plastic tanks have resulted in very little adoption of plastic
gasoline tanks in present day motor vehicles.
[0028] The lead content in metal materials is also of some concern
for building materials. This is especially a concern when the metal
materials are in contact with drinking water. In many countries
lead pipe has been outlawed to reduce the amount of lead in the
water. In many remote locations throughout the world, piped water
or well water is not readily available. As a result, structures,
such as portable roof systems, are built to capture rain and to
store the rain water for later use. These potable roof systems
supply an important water source for inhabitants utilizing such
structures. Roof systems that are designed to collect rain water
are typically made of metal to increase the longevity of the
roofing system. Typically, the roof systems are made of carbon
steel since such metal is the least expensive. The carbon steel is
commonly coated with a terne alloy to extend the life of the roof
system. Terne alloy is commonly used due to its relatively low
cost, ease of application, excellent corrosion-resistant properties
and desirable colorization during weathering. Roof systems have
been made of other metals such as, but not limited to, stainless
steel, copper, copper alloys and aluminum. Stainless steel, copper,
copper alloys and aluminum were typically not coated with a terne
coating since these metals have excellent corrosion-resistant
properties. However, in some limited applications, these metals
have been coated with terne to extend the life of these metals.
However, as with lead piping, there is a concern that the lead in
the terne coated roofing materials results in lead dissolving in
the collected water.
[0029] Terne coated materials have typically been coated with a 6-8
lb. coating (7-11 microns), which is a very thin coating. This thin
coating commonly includes pinholes. Terne coated materials that are
drawn or formed in various types of materials such as, but not
limited to, gasoline tanks, corrugated roofing materials and the
like typically included one or more defects in the coating. The
defects in the terne coating on the base metal which were designed
to protect the base metal from corroding thus compromised the
corrosion resistance provided by the terne coating. Due to the thin
layer of the terne coating and the pinholes in the coating, the
coating on the base metal, upon being drawn by a die or by being
formed, tended to tear or shear the terne coating and/or elongate
the pin holes on the coating thereby exposing the base metal. These
exposed surfaces were subject to corrosion and over time
compromised the structural integrity, safety and/or performance of
the coated base metal. The non-uniform coating of stainless steel
metal with the terne coating is especially evident since terne
alloy does not bond as well to the stainless steel. Another
disadvantage of using a terne alloy coating is the softness of the
terne layer. The softness of the terne coating is susceptible to
damage from the abrasive nature of forming machines and to
environments that subject the terne coating to frequent contact
with other materials.
[0030] Terne alloys have a further disadvantage in that the newly
applied terne is very shiny and highly reflective. As a result, the
highly reflective coating cannot immediately be used in certain
environments such as on buildings or roofing systems in or near
airports and military establishments. The terne coating eventually
loses its highly reflective properties as the components of the
terne coating are reduced (weathered); however, the desired amount
of reduction takes at least approximately 11/2 to 2 years when the
terne coating is exposed to the atmosphere, thus requiring the
terne metals to be stored over long periods of time prior to being
used in these special areas. The storage time is significantly
prolonged when the terne coated materials are stored in rolls
and/or the terne alloy is protected from the atmosphere.
[0031] Metallic coatings such as tin or zinc have been tested as
substitutes for terne coatings with limited success. The most
popular process for applying a tin coating to a base metal is by an
electroplating process. In an electroplating process, the coating
thickness is very thin and typically ranges between 0.3 microns to
30 microns. The very thin thicknesses of the tin coating typically
results in a tin coating having a network of small pinholes,
thereby making the coated material generally unacceptable for use
in corrosive environments such as on building materials and
automotive products. Such tin plated base metals can include a
flash or intermediate metal layer (plated layer) to reduce the
pinhole problems inherent with the tin plating process. The tin
plated layer is also susceptible to flaking or being scrapped off
when the tin plated base metal is drawn through a die and/or formed
into various components. The flaking of the tin coating can also
cause premature clogging of filter systems and liquid lines, such
as in gasoline lines and filters, when the tin plated based metals
are formed into gasoline tanks. The pinholes problem and flaking
and/or scraping problem that is associated with plated tin coatings
is very problematic since tin is not electroprotective under
oxidizing conditions. Consequently, discontinuities in the plated
tin coating result in the corrosion of the exposed base metal.
[0032] The plated tin coating of carbon steel is a well-known
process in the food industry. However, in the specialized art of
building materials, a tin coating for base metals for use on
building materials and the like has recently been used as disclosed
in U.S. Pat. No. 5,314,758. Tin coatings form a highly-reflective
surface. As a result, materials coated with a tin coating cannot be
used in an environment where highly-reflective materials are
undesirable until the tin coated materials are further treated
(i.e. paint) or the tin is allowed time to sufficiently
oxidize.
[0033] Coating a base metal with zinc metal, commonly known as
galvanizing, is another popular metal treatment to inhibit
corrosion. Zinc is a desirable metal to coat materials because of
its relatively low cost, ease of application, and excellent
corrosion resistance. Zinc is also electroprotective under
oxidizing conditions and inhibits or prevents the exposed metal,
due to discontinuities in the zinc coating, from rapidly corroding.
This electrolytic protection extends away from the zinc coating
over exposed metal surfaces for a sufficient distance to protect
the exposed metal at cut edges, scratches, and other coating
discontinuities. Although zinc coatings bond to many types of
metals, the bond is typically not very strong thereby resulting in
the zinc coating flaking off the base metal over time and/or when
being formed. The flaking of zinc, like the flaking of tin, can
cause premature clogging of filter systems and liquid lines when
zinc coated materials are formed into gasoline tanks. Further, when
using fuel injection systems, the small particles of zinc or zinc
oxide can disable the fuel injectors over time. Such problems are
unacceptable in the automotive field. Zinc further does not form a
uniform and/or thick coating when coating stainless steel, thus
resulting in discontinuities in the coating. Zinc is also a very
rigid and brittle metal, thus tends to crack and/or flake off when
the zinc coated materials are formed and/or drawn through a die.
When zinc oxidizes, the zinc coating forms a white powdery texture
(zinc oxide). This white powdery substance is undesirable for many
building applications and in various other environments and
applications. Consequently, the use of a tin or zinc coating as a
substitute for terne coatings has not been highly reliable, or a
cost effective substitute for traditional terne coatings.
[0034] Metal coatings that include a hot dip coating of tin and
zinc alloy have been used for fuel tanks as disclosed in Japanese
Patent Application No. 47-97776 filed Sep. 29, 1972. The alloy
coating thickness was disclosed to be 10-15 microns.
[0035] Metal coatings that include tin and zinc have also been used
to coated base metals. Electroplating a tin and zinc mixture onto a
steel sheet is disclosed in Japanese Patent Application No.
56-144738 filed Sep. 16, 1981. The Japanese patent application
discloses the plating of a steel sheet with a tin and zinc mixture
to form a coating thickness of less than 20 microns. The Japanese
patent application discloses that after plating, pin holes exist in
the coating and subject the coating to corrosion. The pin holes are
a result of the crystalline layer of the tin and zinc mixture
slowly forming during the plating process. Consequently, the
Japanese patent application discloses that the plated tin and zinc
coating must be covered with chromate or phosphoric acid to fill
the pin holes to prevent corrosion. The Japanese patent application
discloses that a preplated layer of nickel, tin or cobalt on the
steel sheet surface is needed so that the plated tin and zinc
mixture will adhere to the steel sheet.
[0036] The coating of steel articles by a batch hot-dip process
with a tin, zinc and aluminum mixture is disclosed in U.S. Pat. No.
3,962,501 issued Jun. 8, 1976. The '501 patent discloses that the
tin, zinc and aluminum mixture resists oxidation and maintains a
metallic luster. The '501 patent also discloses that the coating is
applied by a batch process involving the immersion of a steel
article into a molten alloy bath for an extended period of time.
The '501 patent further discloses that a molten tin and zinc metal
alloy is very susceptible to oxidation resulting in viscous oxides
forming on the surface of the molten tin and zinc metal alloy.
These viscous oxides cause severe problems with the coating
process. While the steel article is immersed in the molten alloy, a
large amount of dross forms on the surface of the molten alloy. The
dross results in non-uniformity of the coating and the formation of
pin holes as the steel article is removed from the molten metal.
The '501 patent also discloses that the addition of up to 25%
aluminum to the tin and zinc metal alloy inhibits dross formation,
prevents Zn--Fe alloy formation, and reduces viscous oxide
formation on the molten bath surface. The batch process disclosed
in the '501 patent subjects the surface of the article to differing
residence times in the molten alloy which can result in differing
coating thicknesses and coating properties on the coated
article.
[0037] The treatment of a steel sheet by plating tin and zinc
followed by heat flowing is disclosed in U.S. Pat. No. 4,999,258.
The '258 patent discloses a steel sheet plated with a layer of tin
and a subsequent layer of zinc. The tin and zinc plated layers are
then heated until the zinc alloys with the tin. The tin is applied
at 0.2-1.0 g/m.sup.2 and the zinc is applied at 0.01-0.3 g/m.sup.2.
The '258 patent also discloses that when less than 1% zinc is used,
the beneficial effect of the zinc is null; however, when more than
30% zinc is used, the coating will rapidly corrode under adverse
environments. The '258 patent also discloses that a nickel plated
layer is preferably applied to the steel sheet prior to applying
the tin and zinc plated layers to improve corrosion resistance. The
heat treated tin and zinc layer can be further treated by applying
a chromate treatment to the plated layer further to improve
corrosion resistance.
[0038] A continuous process for electroplating a carbon steel strip
is disclosed in U.S. Pat. No. 5,203,985. The '985 patent discloses
that nickel is electroplated on a continuously moving strip of
carbon steel. After the carbon steel has been nickel plated, the
plated strip is hot dip coated with molten zinc.
[0039] The electroplating of tin, tin-nickel or tin and zinc by an
electroplating process and subsequent formation of an intermetallic
layer by heat flowing the plated layer is disclosed in U.S. Pat.
No. 5,433,839.
[0040] Due to the various environmental concerns and problems
associated with corrosion-resistant coatings applied to base metals
and the problems associated with the inadvertent removal of the
corrosion-resistant coating during the forming and/or drawing of
the coated materials, there has been a demand for a coating or
metal material that is corrosion-resistant, is environmentally
friendly, and resists damage during forming into end components.
Many of these demands where met by the tin metal alloy or the tin
and zinc metal alloy and process and method for applying these
alloys to a base metal disclosed in Applicants' U.S. Pat. Nos.
5,314,758; 5,354,624; 5,395,702; 5,395,703; 5,397,652; 5,401,586;
5,429,882; 5,455,122; 5,470,667; 5,480,731; 5,489,490; 5,491,035;
5,491,036; 5,492,772; 5,520,964; 5,597,656; 5,616,424; and
5,667,849. The present invention is an improvement or refinement of
the alloys and/or use of the alloys disclosed in these prior
patents.
SUMMARY OF THE INVENTION
[0041] The present invention relates to a product and method of
producing a corrosion-resistant, environmentally friendly metal
material. More particularly, the invention relates to a metal
material that is at least partially composed of a corrosion
resistant metal alloy, or the coating of a base metal with a
corrosion resistant metal alloy which forms a corrosive-resistant
barrier on the base metal. Even more particularly, the invention
relates to a corrosion resistant metal alloy or a base metal coated
with a corrosion-resistant metal alloy which corrosion resistant
metal alloy or coated base metal is formed into truck and/or
automotive products, architectural or building materials, household
materials, marine products, and/or formed into tools, machinery,
cable, wire, wire solder and/or welding electrodes.
[0042] In accordance with on aspect of the invention, there is
provided a corrosion resistant metal alloy primarily including tin
or tin and zinc. In one embodiment of the invention, the corrosion
resistant metal alloy is formed, molded and/or drawn into a metal
article. In embodiment of the invention, the corrosion resistant
metal alloy is coated on a base metal, which coated base metal is
formed, molded, and/or drawn into a metal article.
[0043] In accordance with another and/or alternative aspect of the
invention, a metal alloy that primarily includes tin and zinc is a
tin and zinc metal alloy. The tin and zinc metal alloy is a
composite alloy wherein the tin and zinc constituents maintain
their own integrity (structure or composition) in the composite
with one phase metal being a matrix surrounding distinct globules
or phases of the second phase metal. The tin and zinc system is a
dual strata of metal globules or phases, each globule or phase
being distinct from the other in structure or composition. The
lowest weight percentage of zinc in an eutectic tin and zinc
mixture is a tin rich mixture containing about 90-91 weight percent
tin and about 9-10 weight percent zinc. For the tin rich matrix or
phase and zinc rich globules or phases to form in a tin and zinc
metal alloy, the zinc must make up at least over about 9-10 weight
percent of the tin and zinc metal alloy. A zinc content over about
9-10 weight percent of the tin and zinc alloy results in the zinc
precipitating out of the tin and forming zinc globules or phases
within the tin and zinc metal alloy. The tin content of the tin and
zinc metal alloy must be at least about 15 weight percent of the
tin and zinc metal alloy so that there is a sufficient amount of
tin within the tin and zinc metal alloy to form the tin phase about
the zinc phase. A metal alloy that primarily includes tin and zinc
but has a zinc content that is equal to or less than the minimum
eutectic weight percentage of zinc is not a tin and zinc metal
alloy. As defined herein, a tin and zinc alloy is a metal alloy
that includes at least about 15 weight percent tin and at least
about 10 weight percent zinc and the tin content plus zinc content
of the metal alloy constitutes at least a majority of the metal
alloy. One of the important and desirable properties of the tin and
zinc metal alloy is its excellent corrosion-resistance in many
different environments. The tin and zinc metal alloy is very
corrosion resistant in marine environments wherein chloride salts
are common, and in industrial environments wherein sulfur and
sulfur compounds are present. The excellent corrosion-resistance of
the tin and zinc metal alloy is believed to result from the
formation of a stable, continuous, adherent, and protective film on
the surface. The film, when damaged, generally reheals itself
quickly. Because of the general inertness of the film, that is at
least partially formed of tin and zinc oxide, in most atmospheres,
the corrosion resistant tin and zinc metal alloy is considered to
be environmentally safe and friendly, and considered a safe
material to be used in the human environment. The tin and zinc
metal alloy also forms a dull, low-reflecting surface; has a
pleasing color; performs well in low temperatures; has a relatively
low coefficient of thermal expansion; resists degradation by solar
energy; can be molded, cast, formed, drawn, soldered, painted
and/or colored; and/or can be installed in a variety of weather
conditions. The tin and zinc metal alloy is further a cost
effective material for use in structures used in corrosive
environments such as in the tropics and other areas where buildings
are exposed to strong winds, corrosive fumes, and/or marine
conditions. The tin and zinc metal alloy can also be used as a
solder and/or wire electrode. In one embodiment of the invention,
the tin content plus the zinc content in the tin and zinc metal
alloy makes up over 50 weight percent of the tin and zinc metal
alloy. In one aspect of this embodiment, the tin content plus the
zinc content in the tin and zinc metal alloy is at least about 60
weight percent of the tin and zinc metal alloy. In aspect of this
embodiment, the tin content plus the zinc content in the tin and
zinc metal alloy is at least about 75 weight percent of the tin and
zinc metal alloy. In yet aspect of this embodiment, the tin content
plus the zinc content in the tin and zinc metal alloy is at least
about 80 weight percent of the tin and zinc metal alloy. In still
yet aspect of this embodiment, the tin content plus the zinc
content in the tin and zinc metal alloy is at least about 85 weight
percent of the tin and zinc metal alloy. In a further and/or
alternative aspect of this embodiment, the tin content plus the
zinc content in the tin and zinc metal alloy is at least about 90
weight percent of the tin and zinc metal alloy. In yet a further
and/or alternative aspect of this embodiment, the tin content plus
the zinc content in the tin and zinc metal alloy is at least about
95 weight percent of the tin and zinc metal alloy. In still a
further and/or alternative aspect of this embodiment, the tin
content plus the zinc content in the tin and zinc metal alloy is at
least about 98 weight percent of the tin and zinc metal alloy. In
still yet a further and/or alternative aspect of the embodiment,
the tin plus zinc content in the tin and zinc metal alloy is at
least about 99 weight percent of the tin and zinc metal alloy.
[0044] In accordance with another and/or alternative aspect of the
invention, a metal alloy that primarily includes tin and equal to
or less than the minimum eutectic weight percentage of zinc, when
zinc is included in the metal alloy, is a tin metal alloy. As
defined herein, a tin metal alloy is a metal alloy that includes at
least a majority of the metal alloy and includes less than 9-10
weight percent zinc, when zinc is included in the metal alloy. The
corrosion resistant tin metal alloy forms a corrosion resistant
coating that protects the surface of the base metal from oxidation.
The corrosion resistant tin metal alloy provides protection to the
base metal in a variety of environments such as rural, industrial,
and marine environments. The corrosion resistant tin metal alloy
also performs well in low temperatures; has a relatively low
coefficient of thermal expansion; has a pleasing color; resists
degradation by solar energy; can be molded, cast, formed, drawn,
soldered, painted and/or colored; and/or can be installed in a
variety of weather conditions. Because of the relative inertness of
the tin oxide in many environments, the corrosion resistant tin
metal alloy is considered to be environmentally safe and friendly
and considered a safe material to be used in the human environment.
The corrosion resistant tin metal alloy is also a cost effective
material for use in structures erected in corrosive environments,
such as in the tropics and other areas where buildings are exposed
to strong winds, corrosive fumes, and/or marine conditions. The tin
metal alloy can be used as a solder and/or wire electrode. In one
embodiment of the invention, the tin content in the tin metal alloy
makes up over 50 weight percent of the tin metal alloy. In one
aspect of this embodiment, the tin content in the tin metal alloy
is at least about 75 weight percent of the tin metal alloy. In
aspect of this embodiment, the tin content in the tin metal alloy
is at least about 80 weight percent of the tin metal alloy. In yet
aspect of this embodiment, the tin content in the tin metal alloy
is at least about 85 weight percent of the tin metal alloy. In
still yet aspect of this embodiment, the tin content in the tin
metal alloy is at least about 90 weight percent of the tin metal
alloy. In a further and/or alternative aspect of this embodiment,
the tin content in the tin metal alloy is at least about 95 weight
percent of the tin metal alloy. In yet a further and/or alternative
aspect of this embodiment, the tin content in the tin metal alloy
is at least about 98 weight percent of the tin metal alloy. In
still a further and/or alternative aspect of this embodiment, the
tin content in the tin metal alloy is at least about 99 weight
percent of the tin metal alloy.
[0045] In accordance with yet aspect of the invention, the
corrosion resistant tin metal alloy and corrosion resistant tin and
zinc metal alloy contain a low lead content. The lead source in the
tin metal alloy or the tin and zinc metal alloy can be from
impurities in the raw tin and/or zinc ore used to make the metal
alloy, and/or can be from directed additions of lead to the metal
alloy. In some metal alloy combinations, lead in the metal alloy
positively affects one or more physical and/or chemical properties
of the metal alloy. Metal alloys that include little or no lead are
considered more environmentally friendly, and the prejudices
associated with high lead containing alloys are overcome. In one
embodiment of the invention, the tin metal alloy and the tin and
zinc metal alloy includes no more than about 9-10 weight percent
lead. In one aspect of this embodiment, the metal alloy includes
less than about 2 weight percent lead. In aspect of this
embodiment, the metal alloy includes less than about 1 weight
percent lead. In yet aspect of this embodiment, the metal alloy
includes less than about 0.5 weight percent lead. In still aspect
of this embodiment, the metal alloy includes less than about 0.05
weight percent lead. In still yet aspect of this embodiment, the
metal alloy includes less than about 0.01 weight percent lead.
[0046] In accordance with a further and/or alternative aspect of
the invention, the tin metal alloy and tin and zinc metal alloy
include one or more additives. In one embodiment of the invention,
the one or more additives generally constitute less than about 25
weight percent of the metal alloy. In one aspect of this
embodiment, the one or more additives constitute less than about
9-10 weight percent of the metal alloy. In aspect of this
embodiment, the one or more additives constitute less than about 5
weight percent of the metal alloy. In yet aspect of this
embodiment, the one or more additives constitute less than about 2
weight percent of the metal alloy. In still aspect of this
embodiment, the one or more additives constitute less than about 1
weight percent of the metal alloy. In still yet aspect of this
embodiment, the one or more additives constitute less than about
0.5 weight percent of the metal alloy. In embodiment of the
invention, the additives include, but are not limited to, aluminum,
antimony, arsenic, bismuth, boron, bromine, cadmium, carbon,
chlorine, chromium, copper, cyanide, fluoride, iron, lead,
magnesium, manganese, molybdenum, nickel, nitrogen, phosphorous,
potassium, silicon, silver, sulfur, tellurium, titanium, vanadium,
and/or zinc. The one or more additives included in the corrosion
resistant metal alloy are used to enhance the mechanical properties
of the metal alloy, to improve corrosion resistance of the metal
alloy, to improve the grain refinement of the metal alloy, to alter
the color of the metal alloy, to alter the reflectiveness of the
metal alloy, to inhibit the oxidation of the metal alloy during
forming or coating of the metal alloy and/or when the metal alloy
is exposed in various types of environments, to inhibit dross
formation during the forming or coating of the metal alloy, to
stabilize one or more components of the metal alloy, to improve the
bonding of the metal alloy on the base metal and/or intermediate
barrier metal layer on the base metal, to improve the flowability
of the metal alloy during the forming or coating process, to
produce the desired thickness of heat created intermetallic layer,
and/or to reduce or inhibit the crystallization of the tin in the
metal alloy. The inclusion of one or more additives in the
corrosion resistant metal alloy preforms one or more of the above
listed functions and/or features in the metal alloy. The believed
functions and features of select additives are described below;
however, the described additives may have additional functions and
features. Aluminum reduces the rate of oxidation of the molten
metal alloy; reduces dross formation during the coating process;
alters the reflective properties of the metal alloy; alters the
mechanical properties of the metal alloy (i.e. coatability,
durability, flexibility, flowability, formability, hardness, and/or
strength); and/or reduces the thickness of the heat created
intermetallic layer to improve the formability of the coated base
metal. Antimony, bismuth, cadmium, and/or copper prevents or
inhibits the crystallization of the tin in the metal alloy, which
crystallization can weaken the bonding and/or result in flaking of
the corrosion resistant metal alloy; improves the bonding
properties of the metal alloy to the base metal and/or intermediate
barrier metal layer; alters the mechanical properties of the metal
alloy; and/or alters the corrosion resistant properties of the
metal alloy. Only small amounts of antimony, bismuth, cadmium,
and/or copper are needed to prevent and/or inhibit the
crystallization of the tin. This small amount can be as low as
about 0.001-0.05 weight percent, and typically as low as
0.001-0.004 weight percent. Arsenic alters the mechanical
properties of the metal alloy. Cadmium, in addition to its bonding,
corrosion resistant, stabilizing and/or mechanical altering
properties, reduces the rate of oxidation of the molten metal
alloy; reduces dross formation during the coating or forming
process of the metal alloy; alters the color and/or reflective
properties of the metal alloy; and/or improves the grain refinement
of the metal alloy. Chromium provides additional corrosion
protection to the metal alloy; alters the mechanical properties of
the metal alloy; and/or alters the color and/or reflective
properties of the metal alloy. Copper, in addition to its corrosion
resistant, stabilizing and/or mechanical altering properties,
alters the color and/or reflective properties of the metal alloy.
Iron alters the mechanical properties of the metal alloy; and/or
alters the color of the metal alloy. Lead provides additional
corrosion protection to the metal alloy; alters the mechanical
properties of the metal alloy; alters the color of the metal alloy;
and/or improves the bonding properties of the metal alloy to the
base metal and/or intermediate barrier metal layer. Magnesium
alters the mechanical properties of the metal alloy; reduces the
anodic characteristics of the metal alloy; reduces the rate of
oxidation of the molten metal alloy; and/or reduces dross formation
during the forming or coating process of the metal alloy. Manganese
provides additional corrosion protection to the metal alloy;
improves the grain refinement of the metal alloy; and/or improves
the bonding properties of the metal alloy to the base metal and/or
intermediate barrier metal layer. Nickel provides corrosion
protection to the metal alloy, especially in alcohol and chlorine
containing environments; alters the mechanical properties of the
metal alloy; and/or alters the color and/or reflective properties
of the metal alloy Silver alters the mechanical properties of the
metal alloy; and/or alters the color and/or reflective properties
of the metal alloy. Titanium improves the grain refinement of the
metal alloy; alters the mechanical properties of the metal alloy;
provides additional corrosion protection to the metal alloy;
reduces the rate of oxidation of the molten metal alloy; reduces
dross formation during the forming or coating process of the metal
alloy; alters the color and/or reflective properties of the metal
alloy; and/or improves the bonding properties of the metal alloy to
the base metal and/or intermediate barrier metal layer. Zinc alters
the mechanical properties of the metal alloy; provides additional
corrosion protection to the metal alloy, alters the color and/or
reflective properties of the metal alloy; improves the bonding
properties of the metal alloy to the base metal and/or intermediate
barrier metal layer, and/or stabilizes the tin to inhibit or
prevent crystallization of the tin in the metal alloy.
[0047] In accordance with aspect of the invention, the thickness of
the corrosion resistant metal alloy is selected to provide the
desired amount of corrosion resistant protection to the surface of
the base metal. Generally thinner coating thicknesses can be
obtained by a plating process and thicker coating thicknesses can
be obtained by immersion in molten metal alloy. The selected
thickness of the coating will typically depend on the use of the
coated base metal and the environment the coated base metal is to
be used. A 6 lb. coating on a base metal is a common thickness for
a thin coating. A 6 lb. coating has a coating thickness of about 7
microns. A 6 lb. coating is commonly applied by a plating process.
In many instances, very thin coating thickness includes one or more
pin holes in the coating. A 40 lb. coating on a base metal is also
a common coating having a thickness of about 50 microns. A 40 lb.
coating typically has few, if any, pin holes, and due to the
thicker coating, resists tearing when the coated metal strip is
drawn or formed into various types of components. Thicker metal
alloy coatings are commonly used for automotive components (i.e.
gasoline tank shell members), and roofing and siding materials. In
one embodiment of the invention, the metal alloy coating is applied
by a single plating process. In one aspect of this embodiment, the
thickness of the metal alloy coating is at least about 1 micron. In
aspect of this embodiment, the thickness of the metal alloy coating
is at least about 2 microns. In still aspect of this embodiment,
the thickness of the metal alloy coating is about 2-30 microns. In
embodiment of the invention, the metal alloy coating is applied by
a) multiple plating processes, b) single or multiple hot-dip
processes, and/or c) at least one plating process and at least one
hot dip process. In one aspect of this embodiment, the thickness of
the metal alloy coating is at least about 1 micron. In aspect of
this embodiment, the thickness of the metal alloy coating is up to
about 2550. In still aspect of this embodiment, the thickness of
the metal alloy coating is about 2.5-1270 microns. In yet aspect of
this embodiment, the thickness of the metal alloy coating is about
7-1270 microns. In still yet aspect of this embodiment, the
thickness of the metal alloy coating is about 7-1250 microns. In a
further and/or alternative aspect of this embodiment, the thickness
of the metal alloy coating is about 15 to 1250 microns. In yet a
further and/or alternative aspect of this embodiment, the thickness
of the metal alloy coating is about 25-77 microns. In still a
further and/or alternative aspect of this embodiment, the thickness
of the metal alloy coating is about 25-51 microns.
[0048] In accordance with still aspect of the invention, the base
metal is a metal strip. A "strip" is defined as metal in the form
of a thin metal sheet that is or can be rolled into a roll of
metal, as opposed to plates of metal or other configurations of the
metal. Metal strip which has a thickness of less than about 127
microns (0.005 inch) can break as the strip is pretreated and/or
coated with a metal alloy coating at high process speeds. A high
process speed is defined as a metal strip moving through the
pretreatment process, intermediate barrier metal coating process
and/or metal alloy coating process at a speed of about 60-400
ft/min. However, the metal strip thickness should not be too great
so as to prevent the strip from being able to be directed, at a
relatively high speed, through the pretreatment process, if any,
and the coating process. Metal strip which is too thick is more
difficult to heat when a heat created intermetallic layer is to be
formed between the base metal and metal alloy coating and/or
intermediate barrier metal, especially when the metal strip is
moving at high speeds and/or coated over a short period of time.
Metal strips having too great of a thickness are also difficult to
maneuver at economical high speeds through the pretreatment
process, if any, and the coating process. In one embodiment of the
invention, the thickness of the metal strip is thin enough such
that the metal strip can be unrolled from a roll of metal, coated
by a metal alloy coating, and re-rolled into a roll of coated metal
strip. In one aspect of this embodiment, the thickness of the metal
strip is not more than about 5080 microns. In aspect of this
embodiment, the thickness of the metal strip is less than about
2540 microns. In yet aspect of this embodiment, the thickness of
the metal strip is less than about 1270 microns. In still aspect of
this embodiment, the thickness of the metal strip is less than
about 762 microns. In a further and/or alternative aspect of this
embodiment, the thickness of the metal strip is about 127-762
microns. In yet a further and/or alternative aspect of this
embodiment, the thickness of the metal strip is about 254-762
microns. In still a further and/or alternative aspect of this
embodiment, the thickness of the metal strip is about 381-762
microns. In yet a further and/or alternative aspect of this
embodiment, the thickness of the metal strap is about 127-381
microns. In still yet a further and/or alternative aspect of this
embodiment, the thickness of the metal strip is about 508-762
microns. In embodiment of the invention, the thickness of the metal
strip is not more than about 1588 microns when the metal strip is
formed of stainless steel, nickel alloys, titanium or titanium
alloys. These types of metal strip are difficult to maneuver at
economical, high speeds through the coating process when the metal
strip thickness is greater than 1588 microns. In one aspect of this
embodiment, metal strip made of stainless steel, nickel alloys,
titanium or titanium alloy strip has a thickness of about 255-762
microns.
[0049] In accordance with still yet aspect of the invention, the
base metal is a metal plate. In one embodiment of the invention,
the metal plate is a rectangular or square metal plate having a
length of about 1 to 15 feet and a width of about 1-20 feet. In
embodiment of the invention, the thickness of the metal plate is
not more than about 51000 microns (2 inches). In one aspect of this
embodiment, the thickness of the metal plate is not more than about
25400 microns. In aspect of this embodiment, the thickness of the
metal plate is not more than about 12700 microns.
[0050] In accordance with aspect of the invention, the base metal
is carbon steel. In one embodiment of the invention, the carbon
steel base metal is a metal strip. In one aspect of this
embodiment, the thickness of the carbon steel strip is less than
about 2540 microns. In aspect of this embodiment, the thickness of
the carbon steel strip is less than about 1588 microns. In yet
aspect of this embodiment, the thickness of the carbon steel strip
is less than about 1270 microns. In still aspect of this
embodiment, the thickness of the carbon steel strip is up to about
762 microns. In a further and/or alternative aspect of this
embodiment, the thickness of the carbon steel strip is about
127-762 microns. In yet a further and/or alternative aspect of this
embodiment, the thickness of the carbon steel strip is about
254-762 microns. In still a further and/or alternative aspect of
this embodiment, the thickness of the carbon steel strip is about
381-762 microns. In embodiment of the invention, the carbon steel
base metal is a metal plate.
[0051] In accordance with still aspect of the invention, the base
metal is stainless steel. "Stainless steel" is used in its
technical sense and includes a large variety of ferrous alloys
containing chromium and iron. Carbon steel base metal that is
plated with chromium and subsequently coated with a metal alloy
coating by a hot dip process transforms the carbon steel into
stainless steel at least at the surface of the base metal surface.
The stainless steel may also contain other elements or compounds
such as, but not limited to, nickel, carbon, molybdenum, silicon,
manganese, titanium, boron, copper, aluminum and various other
metals or compounds. Elements such as nickel can be flashed
(plated) onto the surface of the stainless steel or directly
incorporated into the stainless steel. In one embodiment of the
invention, the stainless steel base metal is 304 or 316 stainless
steel. In embodiment of the invention, the stainless steel base
metal is a metal strip. In one aspect of this embodiment, the
thickness of the stainless steel strip is less than about 2540
microns. In aspect of this embodiment, the thickness of the
stainless steel strip is less than about 1588 microns. In yet
aspect of this embodiment, the thickness of the stainless steel
strip is less than about 1270 microns. In still aspect of this
embodiment, the thickness of the stainless steel strip is up to
about 762 microns. In a further and/or alternative aspect of this
embodiment, the thickness of the stainless steel strip is about
127-762 microns. In yet a further and/or alternative aspect of this
embodiment, the thickness of the stainless steel strip is about
254-762 microns. In still a further and/or alternative aspect of
this embodiment, the thickness of the stainless steel strip is
about 381-762 microns. In still embodiment of the invention, the
stainless steel base metal is a metal plate.
[0052] In accordance with yet aspect of the invention, the base
metal is copper. Copper metal is known for its malleability
properties and natural corrosion resistant properties. Copper metal
that is coated with a metal alloy can be formed into a variety of
simple and complex shapes. In one embodiment of the invention, the
copper base metal is a metal strip. In one aspect of this
embodiment, the thickness of the copper strip is not more than
about 5080 microns. In aspect of this embodiment, the thickness of
the copper strip is less than about 2540 microns. In yet aspect of
this embodiment, the thickness of the copper strip is less than
about 1270 microns. In still aspect of this embodiment, the
thickness of the copper strip is up to about 762 microns. In a
further and/or alternative aspect of this embodiment, the thickness
of the copper strip is about 127-762 microns. In yet a further
and/or alternative aspect of this embodiment, the thickness of the
copper strip is about 254-762 microns. In still a further and/or
alternative aspect of this embodiment, the thickness of the copper
strip is about 381-762 microns. In still embodiment of the
invention, the copper base metal is a metal plate.
[0053] In accordance with still yet aspect of the invention, the
base metal is a copper alloy. "Copper alloys" as used herein
include, but are not limited to, brass and bronze. Brass is defined
as a copper alloy that includes a majority of copper and zinc.
Bronze is defined as an alloy that includes tin and a majority of
copper. Brass and bronze are copper alloys with known corrosion
resistant properties in various environments. Although brass and
bronze are relatively corrosion resistant in many environments,
brass and bronze are susceptible to a greater degree of corrosion
in some environments than others. Brass and bronze are also
relatively bright and reflective materials which can be undesirable
for use in several applications. As a result, it has been found
that brass and bronze coated with a corrosion resistant metal alloy
can overcomes these deficiencies. In one embodiment of the
invention, the copper content of the brass is about 50.1-99 weight
percent and the zinc content is about 1-49.9 weight percent. In one
aspect of this embodiment, the brass includes one or more additives
such as, but not limited to, aluminum, beryllium, carbon, chromium,
cobalt, iron, lead, manganese, magnesium, nickel, niobium,
phosphorous, silicon, silver, sulfur, and/or tin. These additives
typically alter the mechanical and/or corrosion resistant
properties of the brass. In embodiment of the invention, the bronze
includes one or more additives such as, but not limited to,
aluminum, iron, lead, manganese, nickel, nitrogen, phosphorous,
silicon, and/or zinc. In still embodiment of the invention, the
copper alloy base metal is a metal strip. In one aspect of this
embodiment, the thickness of the copper alloy strip is not more
than about 5080 microns. In aspect of this embodiment, the
thickness of the copper alloy strip is less than about 2540
microns. In yet aspect of this embodiment, the thickness of the
copper alloy strip is less than about 1270 microns. In still aspect
of this embodiment, the thickness of the copper alloy strip is less
than about 762 microns. In a further and/or alternative aspect of
this embodiment, the thickness of the copper alloy strip is about
127-762 microns. In yet a further and/or alternative aspect of this
embodiment, the thickness of the copper alloy strip is about
254-762 microns. In still a further and/or alternative aspect of
this embodiment, the thickness of the copper alloy strip is about
381-762 microns. In yet embodiment of the invention, the copper
alloy base metal is a metal plate.
[0054] In accordance with a further and/or alternative aspect of
the invention, the base metal is made of aluminum, aluminum alloys,
nickel alloys, tin, titanium, or titanium alloys. "Aluminum alloys"
are used herein include, but are not limited to, alloys including
at least about 10 weight percent aluminum. "Nickel alloys" are used
herein include, but are not limited to, alloys including at least
about 5 weight percent nickel. In one embodiment of the invention,
the base metal is an aluminum metal strip. In embodiment of the
invention, the base metal is a aluminum alloy metal strip. In yet
embodiment of the invention, the base metal is a nickel alloy, tin,
titanium, or titanium alloy strip. In still embodiment of the
invention, the base metal is a tin metal strip. In still yet
embodiment of the invention, the base metal is a titanium metal
strip. In a further and/or alternative embodiment of the invention,
the base metal is a titanium alloy metal strip. In one aspect of
these embodiments, the thickness of the aluminum, aluminum alloy,
nickel alloy, tin, titanium, or titanium alloy strip is less than
about 2540 microns. In aspect of these embodiments, the thickness
of the aluminum, aluminum alloy, nickel alloy, tin, titanium, or
titanium alloy strip is less than about 1588 microns. In yet aspect
of these embodiments, the thickness of the aluminum, aluminum
alloy, nickel alloy, tin, titanium, or titanium alloy strip is less
than about 1270 microns. In still aspect of these embodiments, the
thickness of the aluminum, aluminum alloy, nickel alloy, tin,
titanium, or titanium alloy strip is up to about 762 microns. In a
further and/or alternative aspect of these embodiments, the
thickness of the aluminum, aluminum alloy, nickel alloy, tin,
titanium, or titanium alloy strip is about 127-762 microns. In yet
a further and/or alternative aspect of these embodiments, the
thickness of the aluminum, aluminum alloy, nickel alloy, tin,
titanium, or titanium alloy strip is about 240-762 microns. In
still a further and/or alternative aspect of these embodiments, the
thickness of the aluminum, aluminum alloy, nickel alloy, tin,
titanium, or titanium alloy strip is about 381-762 microns. In yet
a further and/or alternative embodiment of the invention, the base
metal is an aluminum metal plate. In still a further and/or
alternative embodiment of the invention, the base metal is a
aluminum alloy metal plate. In still yet a further and/or
alternative embodiment of the invention, the base metal is a nickel
alloy plate. In embodiment of the invention, the base metal is a
tin metal plate. In yet embodiment of the invention, the base metal
is a titanium metal plate. In still embodiment of the invention,
the base metal is a titanium alloy metal plate.
[0055] In accordance with a yet further and/or alternative aspect
of the invention, the base metal is pretreated prior to applying
the metal alloy to the base metal. The pretreatment of the base
metal is designed to remove dirt, oil, adhesives, plastic, paper
and/or other foreign substances from the surface of the base metal;
to remove oxides and other compounds from the base metal surface;
etch the base metal surface; and/or improve the bonding of the
metal alloy coating to the surface of the base metal. The
pretreatment process may include one or more process steps
depending on the surface condition of the base metal. In one
embodiment of the invention, the various steps of the pretreatment
process for the base metal are similar to the pretreatment process
disclosed in U.S. Pat. No. 5,395,702, which is incorporated herein.
In embodiment of the invention, the pretreatment process includes,
but is not limited to, an abrasion process; an absorbent process;
solvent and/or cleaning solution process; a low oxygen environment
process; a rinse process; a pickling process; a chemical activation
process; a flux treating process; and/or an intermediate barrier
metal layer coating process. In one aspect of this embodiment, each
of these pretreatment process can be use singly or in combination
with one. The type and/or number of pretreatment process used
generally depends on the type of base metal and/or condition of the
base metal surface. The pretreatment process can be applied to a
portion of the base metal surface or the complete surface of the
base metal.
[0056] The abrasion process, absorbent process and/or solvent or
cleaning process are designed to remove foreign materials and/or
oxides from the base metal surface. In one embodiment of the
invention, the abrasion process includes, but is not limited to,
the use of brushes, scrappers and the like to mechanically remove
oxides and/or foreign material from the surface of the base metal.
In embodiment of the invention, the absorbent process includes, but
is not limited to, the use of absorbing materials (i.e. towels,
absorbent paper products, sponges, squeegees, etc.) to mechanically
remove oxides and/or foreign material from the surface of the base
metal. In still embodiment of the invention, the solvent or
cleaning process includes, but is not limited to, the use of water,
detergents, abrasives, chemical solvents, and/or chemical cleaners
to remove oxides and/or foreign material from the surface of the
base metal. The abrasion process, absorbent process, and/or solvent
or cleaning process can be use individually or in conjunction with
one to remove foreign materials and/or oxides from the base metal
surface.
[0057] The low oxygen environment process is designed to inhibit
the formation and/or reformation of oxides on the surface of the
base metal. The low oxygen environment may take on several forms
such as, but not limited to, a low oxygen-containing gas
environment and/or a low oxygen-containing liquid environment.
Examples of gases used in the low oxygen-containing gas
environments include, but are not limited to, nitrogen,
hydrocarbons, hydrogen, noble gasses and/or other non-oxidizing
gasses. The one or more gases partially or totally shield oxygen
and/or other oxidizing elements or compounds from the base metal.
In one embodiment of the invention, the low oxygen-containing gas
environment includes nitrogen. Examples of liquids used in the low
oxygen-containing liquid environment include, but are not limited
to, non-oxidizing liquids and/or liquids containing a low dissolved
oxygen content. The liquids partially or totally shield oxygen
and/or other oxidizing elements or compounds from the base metal.
In embodiment of the invention, the low oxygen-containing liquid
environment includes heated water that is at least about
37-49.degree. C. (100-110.degree. F.). In still embodiment of the
invention, the low oxygen-containing environment is applied to the
base metal by spraying the low oxygen-containing environment onto
the surface of the base metal, partially or totally immersing the
base metal in the low oxygen-containing environment, and/or
encasing the base metal in the low oxygen-containing environment.
In still yet embodiment of the invention, agitators are used in the
low oxygen-containing liquid environment to facilitate in the
removal of oxides and/or inhibit oxide formation on the base metal.
The agitators can include brushes which contact the base metal.
[0058] The rinsed process is designed to remove foreign materials,
oxides, pickling solution, deoxidizing agent, fluxes, solvents,
and/or cleaning solutions from the surface of the base metal. In
one embodiment of the invention, the rinse process includes the use
of a rinse solution that includes a low or non-oxidizing liquid. In
one aspect of this embodiment, the low or non-oxidizing liquid
includes water that is at least about 21.degree. C. (70.degree.
F.). In embodiment of the invention, the rinse solution can be
applied to the surface of the metal strip by spraying the rinse
solution onto the metal strip and/or partially or totally immersing
the metal strip in the rinse solution. In yet embodiment of the
invention, the rinse solution is agitated to facilitate in the
cleaning of the base metal surface. In still embodiment of the
invention, the rinse solution is recirculated, diluted and/or
temperature is maintained during the rinsing process.
[0059] The pickling process is designed to remove a very thin
surface layer from the base metal. The removal of the thin layer
from the base metal results in the partial or total removal of
oxides and/or other foreign matter from the base metal surface. The
removal of the thin surface layer from the base metal causes a
slight etching of the base metal surface which results in the
formation of microscopic valleys on the base metal surface. These
microscopic valleys increase the surface area to which the metal
alloy and/or intermediate barrier metal layer can bond thereby
facilitating in the formation of a stronger bond between the base
metal and the metal alloy and/or intermetallic barrier metal layer.
The pickling process includes the use of a pickling solution which
can be an acidic or a basic solution. In one embodiment of the
invention, the pickling solution is an acidic solution. The acid
can be an organic acid, an inorganic acid, or combinations thereof.
In one aspect of this embodiment, the inorganic acid used in the
pickling solution includes, but are not limited to, hydrobromic
acid, hydroiodic acid, choleic acid, perchloric acid, hydrofluoric
acid, sulfuric acid, nitric acid, hydrochloric acid, phosphoric
acid, and/or isobromic acid. In aspect of this embodiment, the
organic acid used in the pickling solution includes, but are not
limited to, formic acid, propionic acid, butyric acid, and/or
isobutyric acid. In embodiment of the invention, the pickling
solution includes a single acid. Most base metal surfaces can be
satisfactorily cleaned or pickled with the use of a single acid. In
one aspect of this embodiment, the pickling solution only includes
an inorganic acid. In still embodiment of the invention, the
pickling solution includes two or more acids. Some base metals are
more difficult to clean or pickle. Stainless steel, as with other
metals, is known to have surface oxides that are difficult to
remove. When coating stainless steel, it is very desirable to
activate (i.e. remove surface oxides) the stainless steel surface
so as to form a strong bond and to uniformly coat the stainless
steel base metal. The chromium in the stainless steel surface
reacts with atmospheric oxygen to form a chromium oxide film on the
surface of the stainless steel. The chromium oxide film creates an
almost impenetrable barrier which protects the iron in the
stainless steel from oxidizing. The chromium oxide film also forms
a very tight and strong bond with the stainless steel, thus is not
easily removable. Although the formation of the chromium oxide film
is important in the corrosion-resistant properties of the stainless
steel and is intended for commercial stainless steel, the chromium
oxide film can interfere with the bonding of the metal alloy
coating to the stainless steel surface, thereby resulting in a
weaker bond with the metal alloy coating, thus resulting in flaking
of the metal alloy coating. The surface activation of the stainless
steel, as with other base metals, is accomplished by removing the
oxides on the surface of the base metal. The removal of the
chromium oxide film from the stainless steel surface activates the
stainless steel surface. Testing of coated stainless steel has
revealed that the removal of chromium oxide film improves the
bonding of the metal alloy coating and allows for thick and/or
uniform metal alloy coatings to be formed. Oxide removal on other
base metals also improves the bonding, coating uniformity and/or
coating thickness of the metal alloy coating. Pickling solutions
that include two or more acids typically can provide a more rapid
oxide removal rate. As can be appreciated, the use of a pickling
solution that includes two or more acids is not limited to use on
stainless steel or other base metals wherein oxide removal is
difficult, but can be used on base metals to increase the rate of
cleaning or pickling thereby reducing time for the pickling
process. In one aspect of this embodiment, the pickling solution
contains a combination of hydrochloric acid and nitric acid. One
specific formulation of this dual acid pickling solution is a
pickling solution including about 5-25% by volume hydrochloric acid
and about 1-15% by volume nitric acid. A more specific formulation
of this dual acid pickling solution is a pickling solution
including about 5-15% by volume hydrochloric acid and about 1-5% by
volume nitric acid. A yet more specific formulation of this dual
acid pickling solution is a pickling solution including about 10%
by volume hydrochloric acid and about 3% by volume nitric acid. In
yet embodiment of the invention, the temperature of the pickling
solution is maintained to obtain the desired activity of the
pickling solution. In one aspect of this embodiment, the pickling
solution is maintained at a temperature of above about 26.degree.
C. In aspect of this embodiment, the pickling solution is
maintained at a temperature of about 48-60.degree. C. In yet aspect
of this embodiment, the pickling solution is maintained at a
temperature of about 53-56.degree. C. Higher acid concentrations
and/or higher acid temperatures will typically increase the
activity and aggressiveness of the pickling solution. In yet
embodiment of the invention, the pickling solution is agitated to
prevent or inhibit the pickling solution from stagnating, varying
in concentration, varying in temperature, and/or to remove gas
pockets which form on the base metal surface. In one aspect of this
embodiment, the pickling solution is at least partially agitated by
placing agitators in a pickling tank and/or by recirculating the
pickling solution in a pickling tank. Typically, agitation brushes
in the pickling tank contact the base metal as it passes through
the pickling tank to facilitate in oxide removal and cleaning of
the base metal surface. In embodiment of the invention, the base
metal is exposed to the pickling solution for a sufficient time to
properly clean and/or pickle the surface of the base metal. In one
aspect of this embodiment, the total time for pickling the base
metal is less than about 10 minutes. In aspect of this embodiment,
the total time for pickling the base metal is less than about two
minutes. In still aspect of this embodiment, the total time for
pickling the base metal is less than about one minute. In still yet
aspect of this embodiment, the total time for pickling the base
metal is about 5-60 seconds. In a further and/or alternative aspect
of this embodiment, the total time for pickling the base metal is
about 10-20 seconds. In still embodiment, the pickling solution is
applied to the base metal by sprayjets. In yet embodiment, the base
metal is partially or fully immersed in the pickling solution
contained in a pickling tank.
[0060] The chemical activation process is designed to remove oxides
and/or foreign material from the base metal surface. In one
embodiment of the invention, the chemical activation process
includes the subjecting of the base metal surface to a deoxidizing
agent. Various types of deoxidizing agents may be used. In
embodiment of the invention, the deoxidizing agent includes zinc
chloride. In one aspect of this embodiment, the deoxidizing agent
includes at least about 1% by volume zinc chloride. In aspect of
this embodiment, the deoxidizing agent includes at least about 5%
by volume zinc chloride. The zinc chloride removes oxides and
foreign materials from the base metal surface and/or provides a
protective coating which inhibits oxide formation on the base metal
surface. In still embodiment of the invention, the temperature of
the zinc chloride solution is at least about ambient temperature
(about 15-32.degree. C.). In yet embodiment, the deoxidizing
solution is agitated to maintain a uniform solution concentration
and/or temperature. In one aspect of this embodiment, the agitators
include brushes which contact the base metal. In still yet
embodiment of the invention, small amounts of acid are added to the
deoxidizing solution to enhance oxide removal. In one aspect of
this embodiment, hydrochloric acid is added to the deoxidizing
solution. In this aspect, one formulation of the deoxidizing
solution includes about 1-50% by volume zinc chloride and about
0.5-15% by volume hydrochloric acid. In this aspect, formulation of
the deoxidizing solution includes about 5-50% by volume zinc
chloride and about 1-15% by volume hydrochloric acid. In a further
and/or alternative embodiment of the invention, the base metal is
subjected to the deoxidizing solution for less than about 10
minutes. In one aspect of this embodiment, the base metal is
subjected to the deoxidizing solution for up to about one minute.
In still a further and/or alternative embodiment, the deoxidizing
solution is applied to the base metal by spray jets. In yet a
further and/or alternative embodiment, the base metal is partially
or fully immersed in the deoxidizing solution contained in a
deoxidizing tank.
[0061] The intermediate barrier metal process is designed to coat
one or more surface areas of the base metal with a thin metal
coating. The intermediate metal barrier is applied to part of or
the complete surface of the base metal by a plating process, a
plating and subsequent flow heating process, a metal spraying
process, a coating roller process, and/or an immersion process in
molten metal prior to applying the metal alloy coating to the base
metal surface. The intermediate barrier metal typically provides
additional corrosion resistance to the base metal in many types of
corrosive environments. In marine environments where the coated
base metal is exposed to salt and/or halogens (i.e. chlorine,
fluorine, etc.), the use of an intermediate barrier metal can
significantly extend the life of the coated base metal. The use of
an intermediate barrier metal can also enhance the bonding of the
metal alloy coating to the base metal. Some base metals such as,
but not limited to, stainless steel form a weaker bond with certain
formulations of the metal alloy. The application of an intermediate
barrier metal on part of or the complete surface of the base metal
can, in many instances, improve the strength of the bond of the
metal alloy coating to the base metal. The intermediate barrier
metal is typically tin, nickel, copper, and/or chromium. Other
metals can be used for the intermediate barrier metal, such as, but
not limited to, aluminum, cobalt, molybdenum, Sn--Ni, Fe--Ni,
and/or zinc. Typically, one intermediate barrier metal is formed on
the surface of the base metal; however, more than one layer of one
or more barrier metals can be applied to the surface of the base
metal to form a thicker intermediate barrier metal layer, alter the
composition of the intermediate barrier metal layer, alter the
composition of the heat created intermetallic layer if formed,
and/or improve the bonding of the metal alloy coating to the
intermediate barrier metal layer and/or base metal. In one
embodiment of the invention, the intermediate barrier metal
includes nickel. Typically, the nickel is flashed or plated to the
base metal surface. The nickel including intermediate barrier metal
layer improves corrosion-resistance of the base metal and/or metal
alloy, especially against halogen containing compounds which can
penetrate the metal alloy coating and attack and oxidize the
surface of the base metal, thereby weakening the bond between the
base metal and the metal alloy coating. The nickel including
intermediate barrier metal layer has also been found to provide a
formidable barrier to alcohols and/or various type of petroleum
products. The metal alloy coating and nickel including intermediate
barrier metal effectively complement one to provide superior
corrosion resistance. An intermediate barrier metal layer which
includes nickel also improves the bonding of the metal alloy
coating to the base metal. The bond between the metal alloy coating
and the nickel layer is surprisingly strong and durable, thereby
inhibiting the metal alloy coating from flaking. An intermediate
barrier metal layer which includes nickel also inhibits the
formation of a thick zinc layer in the intermetallic layer, when
zinc is included in the metal alloy. In embodiment of the
invention, the intermediate barrier metal includes tin, chromium
and/or copper. An intermediate barrier metal layer which includes
tin, chromium and/or copper improves the bonding of the metal alloy
coating to the base metal. The tin, chromium and/or copper in the
intermediate barrier metal also has been found to inhibit adverse
zinc intermetallic layer growth from the zinc in a zinc containing
metal alloy. A thick zinc layer can cause poor coating quality or
cracking of the coating during forming and bending of a coated
material, thereby giving rise to localized corrosion, and/or
adversely affecting performance of the coated strip in particular
applications. When copper is included in the intermediate barrier
metal, the copper is typically plated onto the surface of the base
metal. The plated copper layer can be, but is not limited to being
formed by passing the base metal through an electroplating process
or by adding copper sulfate to a pickling solution and pickling the
coated base metal. A copper containing intermediate barrier metal
layer also enhances the corrosion-resistant properties of the heat
created intermetallic layer, improves the bonding of the metal
alloy to the base metal, and/or improves the corrosion resistance
of the metal alloy and/or base metal. When tin is included in the
intermediate barrier metal, the tin is typically coated onto the
base metal by immersion in molten metal, plating and/or metal
spraying. A tin containing intermediate barrier metal
advantageously changes the composition of the heat created
intermetallic layer to form a highly corrosion-resistant heat
created intermetallic layer, improves the bonding of the metal
alloy to the base metal, and/or improves the corrosion-resistance
of the metal alloy and/or base metal. When chromium is included in
the intermediate barrier metal, the chromium is typically plated
onto the surface of the base metal. A chromium containing
intermediate barrier metal layer advantageously changes the
composition of the heat created intermetallic layer to form a
highly corrosion-resistant heat created intermetallic layer,
improves the bonding of the metal alloy, and/or improves the
corrosion resistance of the metal alloy and/or base metal. In still
another and/or alternative embodiment of the invention, the
intermediate barrier metal includes aluminum, cobalt, molybdenum,
Sn--Ni, Fe--Ni, and/or zinc. The aluminum, cobalt, molybdenum,
Sn--Ni, Fe--Ni, and/or zinc are typically plated onto the base
metal by a plating process. An intermediate barrier metal layer
which includes aluminum, cobalt, molybdenum, Sn--Ni, Fe--Ni, and/or
zinc improves the bonding of the corrosion resistant metal alloy
coating to the base metal, enhances the corrosion-resistant
properties of the heat created intermetallic layer, and/or improves
the corrosion-resistance of the metal alloy and/or base metal. In
yet another and/or alternative embodiment of the invention, the
thickness of the intermediate barrier metal layer is at least about
0.3 micron. In one aspect of this embodiment, the thickness of the
intermediate barrier metal layer is at least about 1 micron. In
another and/or alternative aspect of this embodiment, the thickness
of the intermediate barrier metal layer is less than about 500
microns. In yet another and/or alternative aspect of this
embodiment, the thickness of the intermediate barrier metal layer
is less than about 250 microns. In still another and/or alternative
specific aspect of this embodiment, the thickness of the
intermediate barrier metal layer is less than about 50 microns. In
still yet another and/or alternative aspect of this embodiment, the
thickness of the intermediate barrier metal layer is less than
about 20 microns. In a further and/or alternative aspect of this
embodiment, the thickness of the intermediate barrier metal layer
is about 1-10 microns. In yet a further and/or alternative aspect
of this embodiment, the thickness of the intermediate barrier metal
layer is about 1-3 microns. In accordance with still yet another
and/or alternative embodiment of the invention, the intermediate
barrier metal layer is pre-heated and/or flow heated prior to
applying the metal alloy coating to the base metal. The heating of
the intermediate barrier metal layer to a sufficient temperature
for a sufficient amount of time causes a heat created intermetallic
layer to form between the intermediate barrier metal layer and the
base metal. A heat created intermetallic layer is formed without
the use of a subsequent heating step when the intermediate barrier
metal is applied to the base metal by a metal spraying process, a
coating roller process, and/or an immersion process. The
temperature of the intermediate barrier metal in the molten state
causes a heat created intermetallic layer to form between the
intermediate barrier metal and the base metal when the molten
intermediate barrier metal contacts the surface of the base metal.
When the intermediate barrier metal is applied by a plating or
pickling process, a subsequent heating step is needed to form the
heat created intermetallic layer between the intermediate barrier
metal and the base metal. A "heat created intermetallic layer" is
defined herein as a metal layer formed by heat wherein the metal
layer is a mixture of at least the primary surface components of
the base metal and one or more components of a coated metal layer
(i.e. intermediate barrier metal and/or metal alloy coating). The
application of heat to the base metal and a coated metal layer
causes the surface of the base metal to soften and/or melt and to
combine with a portion of the soften or melted coated metal layer.
In many instances, the formation of a heat created intermetallic
layer results in improved bonding of the coated metal to the base
metal, and/or improves the corrosion-resistance of the base metal
and/or coated metal layer. In one aspect of this embodiment, the
thickness of the heat created intermetallic layer formed between
the base metal and the intermediate barrier metal is at least about
0.1 micron. In another and/or alternative aspect of this
embodiment, the thickness of the heat created intermetallic layer
formed between the base metal and the intermediate barrier metal is
at least about 0.3 micron. In still another and/or alternative
aspect of this embodiment, the thickness of the heat created
intermetallic layer formed between the base metal and the
intermediate barrier metal is at least about 0.5 micron. In still
another and/or alternative aspect of this embodiment, the thickness
of the heat created intermetallic layer formed between the base
metal and the intermediate barrier metal is at least about 1
micron. In yet another and/or alternative aspect of this
embodiment, the thickness of the heat created intermetallic layer
formed between the base metal and the intermediate barrier metal is
less than about 100 microns. In still yet another and/or
alternative aspect of this embodiment, the thickness of the heat
created intermetallic layer formed between the base metal and the
intermediate barrier metal is less than about 50 microns. In a
further and/or alternative aspect of this embodiment, the thickness
of the heat created intermetallic layer formed between the base
metal and the intermediate barrier metal is less than about 25
microns. In yet a further and/or alternative aspect of this
embodiment, the thickness of the heat created intermetallic layer
formed between the base metal and the intermediate barrier metal is
less than about 20 microns. In still a further and/or alternative
aspect of this embodiment, the thickness of the heat created
intermetallic layer formed between the base metal and the
intermediate barrier metal is less than about 10 microns. In still
yet a further and/or alternative aspect of this embodiment, the
thickness of the heat created intermetallic layer formed between
the base metal and the intermediate barrier metal is about 1-10
microns. In still yet a further and/or alternative aspect of this
embodiment, the thickness of the heat created intermetallic layer
formed between the base metal and the intermediate barrier metal is
about 1-5 microns. In still yet even a further and/or alternative
aspect of this embodiment, the thickness of the heat created
intermetallic layer formed between the base metal and the
intermediate barrier metal is about 1-3 microns. Typically the
formation of a heat created intermetallic layer takes at least a
couple seconds to form. In one embodiment of the present invention,
the base metal is exposed to heat for at least about 2 seconds to
form the heat created intermetallic layer between the base metal
and the intermediate barrier metal. The time period of heat
exposure for an intermediate barrier metal layer applied by a
plating and/or a pickling process is the time the intermediate
barrier metal is exposed to heat after the plating and/or pickling
process. The time period for heat exposure for an intermediate
barrier metal layer applied by metal spraying, coating rollers,
and/or immersion in molten metal includes the time of applying the
intermediate barrier metal to the base metal and the time the
intermediate barrier metal is exposed to heat after the metal
spraying, coating rollers, and/or immersion in molten metal
process. Typically, the time of total heat exposure is less than
about four hours; however, greater heat exposure times can be used.
In one aspect of this embodiment, the total time period of heat
exposure to an intermediate barrier metal layer applied to the base
metal to form an intermetallic layer between the base metal and the
intermediate barrier metal layer is less than about 20 minutes. In
another and/or alternative aspect of this embodiment, the total
time period of heat exposure to an intermediate barrier metal layer
applied to the base metal to form an intermetallic layer between
the base metal and the intermediate barrier metal layer is less
than about 10 minutes. In yet another and/or alternative aspect of
this embodiment, the total time period of heat exposure to an
intermediate barrier metal layer applied to the base metal to form
an intermetallic layer between the base metal and the intermediate
barrier metal layer is less than about 5 minutes. In still another
and/or alternative aspect of this embodiment, the total time period
of heat exposure to an intermediate barrier metal layer applied to
the base metal to form an intermetallic layer between the base
metal and the intermediate barrier metal layer is about 0.033-2
minutes. When heat is applied to the coated base metal to form or
further and/or alternative form the heat created intermetallic
layer between the base metal and intermediate metal barrier layer,
the heat typically is applied by, but not limited to, an oven
and/or furnace, induction heating coils, lasers, heat exchanger,
and/or radiation. As can be appreciated, the flow heating of the
plated intermediated barrier layer can also function as a pre-heat
process for the base metal. Alternatively or additionally, the heat
can be supplied by coating the base metal and the intermediated
metal barrier layer with a metal alloy by a hot-dip process. The
heat from the hot-dip process causes the formation of the heat
created intermetallic layer. In still another and/or alternative
embodiment of the invention, the application of the intermediate
barrier metal layer on the surface of the base metal is a partial
or complete pretreatment process for the surface of the base metal
prior to applying the metal alloy coating to the base metal. The
application of the an intermediate barrier metal to the surface of
the base metal forms a clean metal surface on the base metal
surface. Due to this clean metal surface, the application of the an
intermediate barrier metal to the surface of the base metal can
function as the sole pretreatment process for the surface of the
base metal. As can be appreciated, the surface of the base metal
can be pretreated with other pretreatment process prior to applying
the intermediate barrier metal layer and/or pretreated with other
pretreatment process subsequent to applying the intermediate
barrier metal layer.
[0062] In accordance with another and/or alternative aspect of the
invention, metal alloy coating is coated on the base metal by a
plating process or by a hot dip process. The coating process for
the metal alloy coating can be by a batch or continuous process. As
defined herein, a "hot dip process" for the metal alloy is any
process that coats the metal alloy coating on the base metal and
causes the formation of a heat created intermetallic layer between
the base metal and the metal alloy coating.
[0063] Examples of a hot dip process include, but are not limited
to, 1) plating a metal alloy coating partially or totally on the
base metal and subsequently heating the plated layer until a heat
created intermetallic layer forms between the plated layer and the
base metal, 2) plating a metal alloy partially or totally on the
base metal and subsequent partial or total immersion of the base
metal in a molten bath of metal alloy for a sufficient period of
time to partially or totally coat the base metal and to form a heat
created intermetallic layer between the coated metal alloy layer
and the base metal, 3) plating a metal alloy partially or totally
on the base metal and subsequent spray coating molten metal alloy
onto the base metal to partially or totally coat the base metal
wherein the base metal is spray coated for a sufficient period of
time to form a heat created intermetallic layer between the coated
metal layer and base metal, 4) plating a metal alloy partially or
totally on the base metal and subsequent partial or total immersion
of the base metal in a molten bath of metal alloy and spray coating
molten metal alloy onto the base metal to partially or totally coat
the base metal wherein the base metal is spray coated and immersed
for a sufficient period of time to form a heat created
intermetallic layer between the coated metal layer and base metal,
5) partial or total immersion of the base metal in a molten bath of
metal alloy for a sufficient period of time to partially or totally
coat the base metal and to form a heat created intermetallic layer
between the coated metal layer and the base metal, 6) partial or
total immersion of the base metal in a molten bath of metal alloy
for a sufficient period of time to partially or totally coat the
base metal and spray coating molten metal alloy onto the base metal
to partially or totally coat the base metal wherein the base metal
is immersed and sprayed for a sufficient period of time to form a
heat created intermetallic layer between the coated metal layer and
base metal, 7) spray coating the base metal with molten metal alloy
to partially or totally coat the base metal for a sufficient period
of time to form a heat created intermetallic layer between the
coated metal layer and the base metal, 8) plating and subsequent
heating and subsequent immersion in molten metal alloy coating
and/or spray coating molten metal alloy coating for a sufficient
period of time to form a heat created intermetallic layer between
the coated metal layer and the base metal, 9) plating and
subsequent heating and subsequent immersion in molten metal alloy
coating and/or spray coating molten metal alloy coating and
subsequent heating after immersion in molten metal alloy coating
and/or spray coating molten metal alloy coating for a sufficient
period of time to form a heat created intermetallic layer between
the coated metal layer and the base metal, 10) immersion in molten
metal alloy coating and subsequent heating for a sufficient period
of time to form a heat created intermetallic layer between the
coated metal layer and the base metal, 11) immersion in molten
metal alloy coating and spray coating molten metal alloy coating
and subsequent heating after immersion and spray coating for a
sufficient period of time to form a heat created intermetallic
layer between the coated metal layer and the base metal, 12) spray
coating molten metal alloy coating and subsequent heating after
spray coating for a sufficient period of time to form a heat
created intermetallic layer between the coated metal layer and the
base metal, 13) coating molten metal alloy by coating rollers for a
sufficient period of time to form a heat created intermetallic
layer between the coated metal layer and the base metal, 14)
coating molten metal alloy by coating rollers and spray coating for
a sufficient period of time to form a heat created intermetallic
layer between the coated metal layer and the base metal, 15)
immersion in molten metal alloy and coating molten metal alloy by
coating rollers for a sufficient period of time to form a heat
created intermetallic layer between the coated metal layer and the
base metal, 16) plating and coating molten metal alloy by coating
rollers for a sufficient period of time to form a heat created
intermetallic layer between the coated metal layer and the base
metal, and/or 17) coating molten metal alloy by coating rollers and
subsequent heating for a sufficient period of time to form a heat
created intermetallic layer between the coated metal layer and the
base metal. As can be appreciated, many other hot dip coating
combinations can be used. As further and/or alternative can be
appreciated, the base metal can be coated multiple of times by
various types of coated processes. When heat is subsequently
applied to the coated base metal to form or further and/or
alternative form the heat created intermetallic layer between the
base metal and the metal alloy coating, the heat typically is
applied to, but not limited to, an oven and/or furnace, induction
heating coils, lasers, a heat exchanger, and/or radiation. In one
embodiment of the invention, the thickness of the heat created
intermetallic layer is at least about 0.3 micron. In one aspect of
this embodiment, the thickness of the heat created intermetallic
layer formed between the base metal and the metal alloy coating is
at least about 1 micron. In yet another and/or alternative aspect
of this embodiment, the thickness of the heat created intermetallic
layer formed between the base metal and the metal alloy coating is
less than about 100 microns. In still yet another and/or
alternative aspect of this embodiment, the thickness of the heat
created intermetallic layer formed between the base metal and the
metal alloy coating is less than about 50 microns. In a further
and/or alternative aspect of this embodiment, the thickness of the
heat created intermetallic layer formed between the base metal and
the metal alloy coating is less than about 25 microns. In yet a
further and/or alternative aspect of this embodiment, the thickness
of the heat created intermetallic layer formed between the base
metal and the metal alloy coating is less than about 20 microns. In
still a further and/or alternative aspect of this embodiment, the
thickness of the heat created intermetallic layer formed between
the base metal and the metal alloy coating is less than about 10
microns. In still yet a further and/or alternative aspect of this
embodiment, the thickness of the heat created intermetallic layer
formed between the base metal and the metal alloy coating is about
1-5 microns. In still yet even a further and/or alternative aspect
of this embodiment, the thickness of the heat created intermetallic
layer formed between the base metal and the metal alloy coating is
about 1-3 microns. Typically, the formation of a heat created
intermetallic layer takes at least a couple seconds to form. In one
embodiment of the invention, the base metal is exposed to heat for
at least 2 seconds to form the heat created intermetallic layer
between the base metal and the metal alloy coating. The time period
of heat exposure of a metal alloy coating layer applied by a
plating process is the time the metal alloy coating is exposed to
heat after the plating process. The time period for heat exposure
for a metal alloy coating layer applied by metal spraying, coating
rollers and/or immersion in molten metal includes the time of
applying the metal alloy coating to the base metal and the time the
metal alloy coating is exposed to heat after the metal spraying,
coating rollers, and/or immersion in molten metal process. In one
aspect of this embodiment, the total time period of heat exposure
to a metal alloy coating layer applied to the base metal to form an
intermetallic layer between the base metal and the metal alloy
coating layer is less than about 3 hours. In another and/or
alternative aspect of this embodiment, the total time period of
heat exposure to a metal alloy coating layer applied to the base
metal to form an intermetallic layer between the base metal and the
metal alloy coating layer is less than about 4 hours. In still
another and/or alternative aspect of this embodiment, the total
time period of heat exposure to a metal alloy coating layer applied
to the base metal to form an intermetallic layer between the base
metal and the metal alloy coating layer is less than about 2 hours.
In yet another and/or alternative aspect of this embodiment, the
total time period of heat exposure to a metal alloy coating layer
applied to the base metal to form an intermetallic layer between
the base metal and the metal alloy coating layer is less than about
1 hour. In still yet another and/or alternative aspect of this
embodiment, the total time period of heat exposure to a metal alloy
coating layer applied to the base metal to form an intermetallic
layer between the base metal and the metal alloy coating layer is
less than about 30 minutes. In a further and/or alternative aspect
of this embodiment, the total time period of heat exposure to a
metal alloy coating layer applied to the base metal to form an
intermetallic layer between the base metal and the metal alloy
coating layer is less than about 20 minutes. In yet further and/or
alternative aspect of this embodiment, the total time period of
heat exposure to a metal alloy coating layer applied to the base
metal to form an intermetallic layer between the base metal and the
metal alloy coating layer is less than about 10 minutes. In still a
further and/or alternative another and/or alternative aspect of
this embodiment, the total time period of heat exposure to a metal
alloy coating layer applied to the base metal to form an
intermetallic layer between the base metal and the metal alloy
coating layer is less than about 5 minutes. In still yet further
and/or alternative aspect of this embodiment, the total time period
of heat exposure to a metal alloy coating layer applied to the base
metal to form an intermetallic layer between the base metal and the
metal alloy coating layer is about 0.033-2 minutes. In still a
further and/or alternative aspect of this embodiment, the total
time period of heat exposure to a metal alloy coating layer applied
to the base metal to form an intermetallic layer between the base
metal and the metal alloy coating layer is about 0.033-0.5 minutes.
In yet a further and/or alternative aspect of this embodiment, the
total time period of heat exposure to a metal alloy coating layer
applied to the base metal to form an intermetallic layer between
the base metal and the metal alloy coating layer is about 0.083-0.5
minutes.
[0064] The metal alloy coating formed on the surface of the base
metal by a batch coating process or by a continuous coating process
can result in different types of coatings. These differences can
include, but are not limited to, the following:
[0065] a) Uniformity of coating (weight and thickness)
[0066] b) Surface appearance
[0067] c) Smoothness
[0068] d) Texture control
[0069] e) Control of intermetallic phases (growth and
uniformity)
[0070] A base metal coated in a continuous coating process
typically produces a coated base metal having superior uniformity
of coating (weight and thickness), superior metallographic
structure, superior surface appearance, superior smoothness,
superior spangle size, and fewer surface defects. Furthermore, the
composition of the heat created intermetallic layer is typically
superior as compared to a base metal coated in a batch coating
process. In addition to surface appearance and uniformity of
thickness, the formability of the coated base metal is generally
better due to a more uniform coating thickness on the surface of
the base metal. In general, thicker coatings provide greater
corrosion protection, whereas thinner coatings tend to give better
formability and weldability. Thinner coatings with uniformity of
thickness can be better formed by a continuous coating process.
[0071] In still another and/or alternative aspect of the invention,
the metal alloy coating is applied to the surface of the base
metal, the surface of the intermediate barrier metal layer, and/or
an existing metal alloy coating by a plating process. When a
plating process is used, a heat created intermetallic layer is not
formed between the metal alloy coating and the surface of the base
metal, the surface of the intermediate barrier metal layer, and/or
a previously applied metal alloy coating. Typically, the plating
process is carried out by standard plating processes, thus a
detailed description of a plating process is not described herein.
The complete or partial surface of the base metal, the surface of
the intermediate barrier metal layer, and/or surface of a
previously applied metal alloy can be coated by the plating
process. The plating of the components of the corrosion resistant
metal alloy can be accomplished at the same time or in subsequent
steps. For instance, a corrosion resistant tin metal alloy which
includes lead can be plated by a) simultaneously plating the tin
and lead onto the surface of the base metal, the surface of the
intermediate barrier metal layer, and/or metal alloy coating, b)
first plating the tin on the surface of the base metal, the surface
of the intermediate barrier metal layer and/or metal alloy coating,
and subsequently plating the lead on the surface of the base metal,
the surface of the intermediate barrier metal layer, and/or metal
alloy coating, or c) first plating the lead on the surface of the
base metal, the surface of the intermediate barrier metal layer,
and/or metal alloy coating, and subsequently plating the tin on the
surface of the base metal, the surface of the intermediate barrier
metal layer, and/or metal alloy coating. Similarly, a corrosion
resistant tin and zinc metal alloy which includes antimony can be
plated by a) simultaneously plating the tin, zinc and antimony onto
the surface of the base metal, the surface of the intermediate
barrier metal layer, and/or metal alloy coating, b) first plating
the tin on the surface of the base metal, the surface of the
intermediate barrier metal layer, and/or metal alloy coating, then
plating the zinc on the surface of the base metal, the surface of
the intermediate barrier metal layer, and/or metal alloy coating,
and subsequently plating the antimony on the surface of the base
metal, the surface of the intermediate barrier metal layer, and/or
metal alloy coating, c) first plating the zinc on the surface of
the base metal, the surface of the intermediate barrier metal
layer, and/or metal alloy coating, then plating the tin on the
surface of the base metal, the surface of the intermediate barrier
metal layer, and/or metal alloy coating, and subsequently plating
the antimony on the surface of the base metal, the surface of the
intermediate barrier metal layer, and/or metal alloy coating, d)
first plating the antimony on the surface of the base metal, the
surface of the intermediate barrier metal layer, and/or metal alloy
coating, and subsequently simultaneously plating tin and zinc on
the surface of the base metal, the surface of the intermediate
barrier metal layer, and/or metal alloy coating, etc. In one
embodiment of the invention, a tin metal alloy is plated on the
surface of the base metal. In one specific aspect of this
embodiment, the plating process includes the plating of tin in an
electrolytic solution containing stannous tin and an acid. In
another and/or alternative embodiment of the invention, a tin and
zinc metal alloy is plated on the surface of the base metal. In one
specific aspect of this embodiment, the plating process includes
the plating of tin and zinc in an electrolytic solution containing
stannous tin, zinc and an acid.
[0072] In yet another and/or alternative aspect of the invention,
the metal alloy coating is applied to the surface of the base
metal, the surface of the intermediate barrier metal layer, and/or
previously applied metal alloy coating by a hot dip process that
includes plating and subsequent heating of the plated metal alloy.
The metal alloy is plated onto the surface of the base metal, the
surface of the intermediate barrier metal layer, and/or a
previously applied metal alloy coating by a plating process that is
the same as or similar to the plating process described above.
After the metal alloy is plated onto the surface of the base metal,
the surface of the intermediate barrier metal layer, and/or
previously applied metal alloy coating, the plated metal alloy
coating is subjected to heat for a sufficient period of time to
form a heat created intermetallic layer between the plated metal
alloy coating and the surface of the base metal, the surface of the
intermediate barrier metal layer, and/or the surface of the
previously applied metal alloy coating. If one or more of the
components of the corrosion resistant metal alloy coating are
plated by a separate plating process, the plated metal components
of the metal alloy coating can be subjected to heat after one or
more of the plating processes, or after all the components of the
metal alloy coating have been coated onto the surface of the base
metal, the surface of the intermediate barrier metal layer, and/or
the surface of the previously applied metal alloy coating. The
heating of the plated metal alloy coating causes at least a portion
of the alloy to enter a molten state and to form an at least
partially uniform and substantially level coating layer. The
heating of the plated metal alloy coating also facilitates in the
reduction and/or elimination of pin holes in the metal alloy
coating which may have formed during the plating process. The time
period selected for flow heating the plated metal alloy coating
depends on the time necessary to soften and/or melt the desired
amount of tin in the tin metal alloy coating or tin and zinc in the
tin and zinc metal alloy coating to form the desired thickness of
the heat created intermetallic layer. When one or more of the
components of the corrosion resistant metal alloy coating are
plated by a separate plating process, the plated metal components
of the metal alloy coating are subjected to heat for a sufficient
period of time to at least partially alloy together the components
of the metal alloy coating. The heating process for the plate metal
alloy can be by a batch or by a continuous process. In one
embodiment of the invention, the plated metal alloy coating is
exposed to heat by the application of another and/or alternative
molten metal alloy coating onto the surface of the plated metal
alloy coating. The heat of the molten metal alloy upon contact with
the plated metal alloy causes the components of the plated metal
alloy coating to at least partially alloy together and/or form the
desired thickness of the heat created intermetallic layer between
the plated metal alloy coating and the surface of the base metal,
the surface of the intermediate barrier metal layer, and/or the
surface of the previously applied metal alloy coating. In one
aspect of this embodiment, a molten metal alloy is applied by
immersion onto the surface of the plated metal alloy coating. In
another and/or alternative aspect of this embodiment, a molten
metal alloy is applied by coating rollers onto the surface of the
plated metal alloy coating. In still another and/or alternative
aspect of this embodiment, a molten metal alloy is applied by spray
coating onto the surface of the plated metal alloy coating. In
another and/or alternative embodiment of the invention, the plated
metal alloy coating is exposed to an external heat source for a
time period and temperature sufficient to at least partially alloy
together the components of the plated metal alloy coating and/or to
form the desired thickness of the heat created intermetallic layer
between the plated metal alloy coating and the surface of the base
metal, the surface of the intermediate barrier metal layer, and/or
the surface of the previously applied metal alloy coating. The
plated metal alloy coating is typically exposed to heat through the
use of a convection oven, a furnace, heated fluids, flames,
induction heating, lasers, hot gasses, radiation, and the like. In
one aspect of this embodiment, the temperature the plated metal
alloy is exposed to is at least about 200.degree. C. In another
and/or alternative aspect of this embodiment, the temperature the
plated metal alloy is exposed to is less than about 2000.degree. C.
In still another and/or alternative aspect of this embodiment, the
temperature the plated metal alloy is exposed to is less than about
1000.degree. C. In yet another and/or alternative aspect of this
embodiment, the temperature the plated metal alloy is exposed to is
less than 500.degree. C.
[0073] In accordance with still yet another and/or alternative
aspect of the invention, the corrosion resistant metal alloy is
coated onto the surface of the base metal, the surface of the
intermediate barrier metal layer, and/or the surface of the
previously applied metal alloy coating by immersion into molten
corrosion resistant metal alloy. In one embodiment of the
invention, the molten corrosion resistant metal alloy is maintained
at a temperature of at least about 232.degree. C. (449.degree. F.).
In one aspect of this embodiment, the molten corrosion resistant
metal alloy is maintained at a temperature of at least about
2-30.degree. C. above the melting point of the corrosion resistant
metal alloy. In another and/or alternative embodiment of the
invention, the residence time of the base metal in the molten
corrosion resistant alloy is selected to form the desired heat
created intermetallic layer between the corrosion resistant alloy
metal coating and the surface of the base metal, the surface of the
intermediate barrier metal layer, and/or the surface of the
previously applied metal alloy coating. In one aspect of this
embodiment, the residence time of the base metal in the molten
metal alloy is at least about 0.033-0.083 minutes. In another
and/or alternative aspect of this embodiment, the residence time of
the base metal in the molten metal alloy is less than about 10
minutes. In still another and/or alternative aspect of this
embodiment, the residence time of the base metal in the molten
metal alloy is less than about two minutes. In yet another and/or
alternative aspect of this embodiment, the residence time of the
base metal in the molten metal alloy is less than about one minute.
In still yet another and/or alternative aspect of this embodiment,
the residence time of the base metal in the molten metal alloy is
about 0.083-0.5 minutes.
[0074] In accordance with another and/or alternative aspect of the
invention, the hot dip coating of the base metal by immersion in
molten metal alloy includes the use of a flux box. The flux box is
designed to receive the base metal prior to the base metal passing
into the molten metal alloy. The flux solution in the flux box is
formulated to remove residual oxides from the base metal surface to
shield the surface of the base metal, the surface of the
intermediate barrier metal layer, and/or the surface of the
previously applied metal alloy coating from oxygen until the
surface of the base metal, the surface of the intermediate barrier
metal layer, and/or the surface of the previously applied metal
alloy coating base metal is coated with the molten metal alloy,
and/or to inhibit the formation of viscous oxides at the point
where the base metal enters the molten metal alloy, and/or inhibits
dross formation on the base metal. The exposure of the base metal
to the flux solution is the last pretreatment process of the base
metal prior to being coated by immersion in molten metal alloy. In
one embodiment of the invention, the flux box contains a flux
solution which has a lower specific gravity than the molten metal
alloy, thus the flux solution floats on the surface of the molten
alloy. In another and/or alternative embodiment of the invention,
the flux solution includes a zinc chloride solution. In one aspect
of this embodiment, the flux solution includes ammonium chloride.
In another and/or alternative aspect of this embodiment, the flux
solution includes about 20-75% by volume zinc chloride. In yet
another and/or alternative aspect of this embodiment, the flux
solution includes zinc chloride and ammonium chloride. In still yet
another and/or alternative aspect of this embodiment, the flux
solution includes about 20-75% by volume zinc chloride and up to
about 40% by volume ammonium chloride. In a further and/or
alternativeaspect of this embodiment, the flux solution includes
about 30-60% by volume zinc chloride and up to about 1-20% by
volume ammonium chloride. In yet a further and/or alternative
aspect of this embodiment, the flux solution includes about 50% by
volume zinc chloride and about 8% by volume ammonium chloride.
[0075] In accordance with still another and/or alternative aspect
of the invention, the hot dip process of coating the base metal is
by immersion in a molten metal alloy includes a melting pot for
heating the molten metal alloy. In one embodiment of the invention,
the melting pot is heated by heating coils, heating rods, gas jets,
induction heating, lasers, radiation, etc. In one aspect of this
embodiment, the melting pot is heated by at least one gas jet
directed toward at least one side of the melting pot. In another
and/or alternative aspect of this embodiment, heating coils and
heating rods are used to heat the metal alloy directly in the
melting pot. In still another and/or alternative aspect of this
embodiment, gas jets are used heat the molten metal alloy in the
melting pot.
[0076] In accordance with a further and/or alternativeaspect of the
invention, the hot dip process of coating the base metal by
immersion in molten metal alloy includes the use of a protective
material on the surface of the molten metal alloy in the melting
pot. The protective material is formulated to at least partially
shield the molten metal alloy from the atmosphere thereby
preventing or inhibiting oxide formation on the surface of the
molten metal alloy, and/or preventing or inhibiting dross formation
on the coated base metal as the coated base metal enters and/or
exits from the melting pot. In one embodiment of the invention, the
protective material has a specific gravity which is less than the
specific gravity of the molten metal alloy so that the protective
material at least partially floats on the surface of the molten
metal alloy. In another and/or alternative embodiment of the
invention, the protective material includes an oil. In one aspect
of this embodiment, the protective material includes palm oil. When
the protective material is palm oil, the melting point of the metal
alloy should be below about 344.degree. C., the degrading point of
palm oil. For metal alloys having a higher melting point, other
oils, fluxes, or other materials and/or special cooling processes
for the protective material are employed when a protective material
is used. In still another and/or alternative embodiment, the
protective material facilitates in forming a smooth and uniform
coating on the surface of the base metal.
[0077] In accordance with another and/or alternative aspect of the
invention, the thickness of the metal alloy coating by immersion in
molten metal alloy is at least partially regulated by the residence
time of the base metal in the molten metal alloy, the temperature
of the molten metal alloy in the melting pot, and/or the speed at
which the base metal moves through the molten metal alloy. In one
embodiment of the invention, the base metal is maintained at a
substantially constant speed through the molten metal alloy. The
substantially uniform speed results in a substantially uniform
growth of the heat created intermetallic layer between the metal
alloy and the base metal, a substantially smooth coating of metal
alloy, and/or a substantially constant metal alloy coating
thickness. As the base metal passes through the molten metal alloy
at a substantially constant speed, the metal alloy adheres to the
moving base metal and shears a portion of the metal alloy coating
from the moving base metal. The shearing effect results from the
viscosity of the molten alloy and the speed of the moving base
metal. For a given speed and metal alloy viscosity, a certain
thickness of metal alloy will be applied to the base metal over a
given time. The shearing effect results in a substantially uniform
coating, excellent surface appearance, excellent smoothness,
excellent texture control and a substantially uniform heat created
intermetallic layer. In another and/or alternative embodiment of
the invention, the base metal is coated by moving the base metal
through the molten metal alloy in the melting pot at a relatively
constant speed of about 1-400 ft/min. In one aspect of this
embodiment, the base metal is moved through the molten metal alloy
in the melting pot at a relatively constant speed of about 50-250
ft/min.
[0078] In accordance with still another and/or alternative aspect
of the invention, the corrosion resistant metal alloy is coated
onto the surface of the base metal, the surface of the intermediate
barrier metal layer, and/or the surface of the previously applied
metal alloy coating by a coating roller process. Molten metal alloy
on the coating rollers is applied to the surface of the base metal,
the surface of the intermediate barrier metal layer, and/or the
surface of the previously applied metal alloy coating by a coating
roller process as the base metal passes by or between one or more
coating rollers. The coating rollers form a smooth and/or uniform
metal alloy coating layer on the base metal. The coating rollers
press against and coat the surface of the base metal, the surface
of the intermediate barrier metal layer, and/or the surface of the
previously applied metal alloy coating and fill pin holes or
uncoated surfaces on the surface of the base metal, the surface of
the intermediate barrier metal layer, and/or the surface of the
previously applied metal alloy coating by a coating roller process.
The coating rollers also control the thickness of the metal alloy
coating on the surface of the base metal, the surface of the
intermediate barrier metal layer, and/or the surface of the
previously applied metal alloy coating by a coating roller process.
In one embodiment of the invention, the coating rollers are used in
conjunction with an immersion process and/or metal spray process.
In another and/or alternative embodiment, the coating rollers are
spaced apart a sufficient distance so that the base metal can pass
between the coating rollers. As the base metal basses between one
or more sets of coating rollers, the coating rollers maintain a
desired coating thickness of the metal alloy on the base metal,
remove excess metal alloy from the base metal, and/or coat any
non-coated regions on the surface of the base metal. In one aspect
of this embodiment, the coating thickness of the metal alloy is
selected to ensure that essentially no uncoated regions exist on
the surface of the base metal. Typically, the average thickness of
the metal alloy on the surface of base metal is at least about 1
micron, and generally at least about 2.5 microns, more generally
about 7 to 2550 microns, and even more generally about 7-1270
microns. In another and/or alternative aspect of this embodiment,
the coating thickness of the metal alloy is selected to ensure the
coated metal alloy has essentially no pin holes, and/or does not
shear when formed into various products. A metal alloy coating
thickness of about 25-51 microns forms a coating that has few, if
any, pin holes, provides greater elongation characteristics, and
resists shearing when formed into various shaped articles. In still
another and/or alternative aspect of this embodiment, the thickness
of the metal alloy is selected for use in certain types of
environments in which the coated base metal is to be used. A metal
alloy coating thickness of about 25-51 microns forms a coating that
significantly reduces the corrosion of the base metal in virtually
all types of environments. Metal alloy coating thicknesses greater
than about 51 microns are typically used in harsh environments to
provide added corrosion protection. In another and/or alternative
embodiment of the invention, the molten metal alloy is maintained
at a temperature at least about 2-30.degree. C. above the melting
point of the metal alloy, while the metal alloy is on the coating
rollers. In another and/or alternative embodiment of the invention,
the coating processes includes at least one set of coating rollers
that partially or fully coat the surface of the base metal as the
base metal passes the coating rollers. In another and/or
alternative embodiment of the invention, one or more coating
rollers are at least partially immersed in molten metal alloy
during the coating process. In one aspect of this embodiment, the
coating process is used in conjunction with an immersion coating
process and one or more of the coating rollers are at least
partially immersed in molten metal alloy in the melting pot. In
another and/or alternative aspect of this embodiment, one or more
of the coating rollers are at least partially immersed in a
protective material in the melting pot. In yet another and/or
alternative embodiment of the invention, one or more coating
rollers are positioned above the molten metal alloy in the melting
pot when the coating rollers are used in conjunction with an
immersion coating process. In still another and/or alternative
embodiment of the invention, one or more coating rollers are at
least partially coated with molten metal alloy by one or more spray
jets that direct molten metal alloy on to the one or more coating
rollers. The one or more spray jets direct the molten metal alloy
on to the surface of the coating rollers as the base metal passes
by or between the coating rollers thereby resulting in the base
metal being partially or completely coated with the metal alloy. In
still another and/or alternative embodiment of the invention, one
or more coating rollers include an internal cavity in which molten
metal alloy is directed into and then directed onto the surface of
the coating roller to direct the molten metal alloy onto the
surface of the coating rollers as the base metal passes by or
between the coating rollers. In still another and/or alternative
embodiment of the invention, the time period the base metal is
exposed to each coating roller is a relatively short time. The time
period is dependant on the speed of the base metal and the size of
the coating rollers. Typically, the base metal is exposed to the
coating rollers for at least about 0.3 seconds and generally about
0.5-30 seconds. In a further and/or alternativeembodiment, one or
more coating rollers include one or more grooves. The one or more
grooves are designed to facilitate in maintaining the molten metal
alloy on the coating roller during the coating process.
[0079] In accordance with yet another and/or alternative aspect of
the present invention, the corrosion resistant metal alloy is
coated onto the surface of the base metal, the surface of the
intermediate barrier metal layer, and/or the surface of the
previously applied metal alloy coating by a spray coating process.
Molten metal alloy is sprayed onto the surface of the base metal,
the surface of the intermediate barrier metal layer, and/or the
surface of the previously applied metal alloy coating by one or
more spray jets. The spray jets spray molten metal alloy onto the
surface of the base metal, the surface of the intermediate barrier
metal layer, and/or the surface of the previously applied metal
alloy coating to at least partially coat the surface of the base
metal, the surface of the intermediate barrier metal layer, and/or
the surface of the previously applied metal alloy coating, and/or
ensure that a uniform and/or continuous coating is applied on the
surface of the base metal, the surface of the intermediate barrier
metal layer, and/or the surface of the previously applied metal
alloy coating. The speed and time the surface of the base metal,
the surface of the intermediate barrier metal layer, and/or the
surface of the previously applied metal alloy is in contact with
the molten metal is controlled so that the desired coating
thickness and desired thickness of the heat created intermetallic
layer is obtained. In one embodiment of the invention, the spray
jets are used in conjunction with coating rollers and/or an
immersion process. In one aspect of this embodiment, the spray jets
at least partially direct molten metal alloy onto the coating
rollers and/or onto the surface of the base metal, the surface of
the intermediate barrier metal layer, and/or the surface of the
previously applied metal alloy coating during the coating process.
In another and/or alternative embodiment of the invention, this
molten metal alloy is maintained at a temperature of at least about
2-30.degree. C. above the melting point of the metal alloy as the
metal alloy is sprayed from the one or more spray jets. In yet
another and/or alternative embodiment of the invention, the base
metal passes by or between one or more metal spray jets during the
coating process to partially or completely coat the surface of the
base metal. In another and/or alternative embodiment of the
invention, the base metal is exposed to the molten metal alloy from
the one or more metal sprayjets for a sufficient time to partially
or fully coat the surface of the base metal. The time the base
metal is exposed to the molten metal alloy from the metal spray
jets is dependent on the speed of the moving base metal. Typically,
the base metal is exposed to the molten metal alloy from the metal
spray jets for at least about 0.3 seconds, generally about 0.5-60
seconds, and typically about 1-30 seconds.
[0080] In accordance with another and/or alternative aspect of the
present invention, the coated base metal which is coated by a hot
dip process is subjected to an air-knife process. In an air-knife
process, the coated metal alloy is subjected to a high velocity
fluid. The high velocity fluid removes surplus molten corrosion
resistant metal alloy coating from the surface of the base metal,
the surface of the intermediate barrier metal layer, and/or the
surface of the previously applied metal alloy coating; smears the
coated corrosion resistant metal alloy over the surface of the base
metal, the surface of the intermediate barrier metal layer, and/or
the surface of the previously applied metal alloy coating thereby
reducing or eliminating pin holes or other uncoated surfaces;
improves the grain size of the coated metal alloy; smooths and/or
reducing lumps or ribs in the coated metal alloy; reduces the metal
alloy coating thickness; and/or cools and/or hardens the molten
metal alloy. In one embodiment of the invention, the air knife
process uses a high velocity fluid which generally does not oxidize
the corrosion resistant alloy. In one aspect of this embodiment,
the fluid used in the air-knife process includes, but is not
limited to, an inert or substantially inert gas such as, but not
limited to, nitrogen, sulfur hexafluoride, carbon dioxide,
hydrogen, noble gases, and/or hydrocarbons. In another and/or
alternative embodiment of the invention, the high velocity fluid of
the air-knife process is directed onto both sides of the coated
base metal and at a direction which is not perpendicular to the
surface of the coated base metal. In still another and/or
alternative embodiment of the invention, the protective material on
the surface of the molten metal alloy in the melting pot is
eliminated when the air-knife process is used in conjunction with a
coating process by immersion in molten alloy. When an air-knife
process is used in conjunction with coating by immersion, the inert
or substantially inert fluid inhibits or prevents dross formation
and/or viscous oxide formation in the region in which the inert or
substantially inert fluid contacts the molten metal alloy in the
melting pot. The high velocity of the inert or substantially inert
fluid also breaks up and/or pushes away dross or viscous oxides on
the surface of the molten metal alloy thus forming a dross and
oxide free region for the coated base metal to be removed from the
melting pot. In yet another and/or alternative embodiment of the
invention, the air-knife process includes one or more blast nozzles
to direct a high velocity fluid toward the metal alloy coating on
the surface of the base metal. In one aspect of this embodiment,
the coated base metal is directed between two or more blast
nozzles. In still yet another and/or alternative embodiment, the
air-knife process at least partially causes molten metal alloy on
the surface of the base metal to be directed back into the melting
pot when the air-knife process is used in conjunction with an
immersion coating process. In a further and/or
alternativeembodiment, one or more blast nozzles are adjustable so
as to direct the high velocity fluid at various angles onto the
surface of the coated base metal. In yet a further and/or
alternative embodiment of the invention, one or more blast nozzles
are partially or fully enclosed in a chamber, which chamber is
designed to accumulate or trap at least a portion of the fluid
after the fluid is directed toward the base metal. The accumulated
fluid can then be recirculated back through the blast nozzles. In
still a further and/or alternativeembodiment of the invention, the
air-knife process is used to control the thickness and/or quality
of the molten metal alloy coating. In still yet a further and/or
alternativeembodiment of the invention, the base metal is exposed
to the fluid from the air-knife process for a relatively short
period of time. The time the base metal is exposed to the fluid is
dependent on the speed of the moving base metal. Typically, the
base metal is exposed to the fluid from the air-knife process for
at least about 0.3 seconds, generally about 0.5-60 seconds, and
more typically about 1-30 seconds.
[0081] In accordance with another and/or alternative aspect of the
present invention, the coated base metal is cooled by a cooling
process. Typically the coated base metal is cooled after being
coated by a hot dip coating process. The coated base metal can be
cooled by spraying with and/or subjecting the coated base metal to
a cooling fluid and/or immersing the coated base metal in a cooling
fluid. As previously stated, when an air-knife process is used, the
coated base metal can be at least partially cooled by the fluid
from the air-knife process. When the heated corrosion resistant
metal alloy slowly cools, larger grain sizes and lower grain
densities generally occur in the corrosion resistant metal alloy
coating, and the corrosion resistant metal alloy coating typically
forms a more reflective surface. When the heated corrosion
resistant metal alloy rapidly cools, fine grain sizes and increased
grain densities occur in the corrosion resistant metal alloy
coating, and the corrosion resistant metal alloy coating forms a
less reflective surface than a slowly cooled corrosion resistant
alloy coating. Small grain sizes and higher grain densities in the
corrosion resistant metal alloy coating typically result in a
stronger bonding coating and greater corrosion resistance. In one
embodiment of the invention, the cooling process is less than about
two hours. In one aspect of this embodiment, the cooling process is
less than about one hour. In another and/or alternative aspect of
this embodiment, the cooling process is less than 10 minutes. In
still another and/or alternative aspect of this embodiment, the
cooling process is less than about 5 minutes. In another and/or
alternative embodiment of the invention, a liquid or gas is jet
sprayed onto the surface of the coated base metal to cool the metal
alloy coating. In one aspect of this embodiment, the cooling fluid
is water. In another and/or alternative aspect of this embodiment,
the temperature of the cooling fluid is about 15-95.degree. C. In
yet another and/or alternative aspect of this embodiment, the
temperature of the cooling fluid is about 20-60.degree. C. In yet
another and/or alternative aspect of this embodiment, the
temperature of the cooling fluid is about ambient temperature
(20-28.degree. C.). In still yet another and/or alternative aspect
of this embodiment, the coated base metal is at least partially
guided by a camel-back guide as the coated base metal is cooled by
the spray jets. The camel-back guide is designed to minimize
contact with the coated base metal thereby reducing the amount of
metal alloy coating inadvertently removed from the base metal. In
one aspect of this embodiment, the camel-back design allows cooling
fluid to be applied to both sides of the coated base metal. In
still another and/or alternative embodiment of the invention, the
coated metal alloy is cooled by immersion in a cooling fluid.
Typically, the coated base metal is directed into a cooling tank
that contains a cooling fluid. In one aspect of this embodiment,
the temperature of the cooling fluid in the cooling tank is
maintained at a desired temperature by use of agitators, heat
exchangers, and/or replenishment of cooling fluid. In another
and/or alternative aspect of this embodiment, the temperature of
the cooling fluid is about 15-95.degree. C. In yet another and/or
alternative aspect of this embodiment, the temperature of the
cooling fluid is about 20-60.degree. C. In yet another and/or
alternative aspect of this embodiment, the temperature of the
cooling fluid is about ambient temperature (20-28.degree. C.). In
still yet another and/or alternative aspect of this embodiment,
water is used as the cooling fluid. The oxygen in the water can
cause discoloration of the metal alloy coating thereby reducing the
reflectiveness of the metal alloy coating.
[0082] In accordance with another and/or alternative aspect of the
invention, the coated base metal is passed through a leveler
whereby the coated metal alloy is molded about the base metal,
and/or smoothed. In one embodiment of the invention, a final
coating thickness is obtained by the leveler. In another and/or
alternative embodiment of the invention, the leveler includes a
plurality of rollers. In yet another and/or alternative embodiment
of the invention, the base metal is maintained at a tension as it
is passed through the leveler.
[0083] In accordance with yet another and/or alternative aspect of
the invention, the coated base metal is rolled into a coil for
later processing or use.
[0084] In accordance with still another and/or alternative aspect
of the invention, the coated base metal is sheared into specific
length plates or strip for later use or immediate processing. In
one embodiment of the invention, a shearing device shears a
continuously moving coated base metal. In one aspect of this
embodiment, the shearing device moves with the moving coated base
metal when shearing.
[0085] In accordance with still yet another and/or alternative
aspect of the present invention, the heat created intermetallic
layer formed between the metal alloy coating and the surface of the
base metal, surface of the intermediate barrier metal layer, and/or
surface of a previously applied metal alloy coating is at least
partially exposed. The exposed heat created intermetallic layer has
been found to provide excellent corrosion resistance in a number of
environments. The heat created intermetallic layer can be exposed
by mechanical and/or chemical processes. In one embodiment of the
invention, at least a portion of the metal alloy coating is removed
by a mechanical process that includes, but is not limited to,
grinding, melting, shearing and the like. In another and/or
alternative embodiment of the invention, at least a portion of the
metal alloy coating is removed by a chemical process which
includes, but is not limited to, an oxidation process. The
oxidation process at least partially removes the coated metal alloy
and at least partially exposes the heat created intermetallic
layer. The oxidation process includes the use of an oxidizing
solution. In one aspect of this embodiment, the oxidation solution
is selected to be autocatalytic in that the oxidation solution
removes the metal alloy coating but does not or only very slowly
removes the heat created intermetallic layer. In another and/or
alternative aspect of this embodiment, the oxidation solution
includes nitric acid and/or chromic acid. When nitric acid is
included in the oxidation solution, the nitric acid concentration
is generally about 5-60% by volume and typically about 10-25% by
volume of the oxidation solution. In still another and/or
alternative aspect of this embodiment, the oxidation solution
includes copper sulfate. When copper sulfate is included in the
oxidation solution, the copper sulfate is generally less than about
10% by volume, typically about 0.5-2% by volume of the oxidation
solution, and typically about 1% by volume of the oxidation
solution. In yet another and/or alternative aspect of this
embodiment, the exposure of the coated base metal to the oxidation
solution in the oxidation process is generally less than about one
hour; however, longer times can be used depending on the
concentration and temperature of the oxidation solution, the type
of metal alloy, the thickness of the metal alloy, and/or the degree
of desired exposure of the heat created intermetallic layer. In one
specific aspect, the exposure to the oxidation solution in the
oxidation process is less than about ten minutes. In another and/or
alternative specific aspect, the exposure to the oxidation solution
in the oxidation process is less than about two minutes. In still
another and/or alternative specific aspect, the exposure to the
oxidation solution in the oxidation process is about 0.08-1.5
minutes. In a further and/or alternativeaspect of this embodiment,
after a sufficient amount of the heat created intermetallic layer
is exposed by the oxidation solution, the oxidation solution is
removed from the base metal. In still a further and/or
alternativeaspect this embodiment, the temperature of the oxidation
solution is about 15-80.degree. C. In yet a further and/or
alternativeaspect this embodiment, the temperature of the oxidation
solution is about 30-80.degree. C. In yet a further and/or
alternativeaspect this embodiment, the temperature of the oxidation
solution is about 15-60.degree. C. In a further and/or
alternativeaspect this embodiment, the temperature of the oxidation
solution is about 12-62.degree. C. In yet a further and/or
alternativeaspect this embodiment, the temperature of the oxidation
solution is about 40-60.degree. C. In yet a further and/or
alternativeaspect this embodiment, the temperature of the oxidation
solution is about 22-42.degree. C. In still a further and/or
alternative aspect this embodiment, the temperature of the
oxidation solution is about 32.degree. C. In still yet a further
and/or alternativeaspect of this embodiment, the oxidation solution
is rinsed off after the intermetallic layer is exposed. In still
another and/or alternative embodiment of the invention, the at
least partial removal of the metal alloy coating is described in
U.S. Pat. No. 5,397,652, which is incorporated herein.
[0086] In accordance with another and/or alternative aspect of the
present invention, the exposed heat created intermetallic layer is
passivated by a passivation process. The passivation process is
designed to at least partially react with the heat created
intermetallic layer and to form a thin corrosion resistant layer.
The corrosion resistant layer exhibits improved corrosion resistant
properties, improved abrasion resistance, improved hardness,
improved formality, resists cracking, and/or has less reflective
color as compared to a non-passified intermetallic layer. The
passivation process includes the use of a passivation solution. In
one embodiment of the invention, the passivation solution includes
a nitrogen containing compound. In another and/or alternative
embodiment of the invention, the passivation solution is the same
as the oxidation solution, thus the oxidation/passivation solution
removes the metal alloy to expose the heat created intermetallic
layer and subsequently passifies the exposed heat created
intermetallic layer to form the corrosion resistant layer. In one
aspect of this embodiment, the oxidizing solution fully or
substantially ceases to react with the intermetallic layer after
the passivation later is formed (auto-catalytic). In another and/or
alternative embodiment of the invention, the coated base metal
material is passivated in a different tank from the oxidation
solution. In yet another and/or alternative embodiment of the
invention, the oxidation solution and/or passivation solution is
rinsed off the coated base metal after the formation of the
passivation layer. In still yet another and/or alternative
embodiment of the present invention, the pacified intermetallic
layer exhibits excellent formability characteristics. The
formability of the base material having a pacified intermetallic
layer on the surface of the base material exhibits improved
formability characteristics over a tin metal alloy or a tin and
zinc metal alloy coated base material. The improved formability is
believed to be the result of the complete or partial removal of the
tin metal alloy or tin and zinc metal alloy from the surface of the
base material. The removal of the tin metal alloy or tin and zinc
metal alloy reduces the thickness of the treated base material. The
tin metal alloy or tin and zinc metal alloy is also less formable
than many types of base metal such as, but not limited to, copper,
copper alloys, aluminum, aluminum alloys. As a result, the reducing
of the thickness of the coated base material and by partial or
complete removal of a less formable metal layer, i.e. the tin metal
alloy or tin and zinc metal alloy, results in improved formability.
In yet another and/or alternative embodiment of the invention, the
thickness of the passivation layer is at least about 0.1 micron. In
still another and/or alternative embodiment of the invention, the
thickness of the passivation layer is about 0.1-5 microns. In still
another and/or alternative embodiment of the invention, the
thickness of the passivation layer is up to about 1.5 microns.
[0087] In accordance with still another and/or alternative aspect
of the present invention, the coated base metal is treated with a
weathering agent to accelerate the weathering, discoloration of the
surface of the metal alloy coating, and/or control the formation of
white rust on the surface of the metal alloy coating. In one
embodiment of the invention, the weathering material is applied to
the metal alloy coating to oxidize the metal alloy coating surface,
reduce the reflectivity of the metal alloy coating, and/or discolor
the metal alloy coating. In another and/or alternative embodiment
of the invention, the weathering material is an asphalt-based paint
which causes accelerated weathering of the metal alloy coating when
exposed to the atmosphere. The asphalt-based paint decreases the
weathering time of the metal alloy coating. In one aspect of this
embodiment, the asphalt paint is a petroleum-based paint which
includes asphalt, titanium oxide, inert silicates, clay, carbon
black or other free carbon and an anti-settling agent. In another
and/or alternative aspect of this embodiment, the asphalt-based
paint is applied at a thickness to form a semi-transparent or
translucent layer over the metal alloy coating. In one specific
aspect, the thickness of the asphalt-based paint is about 1-500
microns. In another and/or alternative specific aspect, the
thickness of the asphalt-based paint is about 6-150 microns. In
still another and/or alternative specific aspect, the thickness of
the asphalt-based paint is about 6-123 microns. In yet another
and/or alternative specific aspect, the thickness of the
asphalt-based paint is about 12-50 microns. In still yet a further
and/or alternativespecific aspect, the thickness of the
asphalt-based paint is about 12-25 microns. In still yet another
and/or alternative embodiment of the invention, the weathering
agent is dried by air drying and/or by heating lamps.
[0088] In accordance with yet another and/or alternative aspect of
the present invention, the metal alloy or base metal coated with
the metal alloy coating is immediately formed, or formed at a
manufacturing site, or formed at a building site. In one embodiment
of the invention, the metal alloy or coated base metal is formed
into roofing materials such as disclosed in, but not limited to,
gutter systems or roofing material which are illustrated in U.S.
Pat. Nos. 4,987,716; 5,001,881; 5,022,203; 5,259,166; and
5,301,474, all of which are incorporated herein by reference. In
one aspect of this embodiment, the roofing materials are formed on
site. In another and/or alternative embodiment of the invention,
the metal alloy or coated base metal is formed into an automotive
part such as, but not limited to a gasoline tank. In one aspect of
this embodiment, the gasoline tank includes a first and second
metal shell member. The two combined cavities of the shell members
are combined to form an inner fuel receiving chamber which holds
fuel within the receptacle. The abutting peripheral edges of the
shell members are joined together and sealed to maintain the fuel
within the inner petroleum receiving chamber. The two shell members
may be joined in any of a number of ways that will securely prevent
the shells from separating and petroleum from leaking from the
interior chamber (i.e. welding, soldering and/or bonding the edges
together). Such a fuel tank is illustrated in U.S. Pat. No.
5,455,122, which is incorporated herein by reference. In still
another and/or alternative embodiment of the invention, the metal
alloy is formed into a wire. In one aspect of this embodiment, the
wire is used as a solder or welding wire to solder or weld together
metals. In one specific aspect, the solder or welding wire is
formulated to have excellent wetting properties which helps to
ensure the formation of a high quality bond between metal
materials. In another and/or alternative specific aspect, the
solder or welding wire is formulated to have a low lead content. In
still another and/or alternative specific aspect, the solder or
welding wire can be used in standard soldering guns or welding
apparatuses (i.e. ultrasonic welding, arc welding, gas welding,
laser welding). In still yet another and/or alternative specific
aspect, the solder has low dissolving activity with the welded
metal materials. In a further and/or alternativespecific aspect,
the welding wire is a solid welding wire or a cored welding wire.
In still another and/or alternative embodiment of the invention,
the metal alloy exhibits excellent soldering or welding
characteristics such that various electrodes including lead and/or
no-lead containing solders and/or electrodes can be used to solder
and/or weld the metal alloy or coated base metal.
[0089] In accordance with yet another and/or alternative aspect of
the present invention, the metal alloy and/or coated base metal
base material can be formed on site without the metal alloy
cracking and/or flaking off.
[0090] In accordance with still another and/or alternative aspect
of the present invention, the metal alloy is formed into a
corrosion-resistant strip or sheet. In one embodiment of the
invention, the metal alloy strip is formed by a roll forming
process. In the roll forming process, a vat of molten metal alloy
is provided. The molten alloy is then directed through a series of
rollers until the desired thickness of the metal alloy strip or
sheet is obtained.
[0091] The primary object of the present invention is the provision
of a metal alloy having corrosion-resistant properties.
[0092] Another and/or alternative object of the present invention
is the provision of a base metal coated with a metal alloy having
corrosion resistant properties.
[0093] Yet another and/or alternative object of the present
invention is the provision of a metal material at least partially
formed from a metal alloy having corrosion resistant
properties.
[0094] Still another and/or alternative object of the present
invention is the provision of a metal alloy and/or coated base
metal which is both corrosion-resistant and
environmentally-friendly.
[0095] Still yet another and/or alternative object of the present
invention is the provision of a coated base metal having a
sufficient coating thickness to reduce or eliminate pinholes in the
coating and/or which the shearing of the coating is inhibited when
the coated base metal is formed.
[0096] Another and/or alternative object of the present invention
is the provision of a coated base metal having a heat created
intermetallic layer formed between the base metal and the metal
alloy coating.
[0097] Yet another and/or alternative object of the present
invention is the provision of a coated base metal coated by a hot
dip process.
[0098] Still another and/or alternative object of the present
invention is the provision of coating a base metal by a plating
process.
[0099] Yet still another and/or alternative object of the present
invention is the provision of a base metal coated by a continuous
process.
[0100] Still yet another and/or alternative object of the present
invention is the provision of a metal alloy or a coated base metal
which is formed and sheared into various building and roofing
components, automotive components, marine products, household
materials, and other formed materials that are subsequently
assembled on site or in a forming facility.
[0101] Another and/or alternative object of the present invention
is the provision of a metal alloy or coated base metal that is
corrosion-resistant and which can be formed into complex shapes
and/or ornamental designs.
[0102] Another and/or alternative object of the present invention
is the provision of a corrosion resistant metal alloy which
includes a coloring agent to alter the color of the corrosion
resistant metal alloy, a corrosion-resistance agent to improve the
corrosion-resistance of the corrosion resistant metal alloy, a
mechanical agent to improve the mechanical properties of the
corrosion resistant metal alloy, a grain agent to positively affect
grain refinement of the corrosion resistant metal alloy, an
oxidation agent to reduce oxidation of the molten corrosion
resistant metal alloy, an inhibiting agent to inhibit the
crystallization of the corrosion resistant metal alloy, and/or a
bonding agent to improve the bonding characteristics of the
corrosion resistant metal alloy.
[0103] Still another and/or alternative object of the present
invention is the provision of a corrosion resistant metal alloy
which includes a majority of tin.
[0104] Yet another and/or alternative object of the present
invention is the provision of a corrosion resistant metal alloy
which includes a majority of tin and zinc.
[0105] Another and/or alternative object of the present invention
is the provision of applying an intermediate barrier metal layer to
the surface of the base metal prior to applying the corrosion
resistant metal alloy coating.
[0106] Still another and/or alternative object of the present
invention is the provision of a coated base metal or metal alloy
which is formed into wire, wire solder and/or welding
electrodes.
[0107] Still yet another and/or alternative object of the invention
is the provision of a metal alloy and/or a coated base metal which
is economical to produce.
[0108] Another and/or alternative object of the invention is the
provision of a metal alloy and/or a coated base metal that can be
soldered with conventional tin-lead solders or no-lead solders.
[0109] Yet another and/or alternative object of the present
invention is the provision of pretreating the base metal prior to
coating the base metal with a corrosion resistant alloy to remove
oxides and/or foreign materials from the surface of the base
metal.
[0110] Another and/or alternative object of the present invention
is the provision of pickling the base metal to remove surface
oxides on the base metal prior to coating the base metal with a
metal alloy.
[0111] Yet another and/or alternative object of the present
invention is the provision of chemically activating the base metal
to remove surface oxides on the base metal prior to coating the
base metal with a metal.
[0112] Still yet another and/or alternative object of the present
invention is the provision of reducing the oxygen interaction with
the base metal prior to and/or during the coating process.
[0113] Another and/or alternative object of the present invention
is the provision of abrasively treating the surface of the base
metal prior to coating the base metal with a metal alloy.
[0114] Still yet another and/or alternative object of the present
invention is the provision of a metal alloy and/or a metal coating
that is not highly reflective.
[0115] Yet another and/or alternative object of the present
invention is the provision of a metal alloy and/or a metal coating
for a base metal which has a low lead content.
[0116] Still yet another and/or alternative object of the present
invention is the provision of using spray jets to spray molten
metal alloy onto the surface of the base metal to coat the surface
of the base metal.
[0117] Another and/or alternative object of the present invention
is the provision of coating a metal alloy and/or a metal coating
with a weathering agent to accelerate the dulling of the surface of
the metal alloy.
[0118] Still another and/or alternative object of the present
invention is the use of an air-knife process to control the
thickness and quality of the metal alloy coating on the base
metal.
[0119] Yet still another and/or alternative object of the present
invention is the provision of cooling the metal alloy and/or a
metal coating to form fine, high density grains which produce a
strong bonding, corrosive-resistant, discolored coating.
[0120] Another and/or alternative object of the present invention
is the provision of subjecting the coated base metal to an
oxidation solution to at least partially remove the metal alloy
from the base metal and to at least partially expose the heat
created intermetallic layer.
[0121] Still another and/or alternative object of the present
invention is the provision of subjecting the heat created
intermetallic layer to a passivation solution to form a highly
corrosion-resistant, non-reflective surface layer on the base
metal.
[0122] Still yet another and/or alternative object of the present
invention is the provision of a metal alloy coating which has
superior corrosive characteristics permitting a thinner coating of
the metal alloy on the base metal than that which is required for
conventional terne coatings with the high lead content. Still yet
another and/or alternative object of the present invention is the
provision of using spray jets which spray metal alloy onto the
coating rollers and/or base metal surface to eliminate non-coated
surfaces on the base metal.
[0123] Another and/or alternative object of the present invention
is the indirect heating of the melting pot without use of heating
coils or heating rods.
[0124] Another and/or alternative object of the present invention
is the provision of a corrosion resistant metal alloy that can be
coated on a number of different base metal compositions.
[0125] Yet another and/or alternative object of the present
invention is the provision of a corrosion resistant metal alloy
that can be coated a base metal having a number of different
shapes.
[0126] Still another and/or alternative object of the present
invention is the provision of providing a coated base metal which
is formed by a continuous, hot dip process wherein the base metal
has a controlled residence time when exposed to the molten metal
alloy.
[0127] Still yet another and/or alternative object of the present
invention is the provision of producing a highly
corrosion-resistant metal alloy or coated base material that is
economical to make.
[0128] These and other objects and advantages will become apparent
to those skilled in the art upon the reading and following of this
description taken together with the accompanied drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0129] Reference may now be made to the drawings, which illustrate
various embodiments that the invention may take in physical form
and in certain parts and arrangements of parts wherein;
[0130] FIG. 1A-1B is a cross-sectional view of a hot dip process
wherein a metal strip is coated with a corrosion resistant alloy by
immersing the metal strip in molten corrosion resistant metal
alloy;
[0131] FIG. 2 is a cross-section view of additional and/or
alternative processes for handling the coated metal strip;
[0132] FIG. 3 is a cross-sectional view of the process of plating a
metal strip with a corrosion resistant metal alloy;
[0133] FIG. 4 illustrates a cross-sectional view of the process of
flow heating the plated metal alloy;
[0134] FIG. 5 illustrates a cross-section view of an alternative
process of cooling the hot-dip coated base metal in a cooling
tank;
[0135] FIG. 6 illustrates a cross-sectional view of an alternative
process of using metal spray jets during the hot-dip coating
process to coat the metal strip;
[0136] FIG. 7 illustrates a cross-sectional view of an alternative
process of using an air-knife during the hot-dip coating process to
control the thickness of the coating on the metal strip;
[0137] FIG. 8 illustrates a cross-sectional view of an alternative
process of cooling the hot-dip metal alloy coated base metal by
spray jets;
[0138] FIG. 9 illustrates a cross-sectional view of an alternative
process of using abrasion treaters in conjunction with a low oxygen
environment to pre-treat the base metal;
[0139] FIG. 10 is a frontal view of a camel-back guide;
[0140] FIG. 11 is a prospective view of a melting pot heated by gas
torches;
[0141] FIG. 12 is a cross-sectional view of a coated metal strip
having a heat-created intermetallic layer;
[0142] FIG. 13 illustrates a cross-sectional view of an alternative
process of using an oxidation process and rinse process to at least
partially remove the metal alloy coating from the base metal to at
least partially expose the heat created intermetallic layer;
[0143] FIG. 14 is a cross-sectional view of a coated metal strip
having a heat-created intermetallic layer and passivated surface
layer.
[0144] FIG. 15 illustrates a cross-sectional view of an alternative
process of coating a base metal by a hot dip process wherein a base
metal strip is unrolled and coated by immersing the metal strip in
a molten pot of molten alloy and then subjecting the metal strip to
coating rollers and an air-knife process and then rolling the
coated metal strip into a coil;
[0145] FIG. 16 is a plane view of a gasoline tank formed from the
metal alloy or base metal coated with the metal alloy of the
present invention;
[0146] FIG. 17 illustrates the joining of the first and second
shell members of the gasoline tank at the peripheral edges;
[0147] FIG. 18 is a partial cross-sectional view of a gasoline tank
illustrating a corrosion resistant coating on the metal shell after
a coated base metal shell has been drawn;
[0148] FIG. 19 is a perspective view of a pair of adjacent roofing
panels formed from the metal alloy or base metal coated with the
alloy of the present invention;
[0149] FIG. 20 is a cross-sectional view showing the initial
assembly of the roofing panels of FIG. 19; and
[0150] FIG. 21 is a cross-sectional view of the process of roll
forming the metal alloy of the present invention into a metal alloy
strip.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0151] Referring now to the drawings, wherein the showings are for
the purpose of illustrating preferred embodiments of the invention
only and not for the purpose of limiting the same, reference is
first had to FIGS. 1A-1B which illustrates one type of hot dip
process for coating a metal alloy on a base metal and for forming a
heat created intermetallic layer between the metal alloy coating
and the base metal. However, as will be later discussed, the base
metal can be alternatively coated by a process that does not form a
heat created intermetallic layer between the metal strip and metal
alloy coating. The base metal and process used to coat and/or
pre-treat the base metal are illustrated in FIGS. 1-15. The base
metal is in the form of a metal strip; however, other forms of the
base metal can be used (i.e. metal plates, metal strip or metal
plate formed into various shapes, various shaped metal objects) and
be coated with a metal alloy in accordance with the present
invention.
[0152] The metal alloy is a corrosion resistant alloy. When the
metal alloy is coated onto the surface of a base metal, the metal
alloy inhibits or prevents the base metal from corroding when
exposed to the atmosphere. The metal alloy is highly corrosive
resistant, abrasive resistant, pliable, weldable and/or
environmentally friendly. The metal alloy binds with the base metal
to form a durable protective coating which typically not easily
removable.
[0153] The amount of corrosion resistance protection provided by
the metal alloy is typically of primary importance. The coating of
the metal strip with the metal alloy functions to form a barrier to
the atmosphere which inhibits or prevents the metal strip from
corroding. By coating the metal strip with the metal alloy, the
life of the metal strip can be extended for many years. The
pliability of the metal alloy can also be important when the coated
metal strip is to be formed. For materials such as, but not limited
to, wall systems, roofing systems and petroleum receptacles, the
coated base metal can be formed into various shapes and can be
folded to form seams to bind together the coated base metal
components. A coating on a metal strip that forms a rigid or
brittle coating can crack and/or prevent the coated base metal
components from being properly shaped. The metal alloy is typically
formulated to be connected together by solder or a weld.
[0154] Metal strips such as, but not limited to, carbon steel,
stainless steel, copper, copper alloys, aluminum and aluminum
alloys, oxidize when exposed to the atmosphere and/or various types
of chemicals or petroleum products. Over a period of time, the
oxidized metal strip begins to weaken and disintegrate. The
application of a corrosion resistant metal alloy onto the metal
strip acts as a barrier to the atmosphere and/or to chemical or
petroleum products to inhibit or prevent the oxidation of the metal
strip. By coating the metal strip with the corrosion resistant
metal alloy, the life of the metal strip can be extended for many
years.
[0155] As illustrated in FIGS. 1A-1B, metal strip 12 is provided
from a large metal roll 10. Metal strip 12 has an average thickness
of less than about 12700 microns, and typically about 127-5080
microns; however, other metal strip thickness can be used depending
on the type of base metal and the use of the coated base metal.
Metal strip 12 is typically unwound from roll 10 at speeds which
are generally less than about 400 ft./min., typically about 1-150
ft./min., more typically about 70-250 ft./min., and yet more
typically about 50-115 ft/min. The metal strip speed is ultimately
selected so that the residence time of the metal strip in contact
with the molten metal alloy is sufficient to coat the desired
amount of strip to a desired thickness and to form a heat created
intermetallic layer of a desired thickness.
[0156] After metal strip 12 is unrolled from metal roll 10, metal
strip 12 is optionally pretreated prior to being coated with the
metal alloy. As illustrated in FIGS. 1A-1B, metal strip 12 can be
pretreated to clean and/or remove surface oxides from the surface
of the metal strip prior to the metal strip being coated with the
corrosion resistant metal alloy. The type and number of
pretreatment process for metal strip 12 will depend on the surface
condition of the metal strip.
[0157] Metal strip 12 is illustrated in FIGS. 1A and 9 as being
cleaned by an abrasion treater 14 after being unrolled from metal
roll 10. The abrasion treater includes brushes 16 that are driven
by motors. The brushes are placed in contact with metal strip 12 to
remove foreign objects from metal strip 12 and to initially etch
and/or mechanically remove oxides from the surface of metal strip
12. Brushes 16 are typically biased against metal strip 12 to cause
friction between the brushes and metal strip 12, which friction
facilitates in the cleaning of the surface of metal strip 12.
Typically, brushes 16 are located on the top and bottom surface of
strip 12. As can be appreciated, the brushes can be positioned to
only contact a portion of the surface of the metal strip. Brushes
16 are typically made of a material having a hardness equal to or
greater than metal strip 12 so that the brushes will not quickly
wear down when removing foreign materials and/or pre-etching the
surface of metal strip 12. In one arrangement, the brushes are made
of a metal material such as, but not limited to, carbon steel wire
brushes. Brushes 16 typically rotate in a direction that is
opposite of the direction of the moving metal strip. This opposite
rotational direction of the brushes causes increased abrasive
contact with the surface of the metal strip. The abrasion treatment
of the metal strip surface can also include the use of absorbents,
cleaners and/or solvents. These absorbents, cleaners and/or
solvents can be applied to part of or to the full surface of metal
strip 12 before, during and/or after metal strip 12 is typically
treated with brushes 16. The cleaners and/or solvents can include,
but are not limited to, alkaline cleaners, acidic cleaners and/or
organic solvents.
[0158] After metal strip 12 passes through abrasion treater 14,
metal strip 12 can be guided by strip guides 13 to a low oxygen
environment 20. As shown in FIGS. 1A and 9, strip guides 13 are
positioned throughout the pretreatment and coating processes to
guide metal strip 12 through each process. Low oxygen environment
20 is illustrated as being a low oxygen gas environment that fully
surrounds the surface of metal strip 12 with low oxygen-containing
gas 22. As can be appreciated, the low oxygen gas environment can
be designed to only partially protect one or more surfaces of metal
strip 12. The low oxygen-containing gas includes, but are not
limited to, nitrogen, hydrocarbons, hydrogen, noble gases and/or
other non-oxygen containing gases. The low oxygen-containing gas
surrounds metal strip 12 and forms a barrier against the oxygen
containing atmosphere thereby preventing or inhibiting oxide
formation on the surface of metal strip 12. As can be appreciated,
low oxygen environment 20 can include or in the alternative be a
low oxygen liquid environment. In a low oxygen liquid environment,
the liquid can be sprayed on to one or more surfaces of the metal
strip or the metal strip can be partially or fully immersed in the
low oxygen-containing liquid.
[0159] Metal strip 12, after passing through low oxygen gas
environment 20, enters pickling tank 30 which contains a pickling
solution 32. The pickling solution is formulated to remove surface
oxides from the metal strip surface, remove dirt and other foreign
materials from the metal strip surface and/or to etch the surface
of the metal strip. Pickling tank 30 is of sufficient length and
depth to allow for complete immersion of metal strip 12 in pickling
solution 32 and to maintain the metal strip in contact with the
pickling solution for a sufficient period of time. Typically,
pickling tank 30 is at least about 25 feet in length. As can be
appreciated, the pickling tank can be longer or shorter depending
on the speed of the metal strip. Furthermore, the pickling tank can
be designed so that only a portion of the surface of metal strip 12
contacts the pickling solution. The pickling solution typically
contains one or more acids. The acids include organic and/or
inorganic acids. Such acids include, but are not limited to,
perchloric acid, hydrofluoric acid, sulfuric acid, nitric acid,
hydrochloric acid, phosphoric acid, and/or isobromic acid.
Typically, pickling solution 32 includes hydrochloric acid.
Generally, the pickling solution contains at least about 5% by
volume hydrochloric acid. For metal strip having extensive surface
oxides and/or difficult to remove surface oxides, such as on a
stainless steel strip, an aggressive pickling solution is used. One
type of aggressive pickling solution is a dual acid solution of
hydrochloric acid and nitric acid. Formulations of the
hydrochloric-nitric acid include a) about 1-30% by volume
hydrochloric acid and about 0.1-15% by volume nitric acid, b) about
5-25% by volume hydrochloric acid and 1-15% by volume nitric acid,
or c) about 10% hydrochloric acid and 3% nitric acid. Pickling
solution 32 is maintained at a temperature to obtain the desired
activity of the pickling solution. Typically, pickling solution 32
is maintained at a temperature of at least about 26.degree. C.,
generally about 48-60.degree. C., and typically about 53-56.degree.
C. Pickling tank 30 contains one or more agitators 34. Agitator 34
is designed to agitate pickling solution 32 to maintain a uniform
solution concentration, to maintain a uniform solution temperature
and/or to break up gas pockets which form on the surface of metal
strip 12. Agitator 34 typically includes an abrasive material which
can both agitate pickling solution 32 and remove oxides from metal
strip 12 when in contact with the surface of the metal strip.
Agitator 34 is typically made of a material which does not react
with pickling solution 32 and resists undue wear when in contact
with the metal strip surface. Metal strip 12 is typically not
exposed to the pickling solution for more than about 10 minutes so
as to avoid pitting of the metal strip surface; however, longer
pickling times can be used depending on the type of pickling
solution, concentration and temperature of the pickling solution,
type of metal strip, and/or condition of metal strip surface.
Typically, the pickling time is less than about ten minutes, more
typically less than about two minutes, still more typically less
than about one minute, and yet more typically about 10-20 seconds.
A pickling solution vent 36 is placed above pickling tank 30 to
collect and remove acid fumes and other gasses escaping pickling
tank 30.
[0160] As illustrated in FIG. 1A, metal strip 12 enters a low
oxygen environment 20 after exiting pickling tank 30. After metal
strip 12 exits pickling tank 30, the surface of metal strip 12 is
essentially absent surface oxides and other foreign materials and
is typically highly susceptible to oxidation with oxygen and other
gases in the atmosphere. Low oxygen environment 20 shields the
surface of metal strip 12 from oxygen and other oxidizing gases
and/or liquids thereby inhibiting oxide formation on the metal
strip surface. Low oxygen environment 20 is typically a low
oxygen-containing gas environment similar to the low oxygen
environment used after the abrasion treatment process; however, a
low oxygen-containing liquid environment could be used in
conjunction with or as an alternative to the low oxygen-containing
gas environment.
[0161] After metal strip 12 exits low oxygen environment 20, metal
strip 12 enters rinse tank 40 which contains a rinse solution 42.
Rinse tank 40 is designed to remove any remaining pickling solution
32 on the surface of metal strip 12 and/or inhibit the formation of
oxides on the metal strip surface. One type of rinse solution
includes water that is deoxygenated by heating the water above
about 37.7-43.3.degree. C. (100-110.degree. F.). As can be
appreciated, other rinse liquids can be used. Rinse solution 42 can
remove small amounts of oxides that remain on the surface of metal
strip 12. The rinse solution typically is slightly acidic due to
the acidic pickling solution that is removed from the metal strip
surface combining with the rinse solution. As can be appreciated,
the rinse solution can be also acidified by the intentional
addition of acid to the rinse solution. The slightly acidic rinse
solution 42 removes small amounts of oxides on the surface of metal
strip 12. Rinse tank 40 is of sufficient length and depth to
facilitate complete immersion of metal strip 12 in rinse solution
42 and to maintain the metal strip in contact with the rinse
solution for a sufficient period of time. Typically, rinse tank 40
is at least about 20 feet in length. As can be appreciated, the
rinse tank can be longer or shorter depending on the speed of the
metal strip. Furthermore, the rinse tank can be designed so that
only a portion of the surface of metal strip 12 contacts the rinse
solution. The rinse tank typically includes one or more agitators,
not shown. The agitators are designed to agitate rinse solution 42
to maintain a uniform solution concentration, maintain a uniform
solution temperature, and/or break up gas pockets which form on the
surface of metal strip 12. The agitators typically include an
abrasive material which can both agitate the rinse solution and
remove remaining oxides on the surface of metal strip 12 when in
contact with the surface of the metal strip. The agitators are
typically made of a material which does not react with rinse
solution 42 and resists undue wear when in contact with the metal
strip surface. As can be appreciated, the pickling solution can be
alternatively or additionally be removed by spraying a rinse fluid
onto a portion or the full surface of metal strip 12.
[0162] Referring now to FIG. 1B, metal strip 12 enters low oxygen
environment 50 after exiting rinse tank 40. Low oxygen environment
50 is a low oxygen-containing liquid environment which includes
spray jets 52. Spray jets 52 are located on each side of metal
strip 12 so as to direct the low oxygen-containing liquid onto both
sides of metal strip 12. As can be appreciated, the sprayjets can
be positioned about metal strip 12 so that only a portion of the
strip surface is subjected to the low oxygen-containing liquid. The
low oxygen-containing liquid 56 inhibits oxide formation on the
metal strip surface. Spray jets 52 also remove remaining pickling
solution 32 or other acid on the surface of metal strip 12. Low
oxygen-containing liquid 56 is typically heated water having a
temperature of at least about 38-43.degree. C. (100-109.degree.
F.). As can be appreciated, other low oxygen-containing liquids can
be used. Furthermore, it can be appreciated that low oxygen
environment 50 can include or in the alternative be a low
oxygen-containing gas environment.
[0163] Metal strip 12, upon leaving low oxygen liquid environment
50, enters chemical activation tank 60 which includes a chemical
activating solution or deoxidizing solution 62. The chemical
activation tank is of sufficient length and depth to facilitate in
the complete immersion of metal strip 12 in deoxidizing solution 62
and to maintain the metal strip in contact with the deoxidizing
solution for a sufficient period of time. Typically, chemical
activation tank is at least about 25 feet in length. As can be
appreciated, the chemical activation tank can be longer or shorter
depending on the speed of the metal strip. Furthermore, the
chemical activation tank can be designed so that only a portion of
the surface of metal strip 12 contacts the deoxidizing solution.
The chemical activation tank typically includes one or more
agitators, not shown. The agitators are designed to agitate
deoxidizing solution 62 to maintain a uniform solution
concentration, to maintain a uniform solution temperature and/or to
break up gas pockets which form on the surface of metal strip 12.
The agitators typically include an abrasive material which can both
agitate the deoxidizing solution and remove any remaining oxides on
the surface of metal strip 12 when in contact with the surface of
the metal strip. The agitators are typically made of a material
which does not react with deoxidation solution and resists undue
wear when in contact with the metal strip surface. The metal strip
is generally subjected to the deoxidizing solution for less than
about 10 minutes, and typically less than about one minute;
however, longer times can be used. Deoxidizing solution 62 is
formulated to remove the remaining oxides on the surface of metal
strip 12 and/or act as a protective coating to inhibit oxide
formation on the surface of metal strip 12. The temperature of the
deoxidizing solution is maintained at a temperature to achieve
sufficient activity of the deoxidizing solution. Typically, the
temperature of the deoxidizing solution is maintained at least
about 15.degree. C. (59.degree. F.), typically about 15-33.degree.
C. (59-91.4.degree. F.), and more typically about 26-33.degree. C.
(78.8-91.4.degree. F.). The deoxidizing solution typically includes
zinc chloride; however, other chemical compounds can be used. Small
amounts of an acid can be add to the deoxidizing solution to
further and/or alternativeenhance oxide removal from the metal
strip surface. One specific deoxidizing solution formulation
includes at least about 1% by volume zinc chloride. Another and/or
alternative specific deoxidizing solution formulation includes
about 5-50% by volume zinc chloride. Yet another and/or alternative
specific deoxidizing solution formulation includes about 5-50% by
volume zinc chloride and about 0.5-15% by volume hydrochloric
acid.
[0164] After metal strip 12 exits chemical activation tank 60,
metal strip 12 enters the final pretreatment step of immersion in a
flux solution 74 contained in flux box 72. As can be appreciated,
metal strip 12 can be exposed to a low oxygen environment, not
shown, prior to entering flux solution 74 to inhibit or prevent
oxide formation on the metal strip surface after the metal strip
exits chemical activation tank 60. As also can be appreciated, flux
box 72 can be designed so that only a portion of metal strip 12 is
exposed to flux solution 74. Flux box 72 is located in melting pot
70. The flux solution in flux box 72 has a specific gravity that is
less than or equal to the specific gravity of molten corrosion
resistant metal alloy 76 so that flux solution 74 at least
partially floats on the surface of the molten corrosion resistant
metal alloy. Flux solution 74 typically includes zinc chloride and
ammonium chloride; however, other compounds can be used. Specific
formulations of flux solution 74 include a) about 20-75% by volume
zinc chloride and 1-40% by volume ammonium chloride, b) about
20-75% by volume zinc chloride and 1-20% by volume ammonium
chloride, c) about 30-60 weight percent zinc chloride and up to
about 40 weight percent ammonium chloride, d) about 30-60 weight
percent zinc chloride and about 5-40 weight percent ammonium
chloride, or e) about 50 weight percent zinc chloride and about 8
weight percent ammonium chloride. As can be appreciated, other
concentrations of these two components can be used. Flux solution
74 is the final pre-treating process of metal strip 12 for removal
of remaining oxides on the surface of metal strip 12 prior to being
coated with metal alloy 76. Flux box 74 also acts as a barrier to
oxygen and prevents or inhibits oxides from forming on the surface
of the metal strip and on the surface of the molten metal alloy
covered by the flux solution.
[0165] An additional or alternative pretreatment process is the
coating of metal strip 12 with an intermediate barrier metal layer
prior to coating the metal strip with the corrosion resistant metal
alloy. The coating of the metal strip with an intermediate barrier
metal layer can constitute the only pretreatment process for the
metal strip, or the metal strip can be pretreated with one or more
other pretreatment process before and/or after the metal strip is
coated with an intermediate barrier metal layer. The intermediate
barrier metal layer is typically a thin layer of metal such as, but
not limited to, tin, nickel, copper, chromium, aluminum, cobalt,
molybdenum, Sn--Ni, Fe--Ni, and/or zinc. The thickness of the layer
is generally less than about 500 microns and typically less than
about 100 microns. The intermediate barrier metal layer can be
applied by an electroplating process, an electroplating process and
subsequent heating of the plated layer, immersion in molten metal,
metal spraying, coating rollers, and the like. The process for
plating the intermediate barrier metal layer onto the surface of
metal strip 12 is typically by a conventional continuous plating
process. The applied intermediate barrier metal layer typically
forms a strong bond with the metal strip, whether or not the strip
surface has been activated. The bonding of the intermediate barrier
metal layer to the strip is enhanced by heating the intermediate
barrier metal layer and the forming a heat created intermetallic
layer between the metal strip and the intermediate barrier metal
layer. When the intermediate barrier metal layer is plated and then
flow heated, the thickness of the intermediate barrier metal layer
is typically at least about 2 microns so that a sufficiently thick
intermediate barrier metal layer exists for proper flow heating.
The selection of metal of the intermediate barrier metal layer can
advantageously change the composition of the heat created
intermetallic layer thereby improving corrosion resistance,
improving metal alloy bonding, improving metal alloy pliability,
and/or inhibiting the formation of a thick zinc layer in the
intermetallic layer when zinc is included in the metal alloy.
[0166] Another and/or alternative additional or alternative
pretreatment process is the preheating of the metal strip prior to
coating the metal strip with the corrosion resistant metal alloy.
Metal strip that has a thickness of less than about 762 microns is
typically not pre-heated. Thicker metal strip can be preheated to
assist in the formation of the heat created intermetallic layer. A
thin metal strip need not be preheated since the surface of the
thin strip quickly heats to the temperature of the molten metal
alloy. As the surface of the metal strip approaches the temperature
of the molten metal alloy, an intermetallic layer begins to form
between the surface of the metal strip and the metal alloy coating.
Metal strip having a thickness of up to about 762 microns is
classified as thin metal strip. However, thin metal strip can be
preheated and such preheated strip forms an intermetallic layer
quicker than a non pre-heated strip. Metal strip having a thickness
over about 762 microns is classified as a thick metal strip. Thick
metal strip is typically preheated prior to coating with the metal
alloy. The surface of a thick metal strip takes a longer time to
approach the temperature of the molten metal alloy due to the
larger heat sink of the thicker metal strip. Preheating the thick
metal strip facilitates in the surface of the metal strip reaching
or approaching the molten temperature of the metal alloy during the
coating process so that a desired heat created intermetallic layer
is formed. Metal strip 12 can be preheated in any number of ways,
such as but not limited to, convection or induction heating,
flames, lasers, and the like. When a heat created intermetallic
layer is not to be formed, the meal strip is typically not
pre-heated.
[0167] Although FIGS. 1A-1B illustrate metal strip 12 being
pretreated by the pretreatment processes of abrasion, pickling and
rinsing, chemical activation, exposure to low oxygen environment,
and the flux solution. The use of all these pretreatment process on
all types of metal strip is not always required. When the metal
strip has a clean surface and/or little or no oxide formation on
the metal strip surface, the pretreatment process can be eliminated
or only a select number of pretreatment processes can be used prior
to coating the metal strip with the corrosion resistant metal
alloy.
[0168] Referring to FIG. 1B, metal strip 12, after exiting flux box
72, enters molten corrosion resistant metal alloy 76. Melting pot
70 is typically heated by heating jets, coils, rods, heat
exchangers, etc. In one particular arrangement, melting pot 70 is
heated by four heating jets 71 directed at the outside sides of
melting pot 70 as shown in FIG. 11. The heatingjets are typically
gas jets. Melting pot 70 is maintained at a temperature of at least
several degrees above the melting point of corrosion resistant
metal alloy 76 to prevent solidification of metal alloy 76 as metal
strip 12 enters melting pot 70. Tin melts at about 232.degree. C.
(450.degree. F.). Zinc melts at about 419.6.degree. C. (787.degree.
F.). When additives and/or impurities are included in the tin metal
alloy or tin and zinc metal alloy, the melting point of metal alloy
76 will be altered. The composition and/or thickness of melting pot
70 is selected to accommodate the various alloy melting
temperatures. The temperature of the molten metal alloy can be up
to or more than 38.degree. C. (100.degree. F.) cooler at the top of
the melting pot than at the bottom of the melting pot. Typically,
the tin metal alloy or tin and zinc metal alloy is maintained at
least about 2-30.degree. C. (35.1-86.degree. F.) above the melting
point of the metal alloy at the top of the melting pot. The
temperature of the molten metal alloy is maintained at a sufficient
level to prevent solidification of the molten metal when strip 12
enters the molten metal. The temperature of the metal alloy in the
melting pot is selected to accommodate the inclusion of additives
and/or impurities in metal alloy 76. Generally, the temperature of
the molten metal alloy in the melting pot is about 231-538.degree.
C. (447.8-1000.degree. F.). For high melting point metal alloys,
additional heating jets or other additional heating devices can be
used to heat the metal alloy in the melting pot to the desired
temperature.
[0169] The molten metal alloy in the melting pot is generally
formed by adding ingots of tin for a tin alloy coating and ingots
of tin and ingots of zinc for a tin and zinc metal alloy coating
into the melting pot wherein the ingots are melted and mixed. The
ingots may contain some additional elements which function as
additives or impurities in the tin metal alloy or tin and zinc
metal alloy. The amount of impurities in the metal alloy are
controlled so as to reduce the adverse affects of such
impurities.
[0170] As shown in FIG. 1B, melting pot 70 is divided into two
chambers by barrier 80. Barrier 80 is designed to prevent
protective material 78, such as palm oil, from spreading over the
complete top surface of molten corrosion resistant alloy 76 in
melting pot 70. As can be appreciated, barrier 80 can be
eliminated. When the protective material is palm oil, the melting
point of the metal alloy should be below 343.degree. C.
(649.4.degree. F.) so as to not degrade the palm oil. For metal
alloys having higher melting point temperatures, special oils,
fluxes, or other materials and/or special cooling procedures are
employed when a protective material is used. Protective material 78
has a specific gravity which enables the protective material to at
least partially float on the surface of molten alloy 76. The
protective material inhibits or prevents the surface of the molten
metal alloy from solidifying by insulating the surface from the
atmosphere, inhibits or prevents the surface of the molten metal
alloy from oxidizing, and/or aids in the properly distribution the
metal alloy on the surface of metal strip 12 upon exiting the
molten metal alloy.
[0171] Melting pot 70 can be about 10-100 ft. in length so as to
provide an adequate residence time for the metal strip in the
molten metal alloy as the metal strip moves through the molten
metal alloy 76 in the melting pot. Longer melting pot lengths can
be employed for fast moving metal strip. The residence time of the
metal strip in the molten metal alloy is sufficiently long enough
to form the desired thickness of heat created intermetallic layer
140. The residence time of metal strip 12 in melting pot 70 is
generally at least about 5 seconds and less than about 10 minutes,
typically less than about 2-10 minutes, more typically less than
about one minute, still more typically about 5-30 seconds, and even
more typically about 10-30 seconds. When the metal strip is coated
with the metal alloy by a continuous immersion process, the metal
strip is typically moved through the molten tin alloy in the
melting pot in a curvilinear path; however, other paths can be
used. When the metal strip uses a curvilinear path, the metal strip
requires fewer, if any, guide rolls (driving rollers), especially
when the metal strip is made of a more malleable material such as,
but not limited to, copper. The curvilinear path of the metal strip
allows the metal strip to dictate its path in the molten metal
alloy. The coating thickness of the metal alloy onto the metal
strip is typically a function of the time the metal strip is
resident or immersed in the molten tin alloy. The coating thickness
increases the longer the metal strip is maintained in the molten
metal alloy. In a continuous immersion coating process, the
resident time of the surfaces of the metal strip in the molten
metal alloy is substantially the same. The uniformity of residence
time in the molten metal alloy results in a more uniform coating
thicknesses on the surface of the metal strip and substantially
uniform growth of the heat created intermetallic layer. The metal
strip is typically maintained at a constant speed through the
molten metal alloy to create a more smooth coated surface. As the
metal strip passes through the molten metal alloy at a
substantially constant speed, the molten metal alloy about the
metal strip adheres to the moving metal strip and shears a portion
of the coating from the moving metal strip. This shearing effect
results from the viscosity of the molten metal alloy and the speed
at which the metal strip is moving through the molten metal alloy.
For a given speed and molten metal alloy viscosity, a constant
shearing effect is typically applied to the surface of the moving
metal strip thereby smoothing the coated surface and facilitating
in the formation of a constant coating thickness. By using a
continuous coating process to coat the metal strip with a metal
alloy, a uniform of coating (weight and thickness) is typically
obtained, having excellent surface appearance, smoothness, texture
control and a substantially uniform heat created intermetallic
layer.
[0172] During the coating of the metal strip with molten metal
alloy, a heat created intermetallic layer 140 forms between the
metal alloy coating layer 142 and metal strip 12 as shown in FIG.
12. The heat created intermetallic layer includes elements of the
corrosion resistant metal alloy molecularly intertwined with
elements on the surface of metal strip 12. This molecular
intertwining occurs when the temperature of the surface of the
metal strip approaches the temperature of the molten corrosion
resistant metal alloy. The migration of the corrosion resistant
metal atoms into the surface layer of strip 12 results in the
formation of heat created intermetallic layer 140. A carbon steel
strip coated with a tin or tin and zinc metal alloy would form an
intermetallic layer that includes at least iron, zinc, and tin. A
stainless steel strip coated with a tin metal alloy would form an
intermetallic layer that includes at least iron, chromium, and tin.
A copper or copper alloy strip coated with a tin and zinc metal
alloy would form an intermetallic layer that includes at least
copper, zinc, and tin. Intermetallic layer 140 can include a number
of elements such as, but is not limited to, antimony, aluminum,
arsenic, bismuth, cadmium, chromium, copper, hydrogen, iron, lead,
magnesium, manganese, nickel, nitrogen, oxygen, silicon, silver,
sulfur, tellurium, tin, titanium, zinc and/or small amounts of
other elements or compounds depending on the composition of the
metal strip, the corrosion resistant alloy, and the intermediate
barrier metal layer (if used). Heat created intermetallic layer 140
can be thought of as a transition layer between metal strip 12 and
corrosion resistant alloy coating 142. Heat created intermetallic
layer 140 is believed to be at least partially responsible for the
strong bond formed between corrosion resistant metal alloy layer
142 and metal strip 12. The heat created intermetallic layer also
functions as a corrosion-resistant layer. Typically, the thickness
of the heat created intermetallic layer is at least about 0.1
micron, and typically about 1-50 microns; however, thicker heat
created intermetallic layers can be formed. The time needed to form
the heat created intermetallic layer is typically less than about
three minutes and generally less than about one minute; however,
longer times can be used.
[0173] As shown in FIGS. 1B and 6, metal strip 12 passes between at
least one set of coating rollers 82 upon exiting the molten metal
alloy in melting pot 70. As best shown in FIG. 6, the coating
rollers are partially immersed in protective material 78. As can be
appreciated, the coating rollers can be completely immersed in the
protective material or positioned above the protective material.
Coating rollers 82 are spaced apart a sufficient distance so that
metal strip 12 can pass between the coating rollers. The coating
rollers 82 are designed to maintain a desired coating thickness of
the metal alloy on metal strip 12, remove excess metal alloy 76
from metal strip 12, and/or coat any non-coated regions on the
surface of the metal strip. The coating thickness of the metal
alloy is selected to ensure that essentially no uncoated regions
exist on the surface of the metal strip. Typically, the average
thickness of the metal alloy on the surface of metal strip 12 is at
least about 1 micron, and generally about 7 to 2550 microns. The
coating thickness is typically selected to ensure the coated metal
alloy has essentially no pin holes, and/or does not shear when
formed into various products. The thickness of the metal alloy is
selected depending on the environment in which the coated metal
strip is to be used. A metal alloy coating thickness of about 25-51
microns forms a coating that prevents pin holes, provides greater
elongation characteristics of the coating, and/or significantly
reduces the corrosion of the metal strip in virtually all types of
environments. Metal alloy coating thicknesses greater than about 51
microns are typically used in harsh environments to provide added
corrosion protection.
[0174] Referring again to FIGS. 1B and 6, a metal spray process is
shown wherein metal coating jets or spray jets 84 inject molten
metal alloy 76 on the surface of coating rollers 82. As can be
appreciated, metal coating jets 84 can in addition to or in the
alternative direct molten metal alloy onto the surface of metal
strip 12. The molten metal alloy that is spray jetted onto coating
roller 82 is then pressed against metal strip 12 by coating rollers
82 as the metal strip 12 moves between the coating rollers thereby
filling in any uncoated surface areas on metal strip 12 which were
not coated as the metal strip passed through the molten alloy in
melting pot 70. As can be appreciated, the metal spray process
and/or the coating rollers can be used independently of the melting
pot and/or be the sole coating process used to coat the metal alloy
onto the metal strip.
[0175] Referring now to FIG. 7, an air-knife 100 directs a high
velocity gas toward metal alloy coating 76 on metal strip 12 as the
metal strip exits melting pot 70. The air knife includes at least
one blast nozzle 104 that direct a high velocity gas onto the
surface of the metal alloy on the metal strip. Typically, air knife
includes at least two blast nozzles 104 which are mutually opposed
from each other and are disposed over melting pot 70. The blast
nozzles direct high velocity gas 105 toward metal strip 12 and
toward the surface of melting pot 70 as the metal strip moves by or
between the blast nozzles. Generally, the blast nozzles are
adjustable so as to direct the high velocity gas at various angles
on to the surface of the metal strip. The high velocity gas removes
surplus molten metal alloy coating 102 from the metal strip, smears
the molten alloy on metal strip 12 to cover any uncoated regions,
reduces the thickness of the metal alloy coating on the metal
strip, reduces lumps or ribs in the metal alloy coating, and/or
cools and/or hardens the metal alloy coating. The high velocity gas
is typically an inert gas so as not to oxidize the molten metal
alloy. Use of an inert gas also reduces dross formation on the
metal alloy coating and/or acts as a protective barrier to the
atmosphere which causes viscous oxides to form on the surface of
the molten metal alloy in melting pot 70. When inert gas is used,
the use of a protective material on the surface of the melting pot
can be eliminated. Generally, the inert gas is, but is not limited
to, nitrogen or an inert gas that is heavier than air (i.e. has a
higher density than air). The blast nozzles are typically enclosed
in a box shaped sleeve which accumulates at least a portion of the
gas after the gas is directed toward the metal strip. The
accumulated gas can then be recirculated back through the blast
nozzles. When an air-knife is used to control the thickness and/or
quality of the metal alloy coating, the air-knife is generally used
as a substitute for or used in conjunction with coating rollers
82.
[0176] Referring now to FIG. 3, an alternative process for coating
metal strip 12 with a corrosion resistant metal alloy is
illustrated. Metal strip is shown to be coated with a corrosion
resistant metal alloy by a continuous electroplating process. This
coating process is a non-hot dip process in that a heat created
intermetallic layer is not formed between the metal strip and metal
alloy coating. Metal strip 12 is directed into electrolytic tank 44
and submerged in electrolyte 46. Metal strip 12 can be directed
into electrolytic tank 44 immediately after being unrolled from
metal roll 10; after being pretreated by one or more pretreatment
processes; and/or after being coated with metal alloy by immersion,
spray metal coating, and/or roller coating. As metal strip 12
passes through electrolytic tank 44, an electrical current is
directed into electrolyte 46 by electrodes 48. The current through
electrodes 48 is supplied by power source 49. The plating of the
metal alloy onto the surface of the metal strip is typically
effectuated by conventional electroplating processes. The metal
alloy can be plated onto the surface of metal strip 12 by one or
more plating operations. After the metal strip is plated, the metal
strip is moved out of electrolytic tank 44. The average thickness
of the plated corrosion resistant alloy is generally at least about
1 micron, and typically less than about 200 microns. Coating
thickness of 2-77 microns, and generally 10-77 microns are typical
coating thicknesses. After the metal strip exits electrolytic tank
44, the coated metal strip can be further and/or alternative
treated by rinsing, pretreating, heating, coating with a metal
alloy by a hot dip process, and/or post treatment.
[0177] When a heat created intermetallic layer is to be formed
between the metal strip and the plated metal alloy coating, the
plated metal alloy coating is heated. FIG. 4 illustrates one
heating process used to form a heat created intermetallic layer
between the metal strip and the plated metal alloy coating. Coated
metal strip is continuously moved between two heaters 58. Heaters
58 cause the plated corrosion resistant metal alloy to soften
and/or become molten. This process of heating the plated metal
alloy is referred to as flow heating and constitutes another and/or
alternative type of hot dip process. During the flow heating
process, a heat created intermetallic layer is formed between the
metal strip and metal alloy coating. The plated metal alloy is
subjected to heat for a sufficient time period to form a heat
created intermetallic layer having a desired thickness. As can be
appreciated, the heating process can occur in a single or in a
multiple stage process. Furthermore, the heating process can be
designed to heat a part of or the complete coated region on the
metal strip. After the metal strip is flow heated, the metal alloy
coating can be further and/or alternative modified by a process
such as, but not limited to, controlling the coating thicknesses by
an air-knife process and/or a coating roller process, and/or
coating additional layers of metal alloy by additional coating
process such as, but not limited to, a plating process, a metal
spray process, a coating roller process, and/or an immersion
process.
[0178] After metal strip 12 is coated with a corrosion resistant
alloy, the coated metal strip is typically cooled and/or rinsed. A
coated metal strip that is plated as it moves through an
electrolyte solution is typically rinsed off to remove electrolyte
solution remaining on the surface of the coated metal strip. A
coated metal strip that is coated by a hot-dip process is typically
cooled to reduce the temperature and/or harden the metal alloy
coating. Referring to FIGS. 1B, 8 and 10, the coated metal strip
can be cooled by applying a cooling fluid 93 on the coated metal
strip by at least one spray jet 92. Typically, the cooling fluid
is, but not limited to, water maintained at about ambient
temperature. The velocity of the cooling fluid can be varied to
obtain the desired cooling rate and/or rinsing effect of the
corrosion resistant metal alloy. As illustrated in FIGS. 1B and 10,
metal strip 12 is at least partially guided by camel-back guides 90
during the cooling process. Camel-back guide 90 is typically
designed such that it has two receding edges 91 formed by conical
surfaces which contact only the edges of metal strip 12 so as to
minimize the removal of the metal alloy coating from metal strip
12. Alternatively or in addition to the spray cooling process, the
coated metal strip can be cooled in a cooling tank 94 as
illustrated in FIG. 5. The coated metal strip can be partially or
fully immersed in the cooling fluid 96 to cool and/or rinse the
coated metal strip. Typically, the cooling fluid is, but not
limited to, water maintained at about ambient temperature. The
cooling fluid is also typically agitated to increase the rate of
cooling of the metal alloy coating, and/or maintain a relatively
uniform cooling fluid temperature. The temperature of the cooling
water is typically maintained at proper cooling temperatures by
recycling the water through heat exchangers and/or replenishing the
cooling fluid. The cooling water may not be deoxygenated prior to
cooling the coated metal strip coating so as to slightly discolor
the metal alloy coating and/or reduce the reflectiveness of the
metal alloy coating. Immersion of the coated metal strip in cooling
fluid 96 generally results in a faster cooling rate than cooling by
spray jets 92. Rapid cooling of the corrosion resistant metal alloy
generally produces a metal alloy coating having fine grain size
with increased grain density. In addition, cooling of the metal
alloy coating in water results in some oxidation of the metal alloy
coating surface which forms a less-reflective surface. The cooling
period for cooling coated metal strip 12 by cooling jets 92 or by
immersion in cooling tank 94 is generally less than about two
minutes, and typically about 10-30 seconds.
[0179] After the coated metal strip is cooled, the coated metal
strip can be rolled into a metal roll, partially or totally formed
into various shapes (i.e. roofing materials, building materials,
household parts, automotive parts, etc.), oxidized to partially or
fully expose the heat created intermetallic layer, and/or passify
the heat created intermetallic layer prior to the coated metal
strip being rolled, cut into sheets and/or formed.
[0180] As illustrated in FIG. 15, the metal strip is unrolled and
immediately directed into a molten bath of metal alloy without any
prior pretreatment processes. Upon exiting the molten metal bath,
the metal strip passes between coating rollers and is then
subjected to an air-knife process to control the coating thickness
and coat the uncoated regions on the metal strip surface. The
air-knife also cools and hardens the metal alloy coating so that
the coated metal strip can be immediately rolled into a metal roll
150.
[0181] As illustrated in FIG. 2, the coated metal strip can be
further processed prior to being rolled into a metal roll 150 or
cut in to sheets 130. This further processing includes, but is not
limited to, leveling, shearing, oxidizing the coated corrosion
resistant alloy, passifying the metal alloy and/or forming a heat
created intermetallic layer, applying weathering agents, applying
paints, applying sealants, etc. As shown in FIG. 2, the coated
metal strip is subjected to a leveler 100. Leveler 100 includes
several rollers 102 which produce a uniform and smooth corrosion
resistant alloy coating 142 on metal strip 12. After metal strip 12
exits leveler 100, metal strip 12 is illustrated as being cut into
sheets 130 by shear 111. The coated metal sheets or strip can be
further processed by applying a paint, sealant or weathering agent
on the surface of the coated metal sheets or strip. The paint,
sealant or weathering agent 112 can be applied to a portion of or
the full surface of the coated metal alloy. The paint, sealant or
weathering agent can be applied by coaters 114 and/or by sprayers
116. A reservoir 110 holds the paint, sealant or weathering agent
for coaters 114 and/or sprayers 116. After the paint, sealant or
weathering agent is applied, it is dried by heat lamp 120 and/or by
a dryer 122.
[0182] When a weathering agent is applied to the coated metal
strip, the weathering agent is used to accelerate the patina
formation on the metal alloy coating. This process is generally
used to discolor the metal alloy and/or reduce the reflectiveness
of the metal alloy. The natural weathering of the metal alloy can
take, in some instances, over ten years to weather to the desired
degree. The weathering agent is formulated to reduce the time
period of weathering. In one formulation, the weathering agent is
typically a petroleum based product. Generally, the petroleum based
weathering agent is an asphalt based paint containing a suspension
of free carbon and a thinner. When this formulation is used, a thin
film or coating of weathering agent is applied to the surface of
the metal alloy and the ultraviolet light from the atmosphere
facilitates in accelerating the weathering of the metal alloy.
Generally, the thin layer of weathering agent is a semi-transparent
or translucent coating and at least partially allows the metal
alloy to be exposed to oxygen, moisture and to the sun's radiation.
The weathering agent can include, but is not limited to, asphalt,
titanium dioxide, inert silicates and low clay, carbon black
(lampblack) or other free carbon and an anti-settling agent. The
asphalt makeup of the weathering agent is typically about 60% to
80% by weight of the weathering agent, typically about 64% to 78%
by weight of the weathering agent, and more typically about 68% by
weight of the weathering agent. The amount of titanium oxide in the
weathering agent is about 1% to 25% by weight of the weathering
agent, and typically about 19% by weight of the weathering agent.
Typically, over 50% of the titanium oxide is anatase grade. When
carbon black is added to the weathering agent, the carbon black is
present in an amount of up to about 2% by weight of the weathering
agent, typically about 0.5 to 1% by weight of the weathering agent,
and more typically about 0.7% by weight of the weathering agent.
The inert silicates and/or low clay, such as, but not limited to
calcium borosilicate, when added to the weathering agent, is
present in an amount of about 8-11% by weight of the weathering
agent. The antisettling agent, when added to the weathering agent,
is present in an amount of about 0.4-0.7% by weight of the
weathering agent, and typically about 0.5% by weight of the
weathering agent. One specific formulation of the weathering agent
includes about 60-80 weight percent asphalt, about 1-25 weight
percent titanium oxide, about 8-11 weight percent inert silicates
and clay, about 0.5-2 weight percent carbon black, about 0.4-0.7
weight percent anti-settling agent, and solvent. Another and/or
alternative specific formulation of the weathering agent includes
65-75 weight percent gilsonite, 15-20 weight percent titanium
oxide, 8-11 weight percent calcium borosilicate, 0.5-1 weight
percent carbon black, 0.4-0.6 weight percent anti-settling agent,
and solvent. Still another and/or alternative specific formulation
of the weathering agent includes 64-78 weight percent gilsonite,
11.68-20.5 weight percent titanium oxide, 8.4-10.3 weight percent
inert silicates and clay, 0.63-0.77 weight percent carbon black,
0.4-0.52 weight percent anti-settling agent, and solvent. Yet
another and/or alternative specific formulation of the weathering
agent includes 70.86 weight percent gilsonite, 18.65 weight percent
titanium oxide, 9.32 weight percent calcium borosilicate, 0.7
weight percent carbon black, 0.47 weight percent anti-settling
agent, and solvent. A solvent such as, but not limited to,
naphthalene and/or paint thinners, is used to thin the weathering
agent so that a thin, translucent or semi-translucent film can be
formed on the surface of the metal alloy. The thickness of the
weather agent layer is generally less than about 123 mils, more
typically about 6-123 microns, even more typically up to about 50
microns, yet even more typically up to about 25 microns, and still
more typically about 12-25 microns. The color of the weathering
agent is a dull, lackluster color which has low reflective
properties. As a result, the weathering agent accelerates the
patina formation on the metal alloy coating and reduces the
reflective properties of the newly applied or formed metal alloy.
Another and/or alternative type of weathering agent which can be
used is disclosed in U.S. Pat. No. 5,296,300, which is incorporated
herein.
[0183] Metal strip 12 can be oxidized to partially or fully expose
the heat created intermetallic layer prior to or subsequent to the
coated metal strip being rolled into a metal roll, cut into sheets
of strip, and/or formed into various shapes. To expose the heat
created intermetallic layer, the coated metal alloy can be ground
off and/or chemically removed. Typically the metal alloy coating is
chemically removed by an oxidizing solution. As shown in FIG. 13,
coated metal strip is immersed in oxidizing solution 133 in
oxidizing tank 132. The oxidizing solution is formulated to at
least partially remove the metal alloy coating from metal strip 12
thereby at least partially exposing heat created intermetallic
layer 140. The intermetallic layer has been found to be an
excellent corrosion resistant layer. The oxidizing tank 132
typically includes an agitator to prevent or reduce stagnation
and/or vast concentration differences of the oxidizing solution in
the tank, prevent or reduce gas bubbles from forming on the surface
of metal strip 12, and/or maintain a substantially uniform
temperature in the oxidizing solution. The oxidizing solution
typically includes an acid such as, but not limited to, nitric
acid. When nitric acid is included in the oxidation solution, the
nitric acid concentration is generally about 5%-60% by volume,
typically about 10-25% by volume, more typically about 25% by
volume, and even more typically about 20% by volume. Copper sulfate
is generally added to the acid in the oxidizing solution to improve
the oxidation of the metal alloy coating. Copper sulfate, when
present, is generally added in a concentration of less than about
10% by volume, typically about 0.5-2% by volume, and more typically
about 1% by volume. The temperature of the oxidizing solution is
maintained at a temperature that provides sufficient activity of
the oxidizing solution. Generally, the temperature is maintained
between about 20-80.degree. C. (68-176.degree. F.), typically about
30-80.degree. C. (86-176.degree. F.), more typically about
40-60.degree. C. more typically about 50.degree. C. (172.degree.
F.). By increasing the concentration and/or temperature of the
oxidation solution, the time needed to at least partially remove
the metal alloy coating 76 is shortened. The amount of time to
remove the desired amount of the metal alloy coating is generally
less than about ten minutes, typically less than about two minutes,
more typically about 0.08-1.5 minutes, and even more typically
about 0.33 minutes; however, longer times can be used. The exposed
heat created intermetallic layer is typically has a dark grey,
non-reflective surface. As can be appreciated, the oxidation
solution can be applied to the coated metal strip after or just
prior to the metal strip being formed and/or installed. In this
instance, the oxidizing solution can be swabbed or sprayed onto the
surface of the coated metal strip.
[0184] Once the desired amount of metal alloy coating is removed,
the exposed heat created intermetallic layer is typically
passivated to enhance the corrosion-resistance of the intermetallic
layer. The intermetallic layer is generally passivated by a
passivating solution. One type of passivating solution includes a
nitrogen containing solution and/or a chromium solution such as,
but not limited to, nitric acid and/or chromate acid. The
passivation solution can be the same as or different from the
oxidizing solution. When chromate acid is included in the
passivation solution, the concentration of chromate acid is
generally about 0.5-5 g/liter. Phosphate can be added to the
passivation solution to enhance the passivation of the metal alloy.
When the passivation solution and the oxidizing solution are the
same, the removal of metal alloy coating and passivation of the
heat created intermetallic layer can both be accomplished in a
single tank. In a single tank arrangement, the passivation solution
and the oxidizing solution are formulated such that when the heat
created intermetallic layer is exposed and then passified, the
passivated layer is not removed or very slowly removed by the
passivation solution and the oxidizing solution, thus making the
oxidation and passivation process autocatalytic or
semi-autocatalytic. As illustrated in FIG. 13, metal strip 12 is
directed into a passivation tank 135 after being oxidized in
oxidation tank 132. The passivation tank 132 typically includes an
agitator to prevent or reduce stagnation and/or vast concentration
differences of the passivation solution in the tank, prevent or
reduce gas bubbles from forming on the surface of metal strip 12,
and/or maintain a substantially uniform temperature for the
passivation solution. The temperature of the passivation solution
is maintained at a temperature that provides sufficient activity of
the passivation solution. Generally, the temperature of the
passivation solution is maintained between about 15-80.degree. C
(59-176.degree. F.), and typically about 40-60.degree. C.
(104-140.degree. F.). By increasing the concentration and/or
temperature of the passivation solution, the time needed to at
least partially passivate the exposed heat created intermetallic
layer is shortened. The amount of time to passivate the heat
created intermetallic layer is generally less than about ten
minutes, and typically about 0.02-1.5 minutes; however, longer
times can be used.
[0185] Referring now to FIG. 14, passivation layer 146 is a very
thin layer. Generally, the thickness of the passivation layer is
less than about 13 microns, typically less than about 3 microns,
and more typically up to about 1.5 microns. The passivation layer
facilitates in inhibiting or preventing oxidation (i.e. white rust)
of the outer metal layer. The passivation layer 146 significantly
enhances the corrosion-resistance of the intermetallic layer 142.
Although it is not entirely known how passivation layer 148
exhibits increased corrosion resistance, it is believed that a
unique covalently bonded system is formed when the intermetallic
layer is passified. When the intermetallic layer 142 is passified
with passivation solution 162, a chemical reaction is believed to
occur to modify the atomic structure of passivation layer 146.
Other elements such as, but not limited to, nitrogen, hydrogen,
oxygen may also be present in passivation layer 146 to enhance the
stability of passivation layer 146. The special formulation of the
intermetallic layer 142 in combination with the passivation layer
146 provides for superior corrosion resistance for metal strip 12.
Passivation layer 146 is also malleable and will not crack when
formed into various shapes. Passivation layer 146 is generally a
grey, earth tone color non-reflective surface. Passivation layer
146 displays increased corrosion resistance, abrasion resistance,
and increased hardness as compared to the heat created
intermetallic layer. Heat created intermetallic layer 142 and
passivation layer 146 are also resistant to scratching thereby
improving the visual quality of metal strip 12 and enhancing the
damage resistance of metal strip 12. The relative nonexistence of
lead in intermetallic layer 142 and passivated layer, especially
when low lead metal alloys are used, makes the passivated metal
strip a superior substitute to terne coated materials. Not only is
the corrosion resistance of the intermetallic layer and passivated
layer greater than terne coatings, the intermetallic layer and the
passivated layer contain little, if any, lead thereby alleviating
any concerns associated with the use of lead materials.
[0186] After metal strip 12 is oxidized or passified, metal strip
12 is typically rinsed to remove any oxidation solution or
passivation solution remaining of the metal strip. The rinse
process can be performed by liquid spray jets and/or immersion of
the metal strip in a tank that contains a rinse solution.
Typically, the rinse liquid is about ambient temperature. The rinse
tank, when used, typically includes an agitator to assist in the
removal of the oxidizing solution and/or passivation solution from
metal strip 12. Once the rinse process is complete, the metal strip
is rolled into strip roll 150, cut into sheets 130, preformed to
various articles, and/or painted or sealed.
[0187] Referring now to FIGS. 16-18, a fuel tank is formed from
coated metal strip 12. Fuel tank 160 is typically made up of two
shell members 162 and 164. The shell members are each shaped in a
die by placing the coated metal strip or a section thereof on a die
and drawing the coated metal strip over the die. The shells are
typically formed in a cylindrical shape and each have a peripheral
edge 166; however, other shapes can be formed. The two shells are
joined together at the respective peripheral edges to form an inner
fuel receiving chamber 168 wherein the fuel is stored within the
tank. Fuel tank 160 also contains a spout 170 which communicates
with interior chamber 168 of the fuel tank so that the fuel can be
inserted into the inner chamber. Typically, the spout is inserted
at the top portion of shell 162 for easy insertion of the fuel into
the tank; however, the spout can be located in other areas. Fuel
tank 160 also contains a drain hole 172 which communicates with the
interior of the fuel tank chamber with the fuel system of the motor
vehicle. Typically, drain hole 172 is located at the top of the
fuel tank on shell 162; however, the drain hole can be located in
other areas. A fuel pump can be located in the inner chamber of the
fuel tank to pump the fuel through the vehicle's fuel system.
[0188] As illustrated in FIG. 18, shell members 162 and 164 are
joined together by abutting and connecting together peripheral
edges 166 of the respective shell members. Typically, the
peripheral edges are connected together a weld or solder 180. Spout
170 and drain hole 172 are also connected to the shell member
typically by a weld or solder. Generally, the weld or solder is
essentially lead-free so as not to add any lead to the fuel tank.
Each shell member includes a corrosion resistant metal alloy
coating 186 and an inner corrosion resistant metal alloy coating
188, both of which having substantially the same thickness. When
the coated metal strip is drawn over the die, the corrosion
resistant metal alloy coating 186, 188 becomes elongated about the
peripheral edge corner 190. When corrosion resistant metal alloy
coating is elongated, the corrosion resistant metal alloy coating
reduces in thickness. If the corrosion resistant alloy coating is
too thin, the alloy coating will tear or shear and expose the
unprotected surface of metal strip 12. Typically, the thickness of
the corrosion resistant metal alloy coating is at least about 25
microns so that as the metal alloy coating can be elongated and
shaped by the die without shearing and exposing the surface of the
metal strip. As illustrated in FIG. 18, shell members 162 and 164
are joined together by abutting and connecting together peripheral
edges 166 of the respective shell members. Typically, the
peripheral edges are connected together a weld or solder 180. Spout
170 and drain hole 172 are also connected to the shell member
typically by a weld or solder. Generally, the weld or solder is
essentially lead-free so as not to add any lead to the fuel tank.
Each shell member includes a corrosion resistant metal alloy
coating 186 and an inner corrosion resistant metal alloy coating
188, both of which having substantially the same thickness;
however, this is not required. When the coated metal strip is drawn
over the die, the corrosion resistant metal alloy coating 186, 188
becomes elongated about the peripheral edge corner 190. When
corrosion resistant metal alloy coating is elongated, the corrosion
resistant metal alloy coating reduces in thickness. If the
corrosion resistant alloy coating is too thin, the alloy coating
will tear or shear and expose the unprotected surface of metal
strip 12.
[0189] Referring now to FIGS. 19-20, building materials such as
roofing panels are formed from the coated metal strip. Roofing
panels P are joined together by an elongated standing seam S.
Roofing panels P are formed on site or preformed in the shape of
elongated pans as shown in FIG. 19. Pans 200 and 202 have
substantially similar features. Both pans have a right edge portion
204 and a left edge portion 206. As shown in FIG. 20, pans 202 and
204 are adjacently positioned together to define the elongated
direction D lying along base line X. A cleat 210 is used to form
seal S. Nails 212 maintain the pans on roof 220 while seam S is
formed. In standing seam applications, the edges of the roofing
materials are folded together and then soldered to form a water
tight seal. The metal alloy coating inherently includes excellent
soldering characteristics. The metal alloy coating can be also
welded or soldered. Typical solders contain about 50% tin and about
50% lead. The metal alloy has the added advantage of being
solderable with low or no-lead solders. The roofing materials can
be used in mechanically joined roofing systems due to the
malleability of the metal alloy. Mechanically joined systems form
water tight seals by folding adjacent roof material edges together
and subsequently applying a compressive force to the seam in excess
of about 1,000 psi. Under these high pressures, the metal alloy
plastically deforms within the seam and produces a water tight
seal. This type of roofing system is disclosed in U.S. Pat. Nos.
4,934,120; 4,982,543; 4,987,716; 4,934,120; 5,001,881; 5,022,203;
5,259,166; and 5,301,474, which are incorporated herein by
reference.
[0190] Referring now to FIG. 21, a corrosion resistant metal alloy
is formed into a metal alloy strip 230 by a roll forming process.
As can be appreciated, the metal alloy can alternatively be formed
into a wire, a tube, or molded or cast into other shapes. Ingots of
tin or tin and zinc are placed into the melting pot 240 wherein the
tin or the tin and zinc ingots are melted. The molten metal alloy
is maintained above its melting point in the melting pot. Other
metals such as, but not limited to, iron, nickel, aluminum,
titanium, copper, manganese, bismuth, antimony can be added into
the melting pot to alter the composition of the metal alloy. The
inclusion of these other metals typically alters the melting point
of the metal alloy. In order to accommodate for the high melting
temperature of the metal alloy, the melting pot is made of
materials to withstand these higher temperatures. Once the metal
alloy is properly mixed and melted in melting pot 240, the molten
alloy is allowed to flow out of the bottom of the melting pot
through pot opening 242. The molten metal alloy 230 is then
directed through one or more sets of rollers 260 until the desired
thickness of the metal alloy sheet or strip is obtained. The
process of roll forming metal strip is well known in the art, thus
further details as to the forming of the metal alloy strip 230 will
not be discussed.
[0191] The thickness of the formed metal alloy strip 230 is
typically less than about 5080 microns. Once metal alloy strip 230
has passed through rollers 260, metal alloy strip 230 may be
further processed, such as by a pretreatment processes, a coating
process, and/or a post coating process as discussed above.
[0192] As shown in FIG. 21, metal alloy strip 230 is directed into
a passivation tank 270. Passivation tank 270 includes a passivation
solution 272. The passivation solution is typically the same
passivation solution as described above. As the metal alloy strip
is directed into passivation tank 270, guide rollers 280 guide the
metal alloy strip. The passivation solution reacts with the surface
of the metal alloy strip to form a passivation layer which is
highly corrosion resistant. The passivation solution also causes
the surface of the metal strip to change colors. The passivation
tank generally includes an agitator to prevent or inhibit
stagnation and/or vast concentration differences of the passivation
solution in the passivation tank.
[0193] After metal alloy strip 230 passes through the passivation
tank, the metal alloy strip typically proceeds to a rinsing
process, not shown, to remove passivation solution remaining on the
metal alloy strip. Generally, the passivation solution is removed
by passing the metal alloy strip through a rinse tank and/or by
spraying the metal alloy strip with a rinse fluid.
[0194] As shown in FIG. 21, after metal alloy strip is passivated,
the strip is rolled into a roll 290 of metal alloy strip.
[0195] As can be appreciated, the molten metal alloy can be formed
into a wire or tube. Such wire or tube can be used for pipes, wire,
cable, solder or welding wire. When the metal alloy is formed into
a solder or welding wire, the metal alloy is generally not
passivated. The solder or welding wire has been found to form a
strong bond with the metal materials and has excellent wetting
properties to create a high quality bond. The solder also has good
conductive properties so that it can be used to form electrical
connections. The types of base metals which can be soldered by the
metal alloy include, but are not limited to, carbon steel,
stainless steel, copper, copper alloys, aluminum, aluminum alloys,
nickel alloys, tin, titanium, titanium alloys. Materials coated
with tin, tin metal alloys, zinc, zinc alloys, tin and zinc metal
alloys, lead, lead and tin alloys, and various other metals can
also be soldered or welded by the metal alloy. The metal alloy
strip can also be formed into roofing materials and/or gasoline
tanks, as described above, or a variety of components.
[0196] The corrosion resistant metal alloy is a tin metal alloy or
a tin and zinc metal alloy. Both of these metal alloys exhibit
excellent bonding and corrosion resistant properties when applied
to a metal strip by a hot dip process or by a plating process.
[0197] The tin metal alloy is formulated to include at least a
majority of tin. Generally, the tin metal alloy includes at least
about 75 weight percent tin, typically at least about 90 weight
percent tin, more typically at least about 95 weight percent tin,
even more typically at least about 98 weight percent tin, and still
even more typically at least about 99 weight percent tin. The high
percentage of tin in the tin metal alloy is substantially different
from standard terne alloy formulations which contain about 80% lead
and 20% tin. The high concentration of tin in the tin metal alloy
increases the uniformity and strength of the bond between the tin
metal alloy and many types of metal strip 12 as compared with
standard terne alloy coatings. The superior bonding characteristics
of the tin metal alloy makes the tin metal alloy coating ideal for
use with many different types of metal strip compositions, and can
be formed in a variety of simple and complex shapes. Industrial
grade tin typically is used as the tin source for the tin metal
alloy; however, other sources of the tin can be used. Industrial
grade tin typically contains trace amounts of impurities such as,
but not limited to, cobalt, nickel, silver and sulphur. It has been
found that these elements in controlled amounts do not adversely
affect the corrosive resistive properties of the tin metal alloy.
Indeed, elements such as, but not limited to, nickel can enhance
some properties of the tin alloy.
[0198] The tin and zinc metal alloy is a special combination of tin
and zinc. The tin and zinc metal alloy is formulated to include at
least about 9-10 weight percent zinc and at least about 15 weight
percent tin. It has been found that the addition of zinc in the
amount of at least about 9-10 weight percent of the tin and zinc
metal alloy produces a metal alloy having enhanced
corrosion-resistance in various types of environments. The tin
content of the tin and zinc metal alloy is generally about 15-90
weight percent. The zinc content of the alloy is generally about 9
to 10-85 weight percent. The tin plus zinc content of the tin and
zinc metal alloy typically constitutes at least a majority of the
tin and zinc metal alloy. Typically, the tin plus zinc content of
the tin and zinc metal alloy constitutes at least about 75 weight
percent tin and zinc, more typically at least about 80 weight
percent tin and zinc, even more typically at least about 90 weight
percent tin and zinc, still even more typically at least about 95
weight percent tin and zinc, yet still even more typically at least
about 98 weight percent tin and zinc, and yet still even more
typically at least about 99 weight percent tin and zinc. The tin
and zinc formulation oxidizes to form a colored coating which
closely resembles the popular grey, earth-tone color of weathered
terne. The use of large weight percentages of zinc in the tin and
zinc metal alloy does not cause the coating to become too rigid or
too brittle. The tin and zinc metal alloy is formable thus can be
bent into simple or complex shapes without cracking or breaking.
The malleability of tin and zinc metal alloy is believed to be at
partially the result of the unique tin and zinc distributions
within the tin and zinc metal alloy. The tin and zinc form a two
phase matrix wherein zinc globules are surrounded by tin. Zinc
facilitates in stabilizing the tin in the tin and zinc metal alloy
so as to inhibit or prevent tin crystallization in the tin and zinc
alloy. When determining the composition of the tin and zinc metal
alloy, the environment the coating is to be used in should be
considered. In some situations, a higher tin concentration may be
beneficial to limit the amount of zinc rich globules in the tin and
zinc metal alloy. In other environments, the reverse may be
true.
[0199] The tin metal alloy or the tin and zinc metal alloy
typically contains one or more additives without adversely
affecting the tin metal alloy or the tin and zinc metal alloy. The
additives are included and/or added to tin metal alloy or the tin
and zinc metal alloy to modify the mechanical properties of the
metal alloy, the corrosion-resistance of the metal alloy, the color
of the corrosion resistant metal alloy, the stability of the metal
alloy, and/or the coating properties of the metal alloy. The
additive(s) generally constitute less than about 25 weight percent
of the metal alloy. Typically, the additive(s) constitute less than
about 10 weight percent of the metal alloy. The content of the
additives is controlled so that the additives properly mix with the
metal alloy. The proper mixing of the additives in the metal alloy
is of greater importance for a tin and zinc metal alloy wherein the
tin and zinc form a special two phase matrix. Typically, the
additives are added to a tin and zinc alloy in a manner that
maintains the two phase matrix of the tin and zinc so as not to
form a tin and zinc alloy having more than two phases or which
disrupts the tin and zinc matrix.
[0200] The tin metal alloy typically includes at least an effective
amount of one or more stabilizing additives to inhibit or prevent
the tin from crystallizing. Tin and zinc metal alloys can also
include stabilizing additives. Tin can begin to crystallize when
the temperature drops below about 13.degree. C. (55.4.degree. F.).
Crystallization of the tin in the alloy can weaken the bond between
the metal strip and the metal alloy and can result in flaking of
the metal alloy from the metal strip. The addition of small amounts
of stabilizing metals such as, but not limited to, antimony,
bismuth, cadmium, copper, zinc and mixtures thereof prevent and/or
inhibit the crystallization of the tin in the metal alloy. Only
small amounts of antimony, bismuth, cadmium and/or copper are
needed to stabilize the tin in the metal alloy and inhibit and/or
prevent the tin from crystallizing. Amounts of at least about
0.001-0.01 weight percent of the metal alloy are generally
sufficient to inhibit or prevent tin crystallization. Typically,
the one or more stabilizers are included in an amount of at least
about 0.001-0.005 weight percent of the metal alloy to inhibit
crystallization of the tin.
[0201] The tin metal alloy or tin and zinc metal alloy can include
other additives to alter and/or enhance one or more properties of
the metal alloy. The metal alloy can include at least an effective
amount of corrosion-resistant agent to enhance the
corrosion-resistant properties of the metal alloy. The
corrosion-resistant agent includes, but is not limited to,
antimony, bismuth, cadmium, chromium, copper, lead, manganese,
magnesium, nickel, titanium and/or zinc. The metal alloy can
include at least an effective amount of coloring agent to alter the
color of the metal alloy. The coloring agent includes, but is not
limited to, cadmium, copper, iron, lead, silver and/or titanium.
The metal alloy can include at least an effective amount of
reflective agent to positively alter the reflectiveness of said
metal alloy. The reflective agent includes, but is not limited to,
aluminum, cadmium, chromium, copper, silver and/or titanium. A
metal alloy which includes a sufficient amount of coloring agents
and/or reflective agent may not be required to be weathered prior
to use in certain applications. The metal alloy can include at
least an effective amount of grain agent to positively alter the
grain density of the metal alloy. The grain agent includes, but is
not limited to, cadmium, manganese and/or titanium. The metal alloy
can include at least an effective amount of mechanical agent to
positively alter the mechanical properties of the metal alloy. The
mechanical properties of the metal alloy include, but are not
limited to, the strength of the metal alloy, the hardness of the
metal alloy, the pliability of the metal alloy, the elongation of
the metal alloy, the tensile strength of the metal alloy, the
elasticity of the metal alloy, the rigidity of the metal alloy, the
conductivity of the metal alloy, the heat transfer properties of
the metal alloy, etc. The mechanical agent includes, but is not
limited to, aluminum, antimony, arsenic, bismuth, cadmium,
chromium, copper, iron, lead, magnesium, manganese, nickel, silver,
titanium and/or zinc. The metal alloy can include at least an
effective amount of deoxidizing agent to reduce the amount of
oxidation of the metal alloy in a molten state. The deoxidizing
agent includes, but is not limited to, aluminum, cadmium,
magnesium, manganese and/or titanium. The metal alloy can include
at least an effective amount of bonding agent to enhance the
bonding properties of the metal alloy to the metal strip and/or
intermediate barrier metal layer. The bonding agent includes, but
is not limited to, cadmium, lead, manganese, titanium and/or
zinc.
[0202] Aluminum, if added to and/or included in the metal alloy, is
generally present in amounts up to about 5 weight percent of the
metal alloy; however, higher weight percentages can be used. In
several aspects of the present invention, the aluminum content of
the metal alloy is a) up to about 2 weight percent of the metal
alloy, b) up to about 1 weight percent of the metal alloy, c) up to
about 0.75 weight percent of the metal alloy, d) up to about 0.5
weight percent of the metal alloy, f) up to about 0.4 weight
percent of the metal alloy, g) up to about 0.3 weight percent of
the metal alloy, h) up to about 0.25 weight percent of the metal
alloy, i) at least about 0.05 weight percent of the metal alloy, j)
about 0.1-1 weight percent of the metal alloy, k) about 0.1-0.5
weight percent of the metal alloy, 1) about 0.1-0.3 weight percent
of the metal alloy, m) about 0.01-1 weight percent of the metal
alloy, n) about 0.01-0.5 weight percent of the metal alloy, o)
about 0.01-0.3 weight percent of the metal alloy, p) about 0.01-0.1
weight percent of the metal alloy, q) about 0.0005-0.75 weight
percent of the metal alloy, r) about 0.001-0.5 weight percent of
the metal alloy, s) about 0.001-0.4 weight percent of the metal
alloy, t) about 0.002-0.4 weight percent of the metal alloy, u)
about 0.001-0.4 weight percent of the metal alloy, v) about
0.001-0.01 weight percent of the metal alloy, and w) about
0.0001-0.005 weight percent of the metal alloy, x) about
0.001-0.005 weight percent of the metal alloy, or y) less than
about 0.001 weight percent of the metal alloy. When aluminum is
added to the metal alloy, the aluminum is typically added in the
form of an alloy such as, but not limited to, Al--Cu--Mg alloy.
[0203] Antimony, if added to and/or included in the alloy, is
generally present in amounts up to about 7.5 weight percent of the
metal alloy; however, higher weight percentages can be used. In
several aspects of the present invention, the antimony content of
the metal alloy is a) up to about 5.5 weight percent of the metal
alloy, b) up to about 2.5 weight percent of the metal alloy, c) up
to about 2 weight percent of the metal alloy, d) up to about 1
weight percent of the metal alloy, e) up to about 0.75 weight
percent of the metal alloy, f) up to about 0.5 weight percent of
the metal alloy, g) about 0.001-1 weight percent of the metal
alloy, h) about 0.005-0.8 weight percent of the metal alloy, i)
about 0.01-0.8 weight percent of the metal alloy,j) about 0.01-0.5
weight percent of the metal alloy, or k) about 0.05-0.5 weight
percent of the metal alloy.
[0204] Bismuth, if added to and/or included in the metal alloy, is
generally present in amounts up to about 1.7 weight percent of the
metal alloy; however, higher weight percentages can be used. In
several aspects of the present invention, the bismuth content of
the metal alloy is a) up to about 1 weight percent of the metal
alloy b) up to about 0.5 weight percent of the metal alloy, c) up
to about 0.01 weight percent of the metal alloy, d) about
0.0001-0.5 weight percent of the metal alloy, e) about 0.05-0.5
weight percent of the metal alloy, f) about 0.0001-0.2 weight
percent of the metal alloy, g) about 0.002-0.1 weight percent of
the metal alloy, or h) about 0.001-0.01 weight percent of the metal
alloy.
[0205] Cadmium, if added and/or included in the metal alloy, is
present in amounts of up to about 0.5 weight percent of the metal
alloy; however, higher weight percentages can be used. In several
aspects of the present invention, the cadmium content of the metal
alloy is a) up to about 0.1 weight percent of the metal alloy, or
b) less than about 0.05 weight percent of the metal alloy.
[0206] Chromium, if added and/or included in the metal alloy, is
present in amounts of at least about 0.0001 weight percent. In
several aspects of the present invention, the chromium content of
the metal alloy is a) less than about 0.1 weight percent of the
metal alloy, or b) up to about 0.02 weight percent of the metal
alloy.
[0207] Copper, if added to and/or included in the metal alloy, is
present in amounts up to about 5 weight percent of the metal alloy;
however, higher weight percentages can be used. In several aspects
of the present invention, the copper content of the metal alloy is
a) up to about 2.7 weight percent of the metal alloy, b) up to
about 2 weight percent of the metal alloy, c) up to about 1.6
weight percent of the metal alloy, d) up to about 1.5 weight
percent of the metal alloy, e) up to about 1 weight percent of the
metal alloy, f) up to about 0.05 weight percent of the metal alloy,
g) at least about 0.001 weight percent of the metal alloy, h) at
least about 0.1 weight percent of the metal alloy, i) about
0.001-2.7 weight percent of the metal alloy, j) about 0.01-2.7
weight percent of the metal alloy, k) about 0.001-1.6 weight
percent of the metal alloy, 1) about 0.1-1.6 weight percent of the
metal alloy, m) about 1-1.5 weight percent of the metal alloy, n)
about 0.001-1 weight percent of the metal alloy, o) about 0.001-0.5
weight percent of the metal alloy, p) about 0.005-0.6 weight
percent of the metal alloy, q) about 0.005-0.1 weight percent of
the metal alloy, r) about 0.01-0.1 weight percent of the metal
alloy, s) about 0.05-0.1 weight percent of the metal alloy, t)
about 0.005-2.7 weight percent of the metal alloy, u) about
0.005-1.6 weight percent of the metal alloy, or v) about 0.1-1.5
weight percent of the metal alloy. When copper is added to the
metal alloy, the copper is typically added in the form of brass
and/or bronze.
[0208] Iron, if added to and/or included in the metal alloy, is
added in amounts up to about 1 weight percent of the metal alloy;
however, higher weight percentages can be used. In several aspects
of the present invention, the iron content of the metal alloy is a)
less than about 0.5 weight percent of the metal alloy, b) less than
about 0.1 weight percent of the metal alloy, c) up to about 0.02
weight percent of the metal alloy, d) less than about 0.01 weight
percent of the metal alloy, e) less than about 0.005 weight percent
of the metal alloy, or f) less than about 0.002 weight percent of
the metal alloy.
[0209] Lead, if added to and/or included in the metal alloy, is
present in low levels, generally less than about 10 weight percent
of the metal alloy; however, higher weight percentages can be used.
In several aspects of the present invention, the lead content of
the metal alloy is a) less than about 2 weight percent of the metal
alloy, b) less than about 1 weight percent of the alloy, c) less
than about 0.5 weight percent of the alloy, d) less than about 0.1
weight percent of the metal alloy, e) less than about 0.075 weight
percent of the metal alloy, f) less than about 0.06 weight percent
of the metal alloy, g) less than about 0.05 weight percent of the
metal alloy, h) less than about 0.02 weight percent of the metal
alloy; i) less than about 0.01 weight percent of the metal alloy,
j) less than about 0.001 weight percent of the metal alloy, or k)
about 0.001-0.1 weight percent.
[0210] Magnesium, if added to and/or included in the metal alloy,
is present in amounts up to about 5 weight percent of the metal
alloy; however, higher weight percentages can be used. In several
aspects of the present invention, the magnesium content of the
metal alloy is a) up to about 2 weight percent of the metal alloy,
b) up to about 1 weight percent of the metal alloy, c) up to about
0.4 weight percent of the metal alloy, d) up to about 0.1 weight
percent of the metal alloy, e) about 0.1-0.4 weight percent of the
metal alloy, f) about 0.01-0.4 weight percent of the metal alloy,
or g) about 0.001-0.1 weight percent of the metal alloy. When
magnesium is added to the metal alloy, the magnesium is typically
added in the form of pure magnesium.
[0211] Manganese, if added to and/or included in the metal alloy,
is present in amounts up to about 0.1 weight percent of the metal
alloy; however, higher weight percentages can be used. In several
aspects of the present invention, the manganese content of the
metal alloy is a) at least about 0.0001 weight percent of the metal
alloy, b) up to about 0.01 weight percent of the metal alloy, c)
about 0.0001-0.1 weight percent of the metal alloy, d) about
0.001-0.1 weight percent of the metal alloy, or e) about
0.0001-0.01 weight percent of the metal alloy.
[0212] Nickel, if added to and/or included in the metal alloy, is
present in amounts up to about 5 weight percent of the metal alloy;
however, higher weight percentages can be used. In several aspects
of the present invention, the nickel content of the metal alloy is
a) up to about 2 weight percent of the metal alloy, b) up to about
1 weight percent of the metal alloy, c) up to about 0.9 weight
percent of the metal alloy, d) up to about 0.7 weight percent of
the metal alloy; e) up to about 0.3 weight percent of the metal
alloy, f) up to about 0.1 weight percent of the metal alloy, g) up
to about 0.005 weight percent of the metal alloy, h) about
0.001-0.1 weight percent of the metal alloy, i) about 0.001-0.9
weight percent of the metal alloy, j) about 0.001-0.3 weight
percent of the metal alloy, k) about 0.001-0.05 weight percent of
the metal alloy, 1) about 0.001-0.005 weight percent of the metal
alloy, or m) about 0.01-0.7 weight percent of the metal alloy.
[0213] Titanium, if added to and/or included in the metal alloy, is
present in amounts up to about 1 weight percent of the metal alloy;
however, higher weight percentages can be used. In several aspects
of the present invention, the titanium content of the metal alloy
is a) up to about 0.5 weight percent of the metal alloy, b) up to
about 0.2 weight percent of the metal alloy, c) up to about 0.18
weight percent of the metal alloy; d) up to about 0.15 weight
percent of the metal alloy; e) up to about 0.1 weight percent of
the metal alloy, f) up to about 0.075 weight percent of the metal
alloy, g) up to about 0.05 weight percent of the metal alloy, h) at
least about 0.0005 weight percent of the metal alloy, i) about
0.01-0.5 weight percent of the metal alloy, j) about 0.01-0.15
weight percent of the metal alloy, k) about 0.0001-0.075 weight
percent of the metal alloy, 1) about 0.0005-0.05 weight percent of
the metal alloy, m) about 0.0005-0.18 weight percent of the metal
alloy; n) about 0.001-0.05 weight percent of the metal alloy, or o)
about 0.005-0.02 weight percent of the metal alloy. When titanium
is added to a tin and zinc metal alloy, the titanium is typically
added as an alloy such as, but not limited to, a Zn--Ti alloy.
[0214] Zinc, if added to and/or included in the tin metal alloy, is
present in amounts up to about 9-10 weight percent of the metal
alloy. Higher weight percentages of zinc transforms the metal alloy
to a tin and zinc metal alloy. In several aspects of the present
invention, the zinc content of the tin metal alloy is a) up to
about 7 weight percent of the tin metal alloy, b) up to about 1.5
weight percent of the tin metal alloy, c) less than about 1 weight
percent of the tin metal alloy, d) up to about 0.5 weight percent
of the tin metal alloy, e) about 0.001-0.5 weight percent of the
tin metal alloy, or f) less than about 0.2 weight percent of the
tin metal alloy.
[0215] A general formulation of the corrosion resistant tin metal
alloy by weight percent includes the following:
1 Tin 75-99.99 Antimony 0-7.5 Bismuth 0-1.7 Copper 0-5 Lead
0-10
[0216] A more specific formulation of the corrosion resistant tin
metal alloy by weight percent includes the following:
2 Tin 75-99.99 Aluminum 0-5 Antimony 0-7.5 Bismuth 0-1.7 Copper 0-5
Lead 0-10 Nickel 0-5 Zinc 0-9
[0217] Another and/or alternative more specific formulation of the
corrosion resistant tin metal alloy by weight percent includes the
following:
3 Tin 90-99.99 Aluminum 0-2 Antimony 0-2 Arsenic 0-0.05 Bismuth
0-1.5 Boron 0-0.1 Cadmium 0-0.5 Carbon 0-1 Chromium 0-1 Copper 0-2
Iron 0-1 Lead 0-2 Magnesium 0-1 Manganese 0-0.1 Molybdenum 0-0.1
Nickel 0-1 Silicon 0-0.5 Silver 0-0.1 Tellurium 0-0.05 Titanium
0-0.5 Vanadium 0-0.1 Zinc 0-7
[0218] Still another and/or alternative more specific formulation
of the tin metal alloy by weight percent includes the
following:
4 Tin 90-99.9 Aluminum 0-5 Antimony 0-7.5 Arsenic 0-0.005 Bismuth
0-1.7 Boron 0-0.1 Cadmium 0-0.1 Carbon 0-1 Chromium 0-1 Copper 0-5
Iron 0-1 Lead 0-2 Magnesium 0-5 Manganese 0-0.1 Molybdenum 0-0.1
Nickel 0-5 Silicon 0-0.5 Silver 0-0.005 Tellurium 0-0.05 Titanium
0-1 Vanadium 0-0.1 Zinc 0-9
[0219] A few examples of the metal alloy composition by weight
percent which have exhibited the desired characteristics as
mentioned above are set forth as follows:
5 Alloy Ingredients A B C D E Tin Bal. Bal. Bal. Bal. Bal. Aluminum
.ltoreq.0.01 .ltoreq.0.01 .ltoreq.0.05 0 0 Antimony .ltoreq.1
.ltoreq.0.1 .ltoreq.0.1 .ltoreq.0.05 .ltoreq.0.05 Bismuth
.ltoreq.0.05 .ltoreq.0.05 .ltoreq.0.01 .ltoreq.0.01 .ltoreq.0.01
Copper .ltoreq.0.5 .ltoreq.0.05 0 1 0 Iron .ltoreq.0.1
.ltoreq.0.005 0 0 0 Lead .ltoreq.1 .ltoreq.0.1 .ltoreq.0.1
.ltoreq.0.1 .ltoreq.2 Nickel .ltoreq.0.005 .ltoreq.0.05
.ltoreq.0.05 .ltoreq.0.005 .ltoreq.0.05 Zinc .ltoreq.1 .ltoreq.2
.ltoreq.3 .ltoreq.0.5 .ltoreq.1 Alloy Ingredients F G H I J Tin
Bal. Bal. Bal. Bal. Bal. Aluminum .ltoreq.0.01 .ltoreq.0.01 0 0
.ltoreq.0.01 Antimony .ltoreq.0.1 .ltoreq.0.1 .ltoreq.0.05
.ltoreq.0.05 .ltoreq.1.0 Bismuth .ltoreq.0.05 .ltoreq.0.01
.ltoreq.0.01 .ltoreq.0.01 .ltoreq.0.05 Copper .ltoreq.0.5 0 0 0
.ltoreq.0.5 Iron .ltoreq.0.005 0 0 0 .ltoreq.0.1 Lead .ltoreq.0.1
.ltoreq.0.1 .ltoreq.0.1 .ltoreq.0.05 .ltoreq.1.0 Nickel 0 0 0 0
.ltoreq.0.005 Zinc .ltoreq.1 .ltoreq.1 .ltoreq.1 .ltoreq.1
.ltoreq.1 Alloy Ingredients K L M N Tin Bal. Bal. Bal. Bal.
Aluminum .ltoreq.0.01 .ltoreq.0.05 0.0 0.0 Antimony .ltoreq.0.1
.ltoreq.0.1 .ltoreq.0.05 .ltoreq.0.05 Bismuth .ltoreq.0.05
.ltoreq.0.01 .ltoreq.0.01 .ltoreq.0.01 Copper .ltoreq.0.5 0.0 1.0
0.0 Iron .ltoreq.0.005 .ltoreq.0.0 .ltoreq.0.0 .ltoreq.0.0 Lead
.ltoreq.0.1 .ltoreq.0.1 .ltoreq.0.1 .ltoreq.2.0 Nickel .ltoreq.0.0
.ltoreq.0.0 .ltoreq.0.005 .ltoreq.0.0 Zinc .ltoreq.2 .ltoreq.3
.ltoreq.0.5 .ltoreq.1
[0220] One formulation of the corrosion resistant tin metal alloy
includes by weight percent at least 75% tin; 0-1% aluminum; 0-2%
antimony; 0-0.02% arsenic; 0-1.5% bismuth; 0-0.1% boron; 0-0.1%
cadmium; 0-0.5% carbon; 0-0.5% chromium; 0-2% copper; 0-1% iron;
0-2% lead; 0-0.4% magnesium; 0-0.1% manganese; 0-0.1% molybdenum;
0-1% nickel; 0-0.05% silicon; 0-0.1% silver; 0-0.02% sulfur;
0-0.04% tellurium; 0-0.15% titanium; 0-0.1% vanadium; and 0-9%
zinc. Another and/or alternativeformulation of the corrosion
resistant tin metal alloy includes 90-99.9% tin; 0-0.5% aluminum;
0-2% antimony; 0-0.01% arsenic; 0-1.5% bismuth; 0-0.05% boron;
0-0.1% cadmium; 0-0.5% carbon; 0-0.5% chromium; 0-2% copper; 0-1%
iron; 0-1% lead; 0-0.4% magnesium; 0-0.1% manganese; 0-0.1%
molybdenum; 0-1% nickel; 0-0.5% silicon; 0-0.1% silver; 0-0.01%
sulfur; 0-0.01% tellurium; 0-0.15% titanium; 0-0.1% vanadium; and
0-9% zinc. Still another and/or alternativeformulation of the
corrosion resistant tin metal alloy includes at least 90% tin; 0-1%
aluminum; 0-2% antimony; 0-0.02% arsenic; 0-1.5% bismuth; 0-0.05%
boron; 0-0.1% cadmium; 0-0.5% carbon; 0-0.5% chromium; 0-2% copper;
0-1% iron; 0-2% lead; 0-0.4% magnesium; 0-0.1% manganese; 0-0.1%
molybdenum; 0-1% nickel; 0-0.05% silicon; 0-0.05% silver; 0-0.02%
sulfur; 0-0.04% tellurium; 0-0.15% titanium; 0-0.05% vanadium; and
0-5% zinc. Yet another and/or alternativeformulation of the
corrosion resistant tin metal alloy includes 95-99.99% tin; 0-0.4%
aluminum; 0-0.8% antimony; 0-0.005% arsenic; 0-0.5% bismuth; 0-0.1%
boron; 0-0.05% cadmium; 0-0.1% carbon; 0-0.05% chromium; 0-1%
copper; 0-1% iron; 0-5% lead; 0-0.01% magnesium; 0-0.01% manganese;
0-0.05% molybdenum; 0-0.9% nickel; 0-0.5% silicon; 0-0.01% silver;
0-0.01% sulfur; 0-0.01% tellurium; 0-0.1% titanium; 0-0.01%
vanadium; and 0-2% zinc. Still yet another and/or
alternativeformulation of the corrosion resistant tin metal alloy
includes 95-99.99% tin; 0-0.4% aluminum; 0-0.8% antimony; 0-0.005%
arsenic; 0-0.5% bismuth; 0-0.1% boron; 0-0.05% cadmium; 0-0.1%
carbon; 0-0.05% chromium; 0-1% copper; 0-0.5% iron; 0-0.5% lead;
0-0.01% magnesium; 0-0.01% manganese; 0-0.05% molybdenum; 0-0.9%
nickel; 0-0.01% silicon; 0-0.01% silver; 0-0.01% sulfur; 0-0.01%
tellurium; 0-0.1% titanium; 0-0.01% vanadium; and 0-2% zinc. A
further and/or alternativeformulation of the corrosion resistant
tin metal alloy includes 98-99.9% tin; 0-0.01% aluminum; 0-1%
antimony and/or bismuth; 0-0.1% copper; 0-0.05% iron; 0-0.5% lead;
0-0.05% magnesium; 0-0.05% manganese; 0-0.1% nickel; and 0-0.1%
zinc. Yet a further and/or alternativeformulation of the corrosion
resistant tin metal alloy includes 98-99.99% tin; 0-0.1% aluminum;
0-1% antimony and/or bismuth; 0-0.001% arsenic; 0-0.001% boron;
0-0.001% cadmium; 0-0.01% carbon; 0-0.01% chromium; 0-0.1% copper;
0-0.05% iron; 0-0.05% lead; 0-0.001% magnesium; 0-0.001% manganese;
0-0.001% molybdenum; 0-0.9% nickel; 0-0.001% silicon; 0-0.001%
silver; 0-0.001% sulfur; 0-0.001% tellurium; 0-0.05% titanium;
0-0.001% vanadium; and 0-1% zinc. Still yet a further and/or
alternativeformulation ofthe corrosion resistant tin metal alloy
includes at least 90% tin and 0.01-0.1% lead. Another and/or
alternative formulation of the corrosion resistant tin metal alloy
includes 90-99.9% tin and 0.001-0.1% lead. Still another and/or
alternativeformulation of the corrosion resistant tin metal alloy
includes 90-99.9% tin; 0-7.5% antimony; 0-1.7% bismuth; 0-2.7%
copper; 0.001-0.1% lead; and 0-1.5% zinc. Yet another and/or
alternativeformulation of the corrosion resistant tin metal alloy
includes 90-99.9% tin; less than 0.001% aluminum; 0-7.5% antimony;
0-1.7% bismuth; less than 0.05% cadmium; 0-2.7% copper; 0.001-0.1%
lead; and 0-1.5% zinc. Still yet another and/or alternative
formulation of the corrosion resistant tin metal alloy includes
90-99.9% tin; 0-2.5% antimony; 0-0.5% bismuth; 0-2.7% copper;
0-0.1% iron; 0.001-0.10% lead; and 0.5-1.5% zinc. A further and/or
alternativeformulation of the corrosion resistant tin metal alloy
includes 90-99.9% tin; 0-7.5% antimony; 0-1.7% bismuth; 0-2.7%
copper; 0-0.1% iron; 0.01-0.1% lead; and 0-1.5% zinc. Yet a further
and/or alternativeformulation of the corrosion resistant tin metal
alloy includes 90-99.95% tin; 0-7.5% antimony; 0-1.7% bismuth;
0-2.7% copper; 0-1% iron; 0-0.5% lead; and 0-0.5% zinc. Still a
further and/or alternativeformulation of the corrosion resistant
tin metal alloy includes 90-99.95% tin; 0-7.5% antimony; 0-1.7%
bismuth; 0-5% copper; 0-1% iron; 0-0.5% lead; and 0-7% zinc. Still
yet a further and/or alternativeformulation of the corrosion
resistant tin metal alloy includes 90-99.95% tin; 0-0.5% antimony
and/or bismuth; 0-1% copper; 0-1% iron; 0-0.05% lead; and 0-1.5%
zinc. Another and/or alternativeformulation of the corrosion
resistant tin metal alloy includes 90-99.95% tin; 0.005-0.5%
antimony; bismuth and/or copper; 0-0.05% lead; and 0-0.5% zinc.
Still another and/or alternativeformulation of the corrosion
resistant tin metal alloy includes 90-99.9% tin; 0-5% aluminum;
0-7.5% antimony; 0-0.005% arsenic; 0-1.7% bismuth; 0-0.1% cadmium;
0-5% copper; 0-1% iron; 0-2% lead; 0-5% magnesium; 0-5% nickel;
0-0.005% silver; 0-1% titanium; and 0-9% zinc. Yet another and/or
alternativeformulation of the corrosion resistant tin metal alloy
includes 95-99.9% tin; 0-0.01% aluminum; 0-0.5% antimony; 0-0.5%
bismuth; 0-0.005% iron; 0-0.1% lead; 0-0.1% nickel; and 0-2% zinc.
Still yet another and/or alternative formulation of the corrosion
resistant tin metal alloy includes 99-99.9% tin; 0-0.4% antimony;
0-0.2% bismuth; 0-0.001% iron; 0-0.05% lead; 0-0.001% nickel; and
0-0.2% zinc. A further and/or alternativeformulation of the
corrosion resistant tin metal alloy includes 90-99.9% tin; 0-0.01%
aluminum; 0-1% antimony; 0-0.05% bismuth; 0-0.5% copper; 0-0.1%
iron; 0-1% lead; 0-0.005% nickel; and 0-1% zinc. Yet a further
and/or alternativeformulation of the corrosion resistant tin metal
alloy includes
[0221] 90-99.9% tin; 0-0.5% aluminum; 0-2% antimony; 0-0.01%
arsenic; 0-1.5% bismuth; 0-0.05% boron; 0-0.1% cadmium; 0-0.5%
carbon; 0-0.5% chromium; 0-2% copper; up to 1% iron; less than 1%
lead; 0-0.4% magnesium; 0-0.1% manganese; 0-0.1% molybdenum; 0-1%
nickel; 0-0.05% silicon; 0-0.1% silver; 0-0.01% sulfur; 0-0.01%
tellurium; 0-0.15% titanium; 0-0.1% vanadium; and 0-9% zinc. Still
a further and/or altemativeformulation of the corrosion resistant
tin metal alloy includes 98-99.9% tin; 0-0.01% aluminum; 0-1%
antimony and/or bismuth; 0-0.1% copper; less than 0.05% iron; less
than 0.5% lead; 0-0.05% magnesium; 0-0.05% manganese; 0-0.1%
nickel; and 0-0.1% zinc. Still yet a further and/or
alternativeformulation ofthe corrosion resistant tin metal alloy
includes 99-99.9% tin; 0.001-0.8% antimony and/or bismuth; 0-0.02%
copper; 0-0.001% iron; and 0-0.08% lead; 0-0.001% nickel; and
0-0.001% zinc. Another and/or alternativeformulation of the
corrosion resistant tin metal alloy includes 90-99.9% tin; 0-5%
aluminum; 0-7.5% antimony; 0-0.005% arsenic; 0-1.7% bismuth;
0-0.005% cadmium; 0-5% copper; 0-1% iron; 0-2% lead; 0-5%
magnesium; 0-5% nickel; 0-0.005% silver; 0-1% titanium; and 0-9%
zinc. Yet another and/or alternativeformulation of the corrosion
resistant tin metal alloy includes 95-99.9% tin; 0-0.05% aluminum;
0-0.2% antimony; 0-0.1% bismuth; 0-0.1% copper; 0-0.1% iron; 0-0.2%
lead; 0-0.1% nickel; and 0-9% zinc. Still yet another and/or
alternativeformulation of the corrosion resistant tin metal alloy
includes 75-99.9% tin; 0-5% aluminum; 0-7.5% antimony; 0-1.7%
bismuth; 0-5% copper; 0-10% lead; 0-5% nickel; 0-0.5 titanium; and
0-9% zinc. A further and/or alternativeformulation of the corrosion
resistant tin metal alloy includes 90-99.9% tin; 0-2% aluminum;
0-2% antimony; 0-0.05% arsenic; 0-1.5% bismuth; 0-0.1% boron;
0-0.5% cadmium; 0-1% carbon; 0-1% chromium; 0-2% copper; 0-1% iron;
0-2% lead; 0-1% magnesium; 0-0.1% manganese; 0-0.1% molybdenum;
0-1% nickel; 0-0.5% silicon; 0-0.1% silver; 0-0.05% tellurium;
0-0.5% titanium; 0-0.1% vanadium; and 0-7% zinc. Yet a further
and/or alternativeformulation of the corrosion resistant tin metal
alloy includes at least 90% tin; 0-1% aluminum; 0-2% antimony;
0-0.02% arsenic; 0-1.5% bismuth; 0-0.5% boron; 0-0.1% cadmium;
0-0.5% carbon; 0-0.05% chromium; 0-2% copper; 0-1% iron; 0-2% lead;
0-0.4% magnesium; 0-0.1% manganese; 0-0.1% molybdenum; 0-1% nickel;
0-0.05% silicon; 0-0.05% silver; 0-0.02% sulfur; 0-0.04% tellurium;
0-0.15% titanium; 0-0.05% vanadium; and 0-5% zinc. Still a further
and/or alternativeformulation of the corrosion resistant tin metal
alloy includes 95-99.99% tin; 0-0.4% aluminum; 0-0.8% antimony;
0-0.005% arsenic; 0-0.5% bismuth; 0-0.1% boron; 0-0.05% cadmium;
0-0.1% carbon; 0-0.5% chromium; 0-1% copper; 0-0.5% iron; 0-0.5%
lead; 0-0.01% magnesium; 0-0.01% manganese; 0-0.05% molybdenum;
0-0.3% nickel; 0-0.01% silicon; 0-0.01% silver; 0-0.01% sulfur;
0-0.01% tellurium; 0-0.1% titanium; 0-0.01% vanadium; and 0-2%
zinc. Still yet a further and/or alternativeformulation of the
corrosion resistant tin metal alloy includes 98-99.99% tin; 0-0.1%
aluminum; 0-1% antimony and/or bismuth; 0-0.001% arsenic; 0-0.001%
boron; 0-0.001% cadmium; 0-0.01% carbon; 0-0.01% chromium; 0-0.1%
copper; 0-0.05% iron; 0-0.05% lead; 0-0.001% magnesium; 0-0.001%
manganese; 0-0.001% molybdenum; 0-0.1% nickel; 0-0.001% silicon;
0-0.001% silver; 0-0.001% sulfur; 0-0.001% tellurium; 0-0.05%
titanium; 0-0.001% vanadium; and 0-1% zinc. Another and/or
alternativeformulation of the corrosion resistant tin metal alloy
includes at least 75% tin; 0-1% aluminum; 0-2% antimony; 0-0.02%
arsenic; 0-1.5% bismuth; 0-0.5% boron; 0-0.1% cadmium; 0-0.5%
carbon; 0-0.5% chromium; 0-2% copper; 0-1% iron; 0-2% lead; 0-0.4%
magnesium; 0-0.1% manganese; 0-0.1% molybdenum; 0-1% nickel;
0-0.05% silicon; 0-0.1% silver; 0-0.02% sulfur; 0-0.04% tellurium;
0-0.15% titanium; 0-0.1% vanadium; and 0-9% zinc. Yet another
and/or alternative formulation of the corrosion resistant tin metal
alloy includes 95-99.99% tin; 0-0.4% aluminum; 0-0.8% antimony;
0-0.005% arsenic; 0-0.5% bismuth; 0-0.1% boron; 0-0.05% cadmium;
0-0.1% carbon; 0-0.05% chromium; 0-1% copper; 0-1% iron; 0-5% lead;
0-0.01% magnesium; 0-0.01% manganese; 0-0.05% molybdenum; 0-0.9%
nickel; 0-0.5% silicon; 0-0.01% silver; 0-0.01% sulfur; 0-0.01%
tellurium; 0-0.1% titanium; 0-0.01% vanadium; and 0-2% zinc. Still
another and/or alternative formulation of the corrosion resistant
tin metal alloy includes 98-99.99% tin; 0-0.1% aluminum; 0-1%
antimony and/or bismuth; 0-0.001% arsenic; 0-0.001% boron; 0-0.001%
cadmium; 0-0.01% carbon; 0-0.01% chromium; 0-0.1% copper; 0-0.05%
iron; 0-0.05% lead; 0-0.001% magnesium; 0-0.001% manganese;
0-0.001% molybdenum; 0-0.9% nickel; 0-0.001% silicon; 0-0.001%
silver; 0-0.001% sulfur; 0-0.001% tellurium; 0-0.05% titanium;
0-0.001% vanadium; and 0-1% zinc. Still yet another and/or
alternativeformulation of the corrosion resistant tin metal alloy
includes 90-99.9% tin; 0-0.5% antimony; 0-1.5% bismuth; 0.00-1%
lead; and 0-0.001% zinc. A further and/or alternativeformulation of
the corrosion resistant tin metal alloy includes 90-99.9% tin;
0-0.75% antimony; 0-0.5% bismuth; 0-0.1% iron; 0-1% lead; and
0-0.5% zinc. Yet a further and/or alternativeformulation of the
corrosion resistant tin metal alloy includes 90-99.9% tin; 0-7.5%
antimony; 0-2.7% copper; and 0-1% lead. Still a further and/or
alternativeformulation of the corrosion resistant tin metal alloy
includes 90-99.9% tin; 0-2.5% antimony; 0-2% copper; 0-1% lead; and
0-0.5% zinc. Still yet a further and/or alternativeformulation of
the corrosion resistant tin metal alloy includes 90-99.9% tin;
0-0.75% antimony; 0-0.5% bismuth; 0-0.1% iron; 0-1% lead; and
0-0.5% zinc. Another and/or alternative formulation of the
corrosion resistant tin metal alloy includes 90-99.9% tin; 0-1%
antimony; 0-0.5% bismuth; 0-0.1% iron; and 0-1% lead. Still another
and/or alternative of the corrosion resistant tin metal alloy
includes 90-99.9% tin; 0-0.5% bismuth; 0-0.1% iron; and 0-1% lead.
Yet another and/or alternative formulation of the corrosion
resistant tin metal alloy. includes 90-99.9% tin; 0-0.75% antimony;
0-0.5% bismuth; 0-0.01% iron; 0.001-0.05% lead; and 0-0.5% zinc.
Still yet another and/or alternative formulation of the corrosion
resistant tin metal alloy includes 90-99.9% tin; 0-0.5% antimony;
0-1.7% bismuth; 0-0.02% lead; and 0-0.001% zinc. A further and/or
alternativeformulation of the corrosion resistant tin metal alloy
includes 90-99.9% tin; 0-0.75% antimony; 0-0.5% bismuth; 0-0.005%
cobalt; 0-2.7% copper; 0-0.1% iron; 0-0.05% lead; 0-0.005% nickel;
0-0.001% silver; 0-0.001% sulfur; and 0-0.5% zinc. Still a further
and/or alternativeformulation of the corrosion resistant tin metal
alloy includes 90-99.9% tin; 0-7.5% antimony; and 0-2.7% copper.
Yet a further and/or alternativeformulation of the corrosion
resistant tin metal alloy includes 90-99.9% tin; 0-2.5% antimony;
0-2% copper; and 0-0.5% zinc. Still yet a further and/or
alternativeformulation of the corrosion resistant tin metal alloy
includes 90-99.9% tin; 0-0.5% antimony; 0-1.5% bismuth; 0-0.005%
cobalt; 0-0.02% lead; 0-0.005% nickel; 0-0.001% silver; 0-0.001%
sulfur; and 0-0.001% zinc. Another and/or alternativeformulation
ofthe corrosion resistant tin metal alloy includes 90-99.9% tin and
0-0.1% lead. Still another and/or alternative formulation of the
corrosion resistant tin metal alloy includes 90-99.9% tin and
0-0.01% lead. Yet another and/or alternativeformulation of the
corrosion resistant tin metal alloy includes 90-99.9% tin; 0-5.5%
antimony; 0-0.5% aluminum; 0-1.7% bismuth; 0-2.7% copper; 0-0.4%
magnesium; 0-1% nickel; and 0-0.15% titanium. Still yet another
and/or alternativeformulation of the corrosion resistant tin metal
alloy includes 90-99.9% tin; 0-0.75% antimony; 0-0.5% bismuth;
0-0.005% cobalt; 0-2.7% copper; 0-0.1% iron; 0-0.05% lead; 0-0.005%
nickel; 0-0.001% silver; 0-0.001% sulfur; and 0-0.5% zinc. A
further and/or alternativeformulation of the corrosion resistant
tin metal alloy includes 90-95% tin; 0-0.25% aluminum; 0-1.5%
copper; 0-0.02% chromium; 0-0.01% iron; 0-0.01% lead; 0-0.01%
manganese; 0-0.018% titanium; and 0-9% zinc. Still a further and/or
alternativeformulation of the corrosion resistant tin metal alloy
includes 0-2.5% antimony, 0-0.5% bismuth, 0-2.7% copper, 0-0.1%
iron, 0.001-0.1% lead, 0.5-1.5% zinc and the remainder tin. Another
and/or alternative formulation of the corrosion resistant tin metal
alloy includes 90-99.9% tin; 0-7.2% antimony; 0-1.7% bismuth;
0-2.7% copper; 0-0.1% iron; 0.001-0.1% lead; and 0-1.5% zinc. Still
another and/or alternative formulation of the corrosion resistant
tin metal alloy includes at least about-95% tin; 0.001-0.1% lead,
and at least about 0.5% stabilizer. Yet another and/or alternative
formulation of the corrosion resistant tin metal alloy includes
0-2.5% antimony, 0-0.5% bismuth, 0-2.7% copper, 0-0.1% iron,
0.001-0.1% lead,0-1.5% zinc and the remainder tin. Still yet
another and/or alternative formulation of the corrosion resistant
tin metal alloy includes 90-99.95% tin; 0-7.2% antimony; 0-1.7%
bismuth; 0-2.7% copper; 0-0.1% iron; 0.001-0.1% lead; and 0-0.5%
zinc. A further and/or alternativeformulation of the corrosion
resistant tin metal alloy includes 90-99.95% tin; 0-7.2% antimony;
0-1.7% bismuth; and 0.001-0.05% lead. Still a further and/or
alternativeformulation of the corrosion resistant tin metal alloy
includes 95-99.9% tin; 0-0.1% aluminum; 0-1% antimony; 0-0.5%
bismuth; 0-0.5% copper; 0-0.1% iron; 0-0.5% lead; 0-0.1% nickel;
and 0-0.2% zinc. Still yet a further and/or alternativeformulation
of the corrosion resistant tin metal alloy includes 98-99.9% tin;
0-0.4% antimony; 0-0.2% bismuth; 0-0.1% copper; 0-0.01% iron;
0-0.05% lead; 0-0.01% nickel; and 0-0.05% zinc. Another and/or
alternative formulation of the corrosion resistant tin metal alloy
includes 75-99.99% tin; 0-5% aluminum; 0-7.5% antimony; 0-1.7%
bismuth; 0-5% copper; 0-10% lead; 0-5% nickel; 0-0.5% titanium; and
0-9% zinc. Still another and/or alternative formulation of the
corrosion resistant tin metal alloy includes 98-99% tin; 0-0.1%
aluminum; 0-1% antimony and/or bismuth; 0-0.001% arsenic; 0-0.001%
boron; 0-0.001% cadmium; 0-0.01% carbon; 0-0.01% chromium; 0-0.1%
copper; 0-0.05% iron; 0-0.05% lead; 0-0.001% magnesium; 0-0.001%
manganese; 0-0.001% molybdenum; 0-0.1% nickel; 0-0.001% silicon;
0-0.001% silver; 0-0.001% sulfur; 0-0.001% tellurium; 0-0.05%
titanium; 0-0.001% vanadium; and 0-1% zinc. Yet another and/or
alternative formulation ofthe corrosion resistant tin metal alloy
includes 50-99.999% tin; 0-7.5% aluminum; 0-2% antimony; 0-0.05%
arsenic; 0-0.1% boron; 0-1.7% bismuth; 0-0.5% cadmium; 0-1% carbon;
0-1% chromium; 0-5% copper; 0-0.5% 0-10% lead; 0-1% magnesium;
0-0.1% manganese; 0-0.1% molybdenum; 0-5% nickel; 0-0.5% silicon;
0-0.1% silver; 0-0.05% tellurium; 0-0.5% titanium; 0-0.1% vanadium;
and 0-9% zionc. Yet another and/or alternative formulation ofthe
corrosion resistant tin metal alloy includes 90-99.999% tin; 0-7.5%
aluminum; 0-2% antimony; 0-0.05% arsenic; 0-0.1% boron; 0-1.7%
bismuth; 0-0.5% cadmium; 0-1% carbon; 0-1% chromium; 0-5% copper;
0-1% iron; 0-10% lead; 0-1% magnesium; 0-0.1% manganese; 0-0.1%
molybdenum; 0-5% nickel; 0-0.5% silicon; 0-0.1% silver; 0-0.05%
tellurium; 0-0.5% titanium; 0-0.1% vanadium; and 0-9% zinc. Still
another and/or alternative formulation of the corrosion resistant
tin metal alloy includes 75-99.999% tin; 0-7.5% aluminum; 0-2%
antimony; 0-0.05% arsenic; 0-0.1% boron; 0-1.7% bismuth; 0-0.5%
cadmium; 0-1% carbon; 0-1% chromium; 0-5% copper; 0-1% iron; 0-10%
lead; 0-1% magnesium; 0-0.1% managanese; 0-0.1% molybdenum; 0-5%
nickel; 0-0.5% silicon; 0-0.1% silver; 0-0.05% tellurium; 0-0.5%
titanium; 0-0.1% vanadium; and 0-10% zinc. Yet another and/or
alternativeformulation of the corrosion resistant tin metal alloy
includes 75-99.999% tin; 0-7.5% aluminum; 0.001-5% antimony,
bismuth, cadmium and/or copper; 0-2% lead; 0-1% nickel; and 0-10%
zinc. Still yet another and/or alternative formulation of the
corrosion resistant tin metal alloy includes 95-99.999% tin; 0-2%
aluminum; 0.001-2% antimony, bismuth, cadmium and/or copper; 0-1%
lead; 0-1% nickel; and 0-2% zinc. Still another and/or alternative
formulation of the corrosion resistant tin metal alloy includes
98-99% tin; 0-0.1% aluminum; 0-1% antimony and/or bismuth; 0-0.001%
arsenic; 0-0.001% boron; 0-0.001% cadmium; 0-0.01% carbon; 0-0.01%
chromium; 0-0.1% copper; 0-0.05% iron; 0-0.05% lead; 0-0.001%
magnesium; 0-0.001% manganese; 0-0.001% molybdenum; 0-0.9% nickel;
0-0.001% silicon; 0-0.001% silver; 0-0.001% sulfuir; 0-0.001%
tellurium; 0-0.05% titanium; 0-0.001% vanadium; and 0-1% zinc.
[0222] A general formulation of the corrosion resistant tin and
zinc metal alloy by weight percent includes the following:
6 Tin 15-90 Zinc 9 to 10-85 Antimony 0-7.5 Bismuth 0-5 Copper
0-5
[0223] One more specific formulation of the corrosion resistant tin
and zinc metal alloy by weight percent includes the following:
7 Tin 15-90 Zinc 9 to 10-85 Aluminum 0-5 Antimony 0-7.5 Bismuth 0-5
Cadmium 0-1 Copper 0-5 Nickel 0-5
[0224] Another and/or alternative specific formulation of the
corrosion resistant tin and zinc metal alloy by weight percent
includes the following:
8 Tin 20-80 Zinc 20-80 Aluminum 0-2 Antimony 0-1 Arsenic 0-0.05
Bismuth 0-1 Boron 0-0.1 Cadmium 0-0.1 Carbon 0-0.5 Chromium 0-0.5
Copper 0-2 Iron 0-1 Lead 0-1 Magnesium 0-1 Manganese 0-0.1
Molybdenum 0-0.1 Nickel 0-1 Silicon 0-0.5 Silver 0-0.1 Tellurium
0-0.05 Titanium 0-0.5 Vanadium 0-0.1
[0225] Still another and/or alternative specific formulation of the
corrosion resistant tin and zinc metal alloy by weight percent
includes the following:
9 Tin 30-85 Zinc 15-70 Aluminum 0-1 Antimony 0-1 Arsenic 0-0.01
Bismuth 0-1 Boron 0-0.1 Cadmium 0-0.1 Carbon 0-0.5 Chromium 0-0.1
Copper 0-1 Iron 0-0.1 Lead 0-0.1 Magnesium 0-1 Manganese 0-0.01
Molybdenum 0-0.1 Nickel 0-0.1 Silicon 0-0.5 Silver 0-0.01 Tellurium
0-0.05 Titanium 0-0.05 Vanadium 0-0.1
[0226] Yet another and/or alternative specific formulation of the
corrosion-resistant tin and zinc metal alloy by weight percent
includes the following:
10 Tin 70-90 Zinc 9 to 10-30 Aluminum 0.001-0.01 Antimony 0.001-0.8
Copper 0.001-0.02 Bismuth 0.001-0.005 Boron 0-0.05 Silver 0-0.005
Carbon 0-0.05 Chromium 0-0.05 Iron 0-0.005 Magnesium 0-0.05
Manganese 0-0.01 Molybdenum 0-0.05 Silicon 0-0.05 Tellurium 0-0.01
Titanium 0-0.05 Vanadium 0-0.05 Arsenic 0-0.005 Cadmium 0-0.01
Nickel 0-0.005 Lead 0.01-0.1
[0227] Still yet another and/or alternative specific formulation
ofthe corrosion-resistant tin and zinc metal alloy by weight
percent includes the following:
11 Tin 79.5-81.5 Zinc 18.5-20.5 Aluminum 0.002-0.008 Antimony
0.6-0.7 Arsenic 0-0.001 Bismuth 0.002-0.005 Cadmium 0-0.001 Copper
0.005-0.02 Iron 0-0.001 Lead 0.02-0.08 Nickel 0-0.001 Silver
0-0.001
[0228] Examples of the tin and zinc metal alloy composition by
weight percent include:
12 Ingredients A B C D E F G H I J K L M N O E Zinc 10 15 20 25 30
35 40 45 50 55 60 65 70 75 80 85 Tin 90 85 80 75 70 65 60 55 50 45
40 35 30 25 20 15 Aluminum .ltoreq.0.5 .ltoreq.0.5 .ltoreq.0.5
.ltoreq.0.5 .ltoreq.0.5 .ltoreq.0.5 .ltoreq.0.5 .ltoreq.0.5
.ltoreq.0.5 .ltoreq.0.5 .ltoreq.0.5 .ltoreq.0.5 .ltoreq.0.5
.ltoreq.0.5 .ltoreq.0.5 .ltoreq.0.5 Antimony .ltoreq.0.5
.ltoreq.0.5 .ltoreq.0.5 .ltoreq.0.5 .ltoreq.0.5 .ltoreq.0.5
.ltoreq.0.5 .ltoreq.0.5 .ltoreq.0.5 .ltoreq.0.5 .ltoreq.0.5
.ltoreq.0.5 .ltoreq.0.5 .ltoreq.0.5 .ltoreq.0.5 .ltoreq.0.5 Bismuth
.ltoreq.0.5 .ltoreq.0.5 .ltoreq.0.5 .ltoreq.0.5 .ltoreq.0.5
.ltoreq.0.5 .ltoreq.0.5 .ltoreq.0.5 .ltoreq.0.5 .ltoreq.0.5
.ltoreq.0.5 .ltoreq.0.5 .ltoreq.0.5 .ltoreq.0.5 .ltoreq.0.5
.ltoreq.0.5 Copper .ltoreq.0.5 .ltoreq.0.5 .ltoreq.0.5 .ltoreq.0.5
.ltoreq.0.5 .ltoreq.0.5 .ltoreq.0.5 .ltoreq.0.5 .ltoreq.0.5
.ltoreq.0.5 .ltoreq.0.05 .ltoreq.0.5 .ltoreq.0.5 .ltoreq.0.5
.ltoreq.0.5 .ltoreq.0.5 Lead .ltoreq.0.1 .ltoreq.0.1 .ltoreq.0.1
.ltoreq.0.1 .ltoreq.0.1 .ltoreq.0.1 .ltoreq.0.1 .ltoreq.0.1
.ltoreq.0.1 .ltoreq.0.1 .ltoreq.0.1 .ltoreq.0.1 .ltoreq.0.1
.ltoreq.0.1 .ltoreq.0.1 .ltoreq.0.1
[0229] One formulation ofthe corrosion resistant tin and zinc metal
alloy includes by weight percent 20-80% tin; 20-80% zinc; 0-1%
aluminum; 0-2% antimony; 0-0.02% arsenic; 0-1.5% bismuth; 0-0.1%
boron; 0-0.1% cadmium; 0-0.5% carbon; 0-0.5% chromium; 0-2% copper;
0-1% iron; 0-1% lead; 0-0.4% magnesium; 0-0.1% manganese; 0-0.1%
molybdenum; 0-1% nickel; 0-0.5% silicon; 0-0.05% silver; 0-0.02%
sulfur; 0-0.04% tellurium; 0-0.15% titanium; and 0-0.05% vanadium.
Another and/or alternative formulation of the corrosion resistant
tin and zinc metal alloy includes 30-70% tin; 30-70% zinc; 0-0.4%
aluminum; 0-0.8% antimony; 0-0.005% arsenic; 0-0.5% bismuth;
0-0.05% boron; 0-0.05% cadmium; 0-0.1% carbon; 0-0.1% chromium;
0-1% copper; 0-0.6% iron; 0-0.5% lead; 0-0.1% magnesium; 0-0.1%
manganese; 0-0.05% molybdenum; 0-0.9% nickel; 0-0.01% silicon;
0-0.01% silver; 0-0.01% sulfur; 0-0.01% tellurium; 0-0.1% titanium;
and 0-0.01% vanadium; and the tin plus zinc content is at least 90
weight percent ofthe alloy. Still another and/or alternative
formulation of the corrosion resistant tin and zinc metal alloy
includes 40-60% tin; 40-60% zinc; 0-0.4% aluminum; 0-1% antimony
and/or bismuth; 0-0.001% arsenic; 0-0.01% boron; 0-0.005% cadmium;
0-0.05% carbon; 0-0.05% chromium; 0-0.1% copper; 0-0.05% iron;
0-0.1% lead; 0-0.01% magnesium; 0-0.01% manganese; 0-0.01%
molybdenum; 0-0.9% nickel; 0-0.001% silicon; 0-0.001% silver;
0-0.001% sulfur; 0-0.001% tellurium; 0-0.05% titanium; and 0-0.001%
vanadium; and the tin plus zinc content is at least 95 weight
percent of the alloy. Yet another and/or alternative formulation of
the corrosion resistant tin and zinc metal alloy includes 45-55%
zinc; 45-55% tin; 0-0.4% aluminum; 0-0.8% antimony and/or bismuth;
0-0.001% arsenic; 0-0.001% boron; 0-0.001% cadmium; 0-0.01% carbon;
0-0.05% copper; 0-0.001 iron; 0-0.08% lead; 0-0.001% magnesium;
0-0.001% manganese; 0-0.001% molybdenum; 0-0.9% nickel; 0-0.001%
silicon; 0-0.005% silver; 0-0.001% sulfur; 0-0.001% tellurium;
0-0.05% titanium and 0-0.001% vanadium; and the tin content plus
the zinc content is at least 99% of the alloy. Still yet another
and/or alternative formulation of the corrosion resistant tin and
zinc metal alloy includes 30-85% tin; 15-70% zinc; 0-0.5% aluminum;
0-2% antimony; 0-0.01% arsenic; 0-1.5% bismuth; 0-0.05% boron;
0-0.1% cadmium; 0-0.1% carbon; 0-0.1% chromium; 0-2% copper; 0-1%
iron; 0-0.5% lead; 0-0.4% magnesium; 0-0.1% manganese; 0-0.05%
molybdenum; 0-1% nickel; 0-0.5% silicon; 0-0.05% silver; 0-0.01%
sulfur; 0-0.01% tellurium; 0-0.15% titanium; and 0-0.05% vanadium.
A further and/or altemativeformulation ofthe corrosion resistant
tin and zinc metal alloy includes 30-65% tin; 35-70% zinc; 0-0.1%
aluminum; 0-1% antimony and/or bismuth; 0-0.05% arsenic; 0-0.01%
cadmium; 0-0.5% copper; less than 0.05% iron; less than 0.1% lead;
0-0.1% magnesium; 0-0.1% manganese; 0-0.5% nickel; 0-0.05% silver;
0-0.05% titanium; and the tin plus zinc content is at least 98% of
the metal alloy. Still a further and/or alternativeformulation of
the corrosion resistant tin and zinc metal alloy includes 40-60%
tin; 40-60% zinc; 0-0.4% aluminum; 0-0.8% antimony and/or bismuth;
0-0.005% arsenic; 0-0.005% cadmium; 0-0.2% copper; 0-0.05% iron;
0-0.1% lead; 0-0.001% magnesium; 0-0.001% manganese; 0-0.05%
nickel; 0-0.005% silver; 0-0.05% titanium; and the tin plus zinc
content is at least 99% of the metal alloy. Yet a further and/or
alternativeformulation of the corrosion resistant tin and zinc
metal alloy includes 60-90% tin; 9 to 10-40% zinc; 0-0.5% aluminum;
0-2% antimony; 0-0.01% arsenic; 0-1.5% bismuth; 0-0.05% boron;
0-0.1% cadmium; 0-0.5% carbon; 0-0.5% chromium; 0-2% copper; up to
1% iron; less than 0.5% lead; 0-0.4% magnesium; 0-0.1% manganese;
0-0.1% molybdenum; 0-1% nickel; 0-0.5% silicon; 0-0.01% silver;
0-0.01% sulfur; 0-0.01% tellurium; 0-0.15% titanium; and 0-0.1%
vanadium. Still yet a further and/or alternativeformulation ofthe
corrosion resistant tin and zinc metal alloy includes 70-90% tin; 9
to 10-30% zinc; 0-0.1% aluminum; 0-1% antimony and/or bismuth;
0-0.05% arsenic; 0-0.01% cadmium; 0-0.5% copper; less than 0.05%
iron; less than 0.1% lead; 0-0.1% magnesium; 0-0.1% manganese;
0-0.5% nickel; 0-0.05% silver; 0-0.05% titanium; and the tin plus
zinc content is at least 95% of the metal alloy. Yet a further
and/or alternativeformulation of the corrosion resistant tin and
zinc metal alloy includes 75-85% tin; 15-25% zinc; 0.001-0.01%
aluminum; 0.001-0.8% antimony and/or bismuth; 0-0.005% arsenic;
0-0.001% cadmium; 0.005-0.02% copper; 0-0.001 iron; 0.01-0.08%
lead; 0-0.001% magnesium; 0-0.001% manganese; 0-0.001% nickel;
0-0.01 silver; 0-0.001% titanium; and the tin plus zinc content is
at least 98% of the metal alloy coating. Another and/or alternative
formulation of the corrosion resistant tin and zinc metal alloy
includes 15-35% tin; 65-85% zinc; 0-7.5% antimony; 0-1.7% bismuth.
Yet another and/or alternative formulation ofthe corrosion
resistant tin and zinc metal alloy includes 15-35% tin; 65-85%
zinc; and 0.01-0.5% antimony and/or bismuth. Still another and/or
alternative formulation of the corrosion resistant tin and zinc
metal alloy includes 15-35% tin; 65-85% zinc; 0.01-0.5% antimony
and/or bismuth; and less than 2% copper and/or iron. Still yet
another and/or alternative formulation of the corrosion resistant
tin and zinc metal alloy includes 15-35% tin; 65-85% zinc; 0-0.5%
antimony; 0-0.5% bismuth; and less than 0.01% lead. A further
and/or alternativeformulation of the corrosion resistant tin and
zinc metal alloy includes 15-35% tin; 65-85% zinc; 0-0.5% antimony;
0-0.5% bismuth; less than 2% copper and/or iron; and less than
0.01% lead. Yet a further and/or alternativeformulation of the
corrosion resistant tin and zinc metal alloy includes 15-35% tin;
65-85% zinc; 0-7.5% antimony; 0-1.7% bismuth; 0-2% copper; 0-0.1%
iron; and 0-0.05% lead. Another and/or alternative formulation of
the corrosion resistant tin and zinc metal alloy includes 70-90%
tin; 9 to 10-30% zinc; 0-7.5% antimony; 0-1.7% bismuth; 0-2%
copper; 0-0.1% iron; and 0-0.05% lead. Still another and/or
alternative formulation of the corrosion resistant tin and zinc
metal alloy includes 80-90% tin; 9 to 10-20% zinc; 0-7.5% antimony;
0-1.7% bismuth; 0-2% copper; 0-0.1% iron; and 0-0.05% lead. Yet
another and/or alternative formulation of the corrosion resistant
tin and zinc metal alloy includes 70-90% tin; 9 to 10-30% zinc;
0-2.5% antimony; 0-0.5% bismuth; 0-2% copper; 0-0.1% iron; and
0-0.05% lead. Still yet another and/or alternative formulation of
the corrosion resistant tin and zinc metal alloy includes 70-90%
tin; 9 to 10-30% zinc; 0.5-7.5% antimony; 0.5-1.7% bismuth; 0-2%
copper; 0-0.1% iron; and 0-0.05% lead. A further and/or
alternativeformulation of the corrosion resistant tin and zinc
metal alloy includes 80-90% tin; 9 to 10-20% zinc; 0-7.5% antimony;
0-1.7% bismuth; 0-2% copper; 0-0.1% iron; and 0-0.01% lead. A
further and/or alternativeformulation of the corrosion resistant
tin and zinc metal alloy includes 15-70% tin; 30-85% zinc; 0-7.5%
antimony; 0-1.7% bismuth; 0-5% copper; 0-0.1% iron 0-0.05% lead;
and 0-5% nickel. Yet a further and/or alternativeformulation of the
corrosion resistant tin and zinc metal alloy includes 15-70% tin;
30-85% zinc; 0-0.5% antimony; 0-0.5% bismuth; 0-2% copper; 0-0.1%
iron; 0-0.01% lead; and 0-1% nickel. Still a further and/or
alternativeformulation of the corrosion resistant tin and zinc
metal alloy includes 35-70% tin; 30-65% zinc; 0-0.5% antimony;
0-0.5% bismuth; 0-2% copper; 0-0.1% iron; 0-0.05% lead; and 0-1%
nickel. Still yet a further and/or alternativeformulation of the
corrosion resistant tin and zinc metal alloy includes 45-55% tin;
45-55% zinc; 0-0.5% antimony and/or bismuth; 1-1.5% copper; 0-0.1%
iron; 0-0.01% lead; 0.3-0.9% nickel; and the tin content plus zinc
content at least 95% of the metal alloy. Another and/or alternative
formulation of the corrosion resistant tin and zinc metal alloy
includes 20-90% tin; 9 to 10-80% zinc; 0-0.5% aluminum; 0-1%
antimony; 0-2.7% copper; and 0-0.15% titanium. Still another and/or
alternative formulation of the corrosion resistant tin and zinc
metal alloy includes 20-90% tin; 9 to 10-80% zinc; 0-0.3% aluminum;
0-5.5% antimony; and 0-1% copper. Yet another and/or alternative
formulation of the corrosion resistant tin and zinc metal alloy
includes 20-90% tin; 9 to 10-80% zinc; 0-5% aluminum; 0-5.5%
antimony; 0-1.7% bismuth; 0-5% copper; 0-0.1% iron; 0-0.05% lead;
0-5% magnesium; 0-5% nickel; and 0-1% titanium. Still another
and/or alternative formulation of the corrosion resistant tin and
zinc metal alloy includes 20-75% tin; 25-80% zinc; 0-1% aluminum;
0-5.5% antimony; 0-1.7% bismuth; 0-2.7% copper; 0-0.1% iron;
0-0.05% lead; 0-1% magnesium; 0-1% nickel; and 0-0.5% titanium.
Still yet another and/or alternative formulation of the corrosion
resistant tin and zinc metal alloy includes 20-80% tin; 20-80%
zinc; 0-0.5% aluminum; 0-5.5% antimony; 0-1.5% bismuth; 0-2.7%
copper; 0-0.1% iron; 0-0.01% lead; 0-0.4% magnesium; 0-1% nickel;
and 0-0.15% titanium. A further and/or alternativeformulation of
the corrosion resistant tin and zinc metal alloy includes 35-70%
tin; 30-65% zinc; 0-0.3% aluminum; 0.05-1% antimony and/or bismuth;
0-1% copper; 0-0.1% iron; 0-0.01% lead; 0-0.4% magnesium; 0-0.7%
nickel; 0-0.15% titanium; and the tin plus zinc content is at least
90% of the metal alloy. Yet a further and/or alternativeformulation
of the corrosion resistant tin and zinc metal alloy includes 15-90%
tin; 9 to 10-85% zinc; 0-5% aluminum; 0-7.5% antimony; 0-1.7%
bismuth; 0-5% copper; 0-1% iron; 0-1% lead; 0-5% magnesium; 0-5%
nickel; and 0-1% titanium. Still yet a further and/or
alternativeformulation of the corrosion resistant tin and zinc
metal alloy includes 10-70% tin; 30-90% zinc; 0-0.25% aluminum;
0-0.02% chromium; 0-1.5% copper; 0-0.01% iron; 0-0.01% lead;
0-0.01% magnesium; and 0-0.18% titanium. Another and/or alternative
formulation of the corrosion resistant tin and zinc metal alloy
includes 10-70% tin; 30-90% zinc; 0-0.25% aluminum; 0-0.02%
chromium; 0-1.5% copper; 0-0.01% iron; 0-0.01% lead; 0-0.01%
magnesium; and 0-0.18% titanium. Still another and/or alternative
formulation of the corrosion resistant tin and zinc metal alloy
includes 15-90% tin; 9 to 10-80% zinc; 0-0.01% aluminum; 0-1%
antimony; 0-0.005% arsennc; 0-0.01% bismuth; 0-0.05% cadmium;
0-0.05% copper; 0-0.005% iron; 0-0.1% lead; 0-0.005% nickel; and
0-0.005% silver. Yet another and/or alternative formulation of the
corrosion resistant tin and zinc metal alloy includes 70-90% tin; 9
to 10-30% zinc; 0-0.01% aluminum; 0.001-0.8% antimony; 0-0.005%
arsenic; 0.001-0.005%bismuth; 0-0.01% cadmium; 0-0.02% copper;
0-0.005% iron; 0-0.1% lead; 0-0.005% nickel; and 0-0.005% silver.
Still yet another and/or alternative formulation of the corrosion
resistant tin and zinc metal alloy includes 79.5-81.5% tin;
18.5-20.5% zinc; 0.002-0.008% aluminum; 0.6-0.7% antimony; 0-0.001%
arsenic; 0.002-0.005% bismuth; 0-0.001% cadmium; 0.005-0.02%
copper; 0-0.001% iron; 0.02-0.08% lead; 0-0.001% nickel; and
0-0.001% silver. A further and/or alternativeformulation of the
corrosion resistant tin and zinc metal alloy includes 70-90% tin; 9
to 10-30% zinc; 0-0.01% aluminum; 0-1% antimony; 0-0.005% arsenic;
0-0.01% bismuth; 0-0.01% cadmium; 0-0.5% copper; 0-0.005% iron;
0-0.1% lead; 0-0.005% nickel; and 0-0.005% silver. Yet further
and/or alternativeformulation ofthe corrosion resistant tin and
zinc metal alloy includes 60-90% tin; 9 to 10-40% zinc; 0-0.5%
aluminum; 0-2% antimony; 0-0.01% arsenic; 0-1.5% bismuth; 0-0.05%
boron; 0-0.1% cadmium; 0-0.5% carbon; 0.0-0.5% chromium; 0-2%
copper; up to 1% iron; less than 0.5% lead; 0-0.4% magnesium;
0-0.1% manganese; 0-0.1% molybdenum; 0-1% nickel; 0-0.5% silicon;
0-0.01% silver; 0-0.01% sulfur; 0-0.01% tellurium; 0-0.15%
titanium; and 0-0.1% vanadium. Still a further and/or
alternativeformulation ofthe corrosion resistant tin and zinc metal
alloy includes 70-90% tin; 9 to 10-30% zinc; 0-0.1% aluminum; 0-1%
antimony and/or bismuth; 0-0.05% arsenic; 0-0.01% cadmium; 0-0.5%
copper; less than 0.05% iron; less than 0.1% lead; 0-0.1%
magnesium; 0-0.1% manganese; 0-0.5% nickel; 0-0.5% silicon; 0-0.05%
silver; 0-0.05% titanium; and the tin plus zinc content is at least
95% of the metal alloy. Still yet a further and/or
alternativeformulation ofthe corrosion resistant tin and zinc metal
alloy includes 75-85% tin; 15-25% zinc; 0.001-0.01% aluminum;
0.001-0.8% antimony and/or bismuth; 0-0.005% arsenic; 0-0.001%
cadmium; 0.005-0.02% copper; 0-0.0015% iron; 0.01-0.08% lead;
0-0.001% magnesium; 0-0.001% manganese; 0-0.001% nickel; 0-0.5%
silicon; 0-0.01% silver; 0-0.001% titanium; and the tin plus zinc
content is at least 98% of the metal alloy. Another and/or
alternative formulation of the corrosion resistant tin and zinc
metal alloy includes 15-90% tin; 9 to 10-85% zinc; 0-2% aluminum;
0-2% antimony; 0-1.7% bismuth; 0-2% copper; 0-1% iron; 0-0.5% lead;
0-2% magnesium; 0-2% nickel; and 0-1% titanium. Still another
and/or alternative formulation of the corrosion resistant tin and
zinc metal alloy includes 15-90% tin; 9to 10-85% zinc; 0-1%
aluminum; 0-2% antimony; 0-1.7% bismuth; 0-2% copper; 0-1% iron;
0-0.5% lead; 0-1% magnesium; 0-1% nickel; and 0-0.5% titanium. Yet
another and/or alternative formulation of the corrosion resistant
tin and zinc metal alloy includes 20-90% tin; 9 to 10-80% zinc;
0-0.51% aluminum; 0-2% antimony; 0-1.5% bismuth; 0-0.01% boron;
0-0.1% cadmium; 0-0.5% carbon; 0-0.5% chromium; 0-2% copper; 0-1%
iron; 0-0.5% lead; 0-0.4% magnesium; 0-0.1% manganese; 0-0.1%
molybdenum; 0-1% nickel; 0-0.5% silicon; and 0-0.15% titanium; and
0-0.1% vanadium. Still another and/or alternative formulation of
the corrosion resistant tin and zinc metal alloy includes 20-65%
tin; 30-80% zinc; 0-0.3% aluminum; 0-1% antimony and/or bismuth;
0-1% copper; 0-0.6% iron; 0-0.5% lead; 0-0.4% magnesium; 0-0.1%
manganese; 0-0.7% nickel; 0-0.15% titanium; and the tin plus zinc
content is at least 95% of the metal alloy. Still yet another
and/or alternative formulation of the corrosion resistant tin and
zinc metal alloy includes 20-50% tin; 50-80% zinc; 0-0.3% aluminum;
0.005-0.5% antimony and/or bismuth; 0-0.05% cadmium; 0-0.2% copper;
0-0.6% iron; 0-0.4% lead; 0-0.1% magnesium; 0-0.05% manganese;
0-0.1% nickel; 0-0.1% silicon; 0-0.15% titanium; and the tin plus
zinc content is at least 95% of the metal alloy. A further and/or
alternativeformulation of the corrosion resistant tin and zinc
metal alloy includes 20-70% tin; 30-75% zinc; 0.0005-2% aluminum;
0.001-2% antimony; 0.0001-1% bismuth; 0-2% copper; 0-0.5% lead; and
0.0001-0.1% titanium. Yet a further and/or alternativeformulation
of the corrosion resistant tin and zinc metal alloy includes 40-60%
tin; 40-60% zinc; 0.0005-0.75% aluminum; 0.001-1% antimony; 0-0.01%
arsenic; 0.0001-0.2% bismuth; 0-0.01% cadmium; 0.001-1% copper;
0-0.01% chromium; 0-0.1% iron; 0-0.1% lead; 0-0.01% manganese;
0-0.2% nickel; 0-0.01% silver; and 0.0005-0.05% titanium. Still yet
a further and/or alternativeformulation ofthe corrosion resistant
tin and zinc metal alloy includes 25-70% tin; 30-75% zinc; 0-0.5%
aluminum; 0-0.5% copper; 0-0.1% lead; and 0-0.05% titanium. Another
and/or alternative formulation of the corrosion resistant tin and
zinc metal alloy includes 30-70% tin; 30-70% zinc; 0.0001-0.5%
aluminum; 0.001-2% antimony; 0-0.01% arsenic; 0.0001-1% bismuth;
0-0.01% boron; 0-0.01% cadmium; 0-0.05% carbon; 0-0.05% chromium;
0-2% copper; 0-0.1% iron; 0-0.5% lead; 0-0.01% magnesium; 0-0.01%
manganese; 0-0.01% molybdenum; 0-1% nickel; 0-0.01% silicon;
0-0.01% silver; 0-0.01% sulfur; 0-0.01% tellurium; 0.0001-0.1%
titanium; and 0-0.01% vanadium. Still another and/or alternative
formulation of the corrosion resistant tin and zinc metal alloy
includes 40-60% tin; 40-60% zinc; 0.0005-0.4% aluminum; 0.01-0.8%
antimony; 0-0.005% arsenic; 0.001-0.05% bismuth; 0-0.005% cadmium;
0.005-0.5% copper; 0-0.05% iron; 0-0.1% lead; 0-0.05% nickel;
0-0.005% silver; and 0.0005-0.05% titanium. Yet another and/or
alternative formulation of the corrosion resistant tin and zinc
metal alloy includes 48-52% tin; 48-52% zinc; 0.005-0.24% aluminum;
0.05-0.64% antimony; 0-0.001% arsenic; 0.002-0.005% bismuth;
0-0.001% cadmium; 0.01-0.3% copper; 0-0.016% iron; 0-0.08% lead;
0-0.001% nickel; 0-0.001% silver; and 0.001-0.02% titanium. Yet
another and/or alternative formulation of the corrosion resistant
tin and zinc metal alloy includes 15-90% tin; 9 to 10-85% zinc;
0-5% aluminum; 0-5% antimony; 0-5% bismuth; 0-1% cadmium; 0-5%
copper; 0-1% iron; 0-1% lead; and 0-1% nickel. Still another and/or
alternative formulation ofthe corrosion resistant tin and zinc
metal alloy includes 30-85% tin; 15-70% zinc; 0-1% antimony; 0-0.1%
arsenic; 0-1% bismuth; 0-0.1% cadmium; 0-1% copper; 0-0.1% iron;
0-0.1% lead; 0-0.1% manganese; 0-0.1% nickel; 0-0.1% silver; and
0-0.05% titanium. Still yet another and/or alternative formulation
ofthe corrosion resistant tin and zinc metal alloy includes 30-80%
tin; 20-70% zinc; 0-0.5% aluminum; 0-0.5% antimony; 0-0.5% bismuth;
0-0.5% copper; and 0-0.1% lead. A further and/or
alternativeformulation of the corrosion resistant tin and zinc
metal alloy includes 30-85% tin; 15-70% zinc; 0-0.5% aluminum; 0-2
antimony; 0-0.01% arsenic; 0-1.5% bismuth; 0-0.05% boron; 0-0.1%
cadmium; 0-0.1% carbon; 0-0.1% chromium; 0-2% copper; 0-1% iron;
0-0.5% lead; 0-0.4% magnesium; 0-0.1% manganese; 0-0.05%
molybdenum; 0-1% nickel; 0-0.5% silicon; 0-0.05% silver;
0-0.01%
tellurium; 0-0.15% titanium; and 0-0.05% vanadium. Yet a further
and/or alternativeformulation of the corrosion resistant tin and
zinc metal alloy includes 30-65% tin; 35-70% zinc; 0-0.1% aluminum;
0-1% antimony and/or bismuth; 0-0.05% arsenic; 0-0.01% cadmium;
0-0.5% copper; 0-0.05% iron; 0-0.1% lead; 0-0.1% magnesium; 0-0.1%
manganese; 0-0.5% nickel; 0-0.05% silver; 0-0.05% titanium; and the
tin plus zinc content is at least 98% of the metal alloy. Still yet
a further and/or alternativeformulation of the corrosion resistant
tin and zinc metal alloy includes 40-60% tin; 40-60% zinc; 0-0.4%
aluminum; 0-0.8% antimony and/or bismuth; 0-0.005% arsenic;
0-0.005% cadmium; 0-0.2% copper; 0-0.001% iron; 0.01-0.08% lead;
0-0.001% magnesium; 0-0.001% manganese; 0-0.05% nickel; 0-0.005%
silver; 0-0.05% titanium; and the tin plus zinc content is at least
99% of the metal alloy. Another and/or alternative formulation of
the corrosion resistant tin and zinc metal alloy includes 15-90%
tin; 9 to 10-85% zinc; 0-5% aluminum; 0-7.5% antimony; 0-5%
bismuth; 0-1% cadmium; 0-5% copper; 0-5% nickel; and 0-0.5%
titanium. Still another and/or alternative formulation of the
corrosion resistant tin and zinc metal alloy includes 20-80% tin;
20-80% zinc; 0-2% aluminum; 0-1% antimony; 0-0.05% arsenic; 0-1%
bismuth;0-0.1% boron; 0-0.1% cadmium; 0-0.5% carbon; 0-0.05%
chromium; 0-2% copper; 0-1% iron; 0-1% lead; 0-1% magnesium; 0-0.1%
manganese; 0-0.1% molybdenum; 0-1% nickel; 0-0.5% silicon; 0-0.1%
silver; 0-0.05% tellurium; 0-0.5% titanium; and 0-0.1% vanadium.
Yet another and/or alternative formulation of the corrosion
resistant tin and zinc metal alloy includes 20-80% tin; 20-80%
zinc; 0-1% aluminum; 0-2% antimony; 0-0.02% arsenic; 0-1.5%
bismuth; 0-0.5% boron; 0-0.1% cadmium; 0-0.5% carbon; 0-0.5%
chromium; 0-2% copper; 0-1% iron; 0-1% lead; 0-0.4% magnesium;
0-0.1% manganese; 0-0.1% molybdenum; 0-1% nickel; 0-0.05% silicon;
0-0.05% silver; 0-0.02% sulfur; 0-0.04% tellurium; 0-0.15%
titanium; and 0-0.05% vanadium. Still yet another and/or
alternative formulation of the corrosion resistant tin and zinc
metal alloy includes 30-70% tin; 30-70% zinc; 0-0.4% aluminum;
0-0.8% antimony; 0-0.005% arsenic; 0-0.5% bismuth; 0-0.1% boron;
0-0.05% cadmium; 0-0.1% carbon; 0-0.1% chromium; 0-1% copper;
0-0.6% iron; 0-0.5% lead; 0-0.1% magnesium; 0-0.1% manganese;
0-0.05% molybdenum; 0-0.7% nickel; 0-0.01% silicon; 0-0.01% silver;
0-0.01% sulfur; 0-0.01% tellurium; 0-0.1% titanium; 0-0.01%
vanadium; and the tin plus zinc content is at least 90 weight
percent of the metal alloy. A further and/or alternativeformulation
of the corrosion resistant tin and zinc metal alloy includes 40-60%
tin; 40-60% zinc; 0-0.4% aluminum; 0-1% antimony and/or bismuth;
0-0.001% arsenic; 0-0.01% boron; 0-0.005% cadmium; 0-0.05% carbon;
0-0.05% chromium; 0-0.1% copper; 0-0.05% iron; 0-0.1% lead; 0-0.01%
magnesium; 0-0.01% manganese; 0-0.01% molybdenum; 0-0.3% nickel;
0-0.001% silicon; 0-0.001% silver; 0-0.001% sulfur; 0-0.001%
tellurium; 0-0.05% titanium; 0-0.001% vanadium; and the tin plus
zinc content is at least 95 weight percent of the metal alloy. Yet
a further and/or alternativeformulation of the corrosion resistant
tin and zinc metal alloy includes 45-55% zinc; 45-55% tin; 0-0.4%
aluminum; 0-0.8% antimony and/or bismuth; 0-0.001% arsenic;
0-0.001% boron; 0-0.001% cadmium; 0-0.01% carbon; 0-0.05% copper;
0-0.001 iron; 0-0.08% lead; 0-0.001% magnesium; 0-0.001% manganese;
0-0.001% molybdenum; 0-0.1% nickel; 0-0.001% silicon; 0-0.005%
silver; 0-0.001% sulfur; 0-0.001% tellurium; 0-0.05% titanium;
0-0.001% vanadium; and the tin content plus the zinc content is at
least 99% of the metal alloy. Another and/or alternative
formulation of the corrosion resistant tin and zinc metal alloy
includes 20-80% tin; 20-80% zinc; 0-1% aluminum; 0-2% antimony;
0-0.02% arsenic; 0-1.5% bismuth; 0-0.05% boron; 0-0.1% cadmium;
0-0.5% carbon; 0-0.5% chromium; 0-2% copper; 0-0.5% iron; 0-1%
lead; 0-0.4% magnesium; 0-0.1% manganese; 0-0.1% molybdenum; 0-1%
nickel; 0-0.5% silicon; 0-0.05% silver; 0-0.02% sulfur; 0-0.04%
tellurium; 0-0.15% titanium; and 0-0.05% vanadium. Yet another
and/or alternative formulation of the corrosion resistant tin and
zinc metal alloy includes 30-70% tin; 30-70% zinc; 0-0.4% aluminum;
0-0.8% antimony; 0-0.005% arsenic; 0-0.5% bismuth; 0-0.1% boron;
0-0.05% cadmium; 0-0.1% carbon; 0-0.1% chromium; 0-1% copper;
0-0.6% iron; 0-0.5% lead; 0-0.1% magnesium; 0-0.1% manganese;
0-0.05% molybdenum; 0-0.9% nickel; 0-0.01% silicon; 0-0.01% silver;
0-0.01% sulfur; 0-0.01% tellurium; 0-0.1% titanium; 0-0.01%
vanadium; and the tin plus zinc content is at least 90 weight
percent of the metal alloy. Still another and/or alternative
formulation of the corrosion resistant tin and zinc metal alloy
includes 40-60% tin; 40-60% zinc; 0-0.4% aluminum; 0-1% antimony
and/or bismuth; 0-0.001% arsenic; 0-0.01% boron; 0-0.005% cadmium;
0-0.05% carbon; 0-0.05% chromium; 0-0.1% copper; 0-0.05% iron;
0-0.1% lead; 0-0.01% magnesium; 0-0.01% manganese; 0-0.01%
molybdenum; 0-0.9% nickel ; 0-0.001% silicon; 0-0.001% silver;
0-0.001% sulfur; 0-0.001% tellurium; 0-0.05% titanium; 0-0.001%
vanadium; and the tin plus zinc content is at least 95 weight
percent ofthe metal alloy. Still yet another and/or alternative
formulation ofthe corrosion resistant tin and zinc metal alloy
includes 45-55% zinc; 45-55% tin; 0-0.4% aluminum; 0-0.8% antimony
and/or bismuth; 0-0.001% arsenic; 0-0.001% boron; 0-0.001% cadmium;
0-0.01% carbon; 0-0.05% copper; 0-0.001% iron; 0-0.08% lead;
0-0.001% magnesium; 0-0.001% manganese; 0-0.001% molybdenum; 0-0.9%
nickel; 0-0.001% silicon; 0-0.005% silver; 0-0.001% sulfur;
0-0.001% tellurium; 0-0.05% titanium; 0-0.001% vanadium; and the
tin content plus the zinc content is at least 99% of the metal
alloy. A further and/or altemativeformulation of the corrosion
resistant tin and zinc metal alloy includes 15-90% tin; 9 to 10-85%
zinc; 0-0.5% aluminum; 0-5.5% antimony; 0-1.7% bismuth; 0-2.7%
copper; 0-0.4% magnesium; 0-1% nickel; 0-0.15% titanium. Yet a
firther and/or alternativeformulation of the corrosion resistant
tin and zinc metal alloy includes 15-90% tin; 9 to 10-85% zinc;
0-0.3% aluminum; 0-1% antimony; 0-1.7% bismuth; 0-1% copper; 0-0.4%
magnesium; 0-1% nickel; 0-0.15% titanium. Still a firther and/or
alternativeformulation of the corrosion resistant tin and zinc
metal alloy includes 15-80% tin; 20-85% zinc; 0-0.3% aluminum; 0-1%
antimony; 0-1.7% bismuth; 0-1% copper; 0-0.4% magnesium; 0-1%
nickel; 0-0.15% titanium. Still yet further and/or
alternativeformulation of the corrosion resistant tin and zinc
metal alloy includes 15-80% tin; 20-85% zinc; 0-0.5% aluminum;
0-5.5% antimony; 0-1.7% bismuth; 0-2.7% copper; 0-0.4% magnesium;
0-1% nickel; and 0-0.15% titanium. Another and/or alternative
formulation of the corrosion resistant tin and zinc metal alloy
includes 15-70% tin; 30-85% zinc; 0-0.25% aluminum; 0-1.5% copper;
0-0.02% chromium; 0-0.01% iron; 0-0.01% lead; 0-0.01% manganese;
and 0-0.18% titanium. Still another and/or alternative formulation
of the corrosion resistant tin and zinc metal alloy includes
49.75-50.25% tin; 49.75-50.25% zinc; 0-0.02% aluminum; 0-0.2%
antimony; 0-0.2% arsenic; 0-0.2% copper; 0-0.025% iron; 0-0.002%
palladium; and 0-0.015% titanium. Yet another and/or alternative
formulation of the corrosion resistanttin and zinc metal alloy
includes 49.5-50.5% tin; 49.5-50.5% zinc; 0.005-0.21% aluminum;
0.05-0.64% antimony; 0-0.001% arsenic; 0-0.004% bismuth; 0-0.001%
cadmium; 0.01-0.3% copper; 0-0.001% iron; 0-0.001% nickel; 0-0.001%
silver; 0.001-0.02% titanium. Still yet another and/or alternative
formulation of the corrosion resistant tin and zinc metal alloy
includes 49.75-50.25% tin; 49.75-50.25% zinc; 0-0.25% aluminum;
0-0.35% antimony; 0-0.02%arsenic; 0-0.001% cadmium; 0-0.02%copper;
0-0.025% iron; 0-0.08% lead; and 0-0.0175% titanium. A further
and/or alternativeformulation of the corrosion resistant tin and
zinc metal alloy includes 35-70% tin; 30-65% zinc; 0-5% copper; and
0-5% nickel. Yet a further and/or alternativeformulation of the
corrosion resistant tin and zinc metal alloy includes 20-80% tin;
20-85% zinc; 0-0.1% lead. Still a further and/or
alternativeformulation ofthe corrosion resistant tin and zinc metal
alloy includes 15-30% tin; 70-85% zinc; and 0-0.1% lead. Yet a
further and/or alternativeformulation of the corrosion resistant
tin and zinc metal alloy includes 15-90% tin; 9 to 10-85% zinc; and
0-2% magnesium. Still yet a further and/or alternativeformulation
ofthe corrosion resistant tin and zinc metal alloy includes 10-75%
tin; 25-90% zinc; 0-0.25% aluminum; 0-1.5% copper; 0-0.02%
chromium; 0-0.01% iron; 0-0.01% lead; 0-0.01% manganese; and
0-0.18% titanium. Another and/or alternative formulation of the
corrosion resistant tin and zinc metal alloy includes 15-35% tin;
65-85% zinc; 0-7.5% antimony; 0-1.7% bismuth; 0-0.1% iron; and
0-0.05% lead. Yet another and/or alternative formulation of the
corrosion resistant tin and zinc metal alloy includes 15-70% tin;
30-85% zinc; 0-7.5% antimony; 0-1.7% bismuth; 0-5% copper; 0-0.1%
iron; 0-0.05% lead; and 0.3-5% nickel. Still another and/or
alternative formulation of the corrosion resistant tin and zinc
metal alloy includes 15-70% tin; 30-85% zinc; 0-7.5% antimony;
0-1.7% bismuth; 0-2% copper; 0-0.1% iron; 0-0.05% lead; and 0.3-1%
nickel. Still yet another and/or alternative formulation of the
corrosion resistant tin and zinc metal alloy includes 15-70% tin;
30-85% zinc; 0.1-5% copper; and 0.3-5% nickel. A further and/or
alternativeformulation of the corrosion resistant tin and zinc
metal alloy includes 35-70% tin; 30-65% zinc; 0.1-2% copper; and
0.3-1% nickel. Still a further and/or alternativeformulation of the
corrosion resistant tin and zinc metal alloy includes 35-70% tin;
30-65% zinc; 0.1-1.5% copper; and 0.3-0.9% nickel. A further and/or
alternativeformulation ofthe corrosion resistant tin and zinc metal
alloy includes at least 15% tin; zinc; and at least 0.05% antimony,
bismuth and/or copper. Still a further and/or
alternativeformulation of the corrosion resistant tin and zinc
metal alloy includes to 10-20% zinc; 0-2.5% antimony; 0-0.5%
bismuth; and the remainder tin. Still a further and/or
alternativeformulation of the corrosion resistant tin and zinc
metal alloy includes 80-90% tin; 9 to 10-20% zinc; 0.5-1.7%
bismuth; 0-2% copper; 0-0.1% iron; and 0-0.05% lead. Still yet a
further and/or alternativeformulation ofthe corrosion resistant tin
and zinc metal alloy includes 80-90% tin; 9 to 10-20% zinc;
0.5-7.5% antimony; 0-2% copper; 0-0.1% iron; and 0-0.05% lead.
Another and/or alternative formulation of the corrosion resistant
tin and zinc metal alloy includes 80-90% tin; 9 to 10-20% zinc;
0-0.5% antimony; 0-2% copper; 0-0.1% iron; and 0-0.05% lead. Still
another and/or alternative formulation of the corrosion resistant
tin and zinc metal alloy includes 80-90% tin; 9 to 10-20% zinc;
0-0.5% bismuth; 0-2% copper; 0-0.1% iron; and 0-0.05% lead. Yet
another and/or alternative formulation of the corrosion resistant
tin and zinc metal alloy includes 70-90% tin; 10-30% zinc; atleast
0.01% antimony. Still yet another and/or alternative formulation of
the corrosion resistant tin and zinc metal alloy includes 70-90%
tin; 9 to 10-30% zinc; 0.01-1.7% bismuth. Still another and/or
alternative formulation ofthe corrosion resistant tin and zinc
metal alloy includes 70-90% tin; 9 to 10-30% zinc; 0.1-2% iron. Yet
another and/or alternative formulation of the corrosion resistant
tin and zinc metal alloy includes 70-90% tin; 9 to 10-30% zinc;
0.1-2% copper. Still yet another and/or alternative formulation of
the corrosion resistant tin and zinc metal alloy includes a
majority of tin and zinc, 0-0.5% aluminum; 0-5.5% antimony; 0-2.7%
copper; and 0-0.15% titanium. A further and/or
alternativeformulation of the corrosion resistant tin and zinc
metal alloy includes a majority of tin and zinc, 0-0.3% aluminum;
0-1% antimony; and 0-1% copper. Yet a further and/or
alternativeformulation of the corrosion resistant tin and zinc
metal alloy includes 20-90% tin; 9 to 10-80% zinc; 0-1% aluminum;
0-5.5% antimony; 0-1.7% bismuth; 0-2.7% copper; 0-0.1% iron;
0-0.05% lead; 0-1% magnesium; 0-1% nickel; and 0-0.5% titanium.
Still a further and/or alternativeformulation of the corrosion
resistant tin and zinc metal alloy includes 20-80% tin; 20-80%
zinc; 0-5% aluminum; 0-5.5% antimony; 0-1.5% bismuth; 0-5% copper;
0-5% magnesium; 0-5% nickel; and 0-1% titanium. Still yet a further
and/or alternativeformulation of the corrosion resistant tin and
zinc metal alloy includes 20-80% tin; 20-80% zinc; 0-0.5% aluminum;
0-5.5% antimony; 0-1.7% bismuth; 0-2.7% copper; 0-0.4% magnesium;
0-1% nickel; and 0-0.15% titanium. Still a further and/or
alternativeformulation of the corrosion resistant tin and zinc
metal alloy includes 20-80% tin; 20-80% zinc; 0-0.3% aluminum; 0-1%
antimony; 0-1.7% bismuth; 0-1% copper; 0-0.4% magnesium; 0-0.7%
nickel; and 0-0.15% titanium. Another and/or alternative
formulation of the corrosion resistant tin and zinc metal alloy
includes a majority of tin and zinc, 0-0.5% aluminum; 0-2%
antimony; 0-2% copper; and 0-0.15% titanium. Still another and/or
alternative formulation of the corrosion resistant tin and zinc
metal alloy includes a majority of tin and zinc, 0-0.3% aluminum;
0-1% antimony; and 0-1% copper. Yet another and/or alternative
formulation of the corrosion resistant tin and zinc metal alloy
includes 20-90% tin; 9 to 10-80% zinc; 0-2% aluminum; 0-2% antimony
and/or bismuth; 0-2% copper; 0-1% iron; 0-0.5% lead; 0-0.4%
magnesium; 0-0.1% manganese; 0-1% nickel; and 0-0.15% titanium.
Still yet another and/or alternative formulation of the corrosion
resistant tin and zinc metal alloy includes 20-65% tin; 35-80%
zinc; 0-2% aluminum; 0-1% antimony and/or bismuth; 0-1% copper;
0-0.6% iron; 0-0.5% lead; 0-0.4% magnesium; 0-0.1% manganese;
0-0.7% nickel; and 0-0.15% titanium. Yet another and/or alternative
formulation of the corrosion resistant tin and zinc metal alloy
includes 20-50% tin; 50-80% zinc; 0-0.3% aluminum; 0.005-0.5%
antimony and/or bismuth; 0-0.2% copper; 0-0.6% iron; 0-0.4% lead;
0-0.4% magnesium; 0-0.05% manganese; 0-0.1% nickel; and 0-0.15%
titanium. A further and/or alternativeformulation of the corrosion
resistant tin and zinc metal alloy includes 15-90% tin; 9 to 10-85%
zinc; 0-2% aluminum; 0-2% antimony; 0-1.7% bismuth; 0-2% copper;
0-0.1% iron; 0-1% lead; 0-2% magnesium; 0-2% nickel; and 0-1%
titanium. Still a further and/or alternativeformulation of the
corrosion resistant tin and zinc metal alloy includes 30-85% tin;
15-70% zinc; 0-1% aluminum; 0-1% antimony; 0-0.01% arsenic; 0-1%
bismuth; 0-0.1% cadmium; 0-0.1% chromium; 0-1% copper; 0-0.1% iron;
0-0.1% lead; 0-0.01% manganese; 0-0.1% nickel; 0-0.01% silver; and
0-0.05% titanium. Still yet a further and/or alternativeformulation
ofthe corrosion resistant tin and zinc metal alloy includes 50-85%
tin; 15-50% zinc; 0-7.5% aluminum; 0-2% antimony; 0-0.05% arsenic;
0-0.1% boron; 0-1.7% bismuth; 0-0.5% cadmium; 0-1% carbon; 0-1%
chromium; 0-5% copper; 0-1% iron; 0-10% lead; 0-1% magnesium;
0-0.1% manganese; 0-0.1% molybdenum; 0-5% nickel; 0-0.5% silicon;
0-0.1% silver; 0-0.05% tellurium; 0-0.5% titanium; and 0-0.1%
vanadium. Yet a further and/or alternativeformulation of the
corrosion resistant tin and zinc metal alloy includes 15-50% tin;
50-85% zinc; 0-7.5% aluminum; 0-2% antimony; 0-0.05% arsenic;
0-0.1% boron; 0-1.7% bismuth; 0-0.5% cadmium; 0-1% carbon; 0-1%
chromium; 0-5% copper; 0-1% iron; 0-10% lead; 0-1% magnesium;
0-0.1% manganese; 0-0.1% molybdenum; 0-5% nickel; 0-0.5% silicon;
0-0.1% silver; 0-0.05% tellurium; 0-0.5% titanium; and 0-0.1%
vanadium. Still a further and/or alternativeformulation of the
corrosion resistant tin and zinc metal alloy includes 20-80% tin;
20-80% zinc; 0-5% aluminum; 0-7.5% antimony; 0-5% bismuth; 0-1%
cadmuim; 0-5% copper; 0-5% nickel; and 0-0.5% titanium. Still yet a
further and/or alternativeformulation of the corrosion resistant
tin and zinc metal alloy includes 15-90% tin; 9 to 10-85% zinc;
0-7.5% aluminum; 0-2% antimony; 0-0.05% arsenic; 0-0.1% boron;
0-1.7% bismuth; 0-0.5% cadmium; 0-1% carbon; 0-1% chromium; 0-5%
copper; 0-1% iron; 0-10% lead; 0-1% magnesium; 0-0.01% manganese;
0-0.1% molybdenum; 0-5% nickel; 0-0.5% silicon; 0-0.1% silver;
0-0.05% tellurium; 0-0.5% titanium; and 0-0.1% vanadium. Another
and/or alternative formulation of the corrosion resistant tin and
zinc metal alloy includes 30-70% tin; 30-70% zinc; 0-7.5% aluminum;
0-2% antimony; 0-1.7% bismuth; 0-0.5% cadmium; 0-5% copper; 0-10%
lead; and 0-5% nickel. Still another and/or alternative formulation
ofthe corrosion resistant tin and zinc metal alloy includes 40-60%
tin; 40-60% zinc; 0-2% aluminum; 0-2% antimony, bismuth, cadmium
and/or copper; 0-2% lead; and 0-1% nickel.
[0230] The following are several examples of tin or tin and zinc
metal alloy being applied by various processes to various types of
metal strip. The following examples also illustrate various ways
the coated metal strip can be formed in various types of products.
The following examples further and/or alternativeillustrate the
formation of the metal alloy into various types of materials. The
following examples only illustrate a few, not all, aspects of the
present invention.
EXAMPLE A
[0231] A metal strip is unwound from a roll of metal strip. The
metal strip has a thickness of less than about 762 microns. The
metal strip is continuously passed through an electrolytic tank to
plate nickel on the strip surface. The nickel plated layer has a
thickness of about 1-3 microns. The metal alloy includes at least
about 85% tin, at least about 9-10% zinc and less than about 0.5%
lead. The metal alloy in the melting pot is at a temperature of
about 301-455.degree. C. The metal strip is passed through the
melting pot having a length of about 16 feet at a speed of about
100 ft/min. The metal strip has a resident time in the melting pot
of less than about 10 seconds. The coated metal strip is passed
through coating rollers and/or an air-knife to achieve a coating
thickness of about 7-77 microns. The coated metal strip is rewound
into a roll of coated metal strip.
EXAMPLE B
[0232] A metal strip is unwound from a roll of metal strip. The
metal strip has a thickness of less than about 762 microns. The
metal strip is plated with chromium of a thickness of less than
about 3 microns. A metal alloy having a composition of at least
about 45% tin, at least about 45% zinc, less than about 1% of a
metal additive, and less than about 0.1% lead is coated onto the
metal strip. The metal alloy is heated in a melting pot at a
temperature of about 301-482.degree. C. The strip is passed through
the melting pot having a length of about 16 feet at a speed of
about 100 ft/min. The metal strip has a resident time in the
melting pot of less than about 10 seconds. The coated metal strip
is passed through coating rollers and/or an air-knife to achieve a
coating thickness of about 7-77 microns. The coated metal strip is
rewound into a roll of coated metal strip.
EXAMPLE C
[0233] A metal strip is unwound from a roll of metal strip. The
metal strip has a thickness of less than about 762 microns. The
metal strip is continuously plated with a tin layer of about 1-3
microns thick. A metal alloy having a composition of at least about
45% tin and at least about 45% zinc is coated onto the metal strip.
The metal alloy is heated in a melting pot at a temperature of
about 301-482.degree. C. The metal strip is passed through the
melting pot having a length of about 16 feet at a speed of about
100 ft./min. The metal strip has a resident time in the melting pot
of less than about 10 seconds. The coated metal strip is passed
through coating rollers and/or an air-knife to achieve a coating
thickness of about 7-77 microns. The coated metal strip is rewound
into a roll of coated metal strip.
EXAMPLE D
[0234] A metal strip is unwound from a roll of metal strip and
continuously plated with a tin layer of a thickness of less than
about 3 microns. The metal strip has a thickness of less than about
762 microns. A metal alloy having a composition of at least about
45% tin, at least about 45% zinc, and less than about 0.1% lead is
coated onto the metal strip. The metal alloy is heated in a melting
pot at a temperature of about 301-427.degree. C. The metal strip is
passed through the melting pot having a length of about 16 feet at
a speed of about 100 ft/min. The metal strip has a resident time in
the melting pot of less than about 10 seconds. The coated metal
strip is passed through coating rollers and/or an air-knife to
achieve a coating thickness of about 7-77 microns. The coated metal
strip is rewound into a roll of coated metal strip.
EXAMPLE E
[0235] A metal strip is unwound from a roll of metal strip. The
metal strip is continuously plated with a tin layer of about 1-3
microns thick. The metal strip has a thickness of less than about
762 microns. A metal alloy having a composition of at least about
20% tin, and at least about 75% zinc and is heated in a melting pot
at a temperature of about 301-427.degree. C. The metal strip is
passed through the melting pot having a length of about 16 feet at
a speed of about 100 ft/min. The metal strip has a resident time in
the melting pot of less than about 10 seconds. The coated metal
strip is passed through coating rollers and/or an air-knife to
achieve a coating thickness of about 7-77 microns. The coated metal
strip is rewound into a roll of coated metal strip.
EXAMPLE F
[0236] A metal strip is unwound from a roll of metal strip and is
pickled with a hydrochloric acid solution and a copper sulfate
solution. Copper is plated onto the metal strip surface during the
pickling process forming a copper layer of about 1-3 microns thick.
The metal strip has a thickness of less than about 762 microns. The
metal alloy includes at least about 70% tin, at least about 25%
zinc, and less than about 0.2% lead. The metal alloy in the melting
pot is heated to a temperature of about 301-482.degree. C. The
metal strip is passed through the melting pot having a length of
about 16 feet at a speed of about 100 ft/min. The metal strip has a
resident time in the melting pot of less than about 10 seconds. The
coated metal strip is passed through coating rollers and/or an
air-knife to achieve a coating thickness of about 7-77 microns. The
coated metal strip is rewound into a roll of coated metal
strip.
EXAMPLE G
[0237] A metal strip is unwound from a roll of metal strip and is
pickled with a hydrochloric acid solution and chemically activated
with a zinc chloride solution prior to coating the metal alloy. The
metal strip has a thickness of less than about 762 microns. The
metal strip is not pre-heated prior to coating. A tin metal alloy
having a composition of about 90-99% tin and less than about 2%
lead is coated onto the metal strip. The tin metal alloy in the
melting pot is heated to at least above 238-246.degree. C. The
metal strip is passed through the melting pot at a speed of about
100 ft/min. The metal strip has a resident time in the melting pot
of less than about 10 seconds. The coated metal strip is passed
through coating rollers and/or an air knife to achieve a coating
thickness of about 7-51 microns. The coated metal strip is then
cooled. The coated metal strip is then oxidized to remove the
coated tin metal alloy and to expose and passify the heat created
intermetallic layer. The metal strip is then wound into a roll of
the metal strip.
EXAMPLE H
[0238] A metal strip is unwound from a roll of metal strip and is
pickled with a hydrochloric acid solution and chemically activated
with a zinc chloride solution prior to coating. The metal strip has
a thickness of less than about 762 microns. The metal strip is
plated with nickel having a thickness of less than about 3 microns.
The metal strip is preheated prior to coating. A tin metal alloy
having a composition of above 90-99% tin and less than about 2%
lead is coated onto the metal strip. The metal alloy is heated in a
melting pot to a temperature of about 238-482.degree. C. The metal
strip is passed through the melting pot at a speed of about 100
ft/min. The metal strip has a resident time in the melting pot of
less than about 10 seconds. The coated metal strip is passed
through coating rollers and/or an air-knife to achieve a coating
thickness of about 7-51 microns. The coated metal strip is cooled
and then oxidized to remove the tin metal alloy to expose and
passify the heat created intermetallic layer. The metal strip is
then wound into a roll of metal strip.
EXAMPLE I
[0239] A metal strip is unwound from a roll of metal strip. The
metal strip has a thickness of less than about 762 microns. The
metal strip is not pre-heated prior to coating with a metal alloy.
A tin metal alloy having a composition of about 90-99% tin, and
less than about 0-5% lead is coated onto the metal strip. The tin
metal alloy is applied to the metal strip by an electroplating
process. The plated metal strip is then flow heated for less than
about 5 minutes. The coated metal strip is then passed through
coating rollers and/or an air-knife to achieve a coating thickness
of about 7-51 microns. The coated metal strip is then cooled. The
coated metal strip is then oxidized to remove the tin metal alloy
and to expose and passify the heat created intermetallic layer. The
metal strip is then wound into a roll of metal strip.
EXAMPLE J
[0240] A metal strip is unwound from a roll of metal strip and
plated with a zinc layer having a thickness of less than about 3
microns. The metal strip has a thickness of less than about 762
microns. The metal strip is pre-heated prior to coating with a
metal alloy. A tin metal alloy having a composition of about 90-99%
tin and less than about 0-1% lead is coated onto the metal strip.
The metal strip is passed through a metal spaying process at a
speed of up to about 100 ft/min to coat the metal strip. The coated
metal strip is then passed through coating rollers and/or an
air-knife to achieve a coating thickness of about 7-51 microns. The
coated metal strip is cooled and then oxidized to remove the tin
metal alloy and to expose and passify the heat created
intermetallic layer. The metal strip is then cut into metal
sheets.
EXAMPLE K
[0241] A metal strip is unwound from a roll of metal strip and is
pickled with an acid solution and then chemically activated with a
chemical activation solution. The metal strip is then plated with a
metal layer of about 1-3 microns thick. The metal strip is not
pre-heated prior to coating with a metal alloy. A tin metal alloy
having a composition of about 90-99% tin is coated onto the metal
strip. The tin metal alloy is plated onto the metal strip and then
flow heated. The metal strip is then coated again by a spray metal
process. The coated metal strip is then passed through coating
rollers and/or an air-knife to achieve a coating thickness of about
7-51 microns. The coated metal strip is then cooled and wound into
a roll of coated metal strip. The roll of coated metal strip is
formed into roofing materials and installed on a building. The
formed coated metal strip is then exposed to an oxidizing solution
on site to remove the tin metal alloy and expose and passify the
heat created intermetallic layer.
EXAMPLE L
[0242] A carbon steel strip is unwound from a roll of carbon steel
strip. The carbon steel strip has a thickness of less than about
762 microns. The carbon steel strip is continuously passed through
an electrolytic tank to plate nickel on the carbon steel strip
surface. The nickel plated layer has a thickness of about 1-3
microns. A metal alloy having a composition of at least about 95%
tin and zinc, and less than about 0.5% lead is coated onto the
carbon steel strip. The metal alloy in the melting pot is at a
temperature of about 301-455.degree. C. The carbon steel strip is
passed through the melting pot having a length of about 16 feet at
a speed of about 100 ft/min. The carbon steel strip has a resident
time in the melting pot of less than about 10 seconds. The coated
carbon steel strip is passed through coating rollers and/or an
air-knife to achieve a coating thickness of about 7-77 microns. The
coated carbon steel strip is rewound into a roll of coated carbon
steel strip.
EXAMPLE M
[0243] A carbon steel strip is unwound from a roll of carbon steel
strip. The carbon steel strip has a thickness of less than about
762 microns. The carbon steel strip is plated with chromium of a
thickness of less than about 3 microns. A metal alloy having a
composition of at least about 98% tin and zinc, less than about 1%
of a metal additive, less than about 0.1% lead is coated onto the
carbon steel strip. The metal alloy is heated in a melting pot at a
temperature of about 301-482.degree. C. The carbon steel strip is
passed through the melting pot having a length of about 16 feet at
a speed of about 100 ft/min. The carbon steel strip has a resident
time in the melting pot of less than about 10 seconds. The coated
carbon steel strip is passed through coating rollers and/or an
air-knife to achieve a coating thickness of about 7-77 microns. The
coated carbon steel strip is rewound into a roll of coated carbon
steel strip.
EXAMPLE N
[0244] A copper strip is unwound from a roll of copper strip. The
copper strip has a thickness of less than about 762 microns. The
copper strip is continuously plated with a tin layer of about 1-3
microns thick. A metal alloy having a composition of at least about
99% tin and zinc is coated onto the copper strip. The metal alloy
is heated in a melting pot at a temperature of about
301-482.degree. C. The coated strip is passed through the melting
pot having a length of about 16 feet at a speed of about 100
ft./min. The copper strip has a resident time in the melting pot of
less than about 10 seconds. The coated copper strip is passed
through coating rollers and/or an air-knife to achieve a coating
thickness of about 7-77 microns. The coated copper strip is rewound
into a roll of coated copper strip.
EXAMPLE O
[0245] A carbon steel strip is unwound from a roll of carbon steel
strip and continuously plated with a tin layer of a thickness of
less than about 3 microns. The carbon steel strip has a thickness
of less than about 762 microns. A metal alloy having a composition
of at least about 98% tin and zinc, and less than about 0.1% lead
is coated onto the carbon steel strip. The metal alloy is heated in
a melting pot at a temperature of about 301-427.degree. C. The
carbon steel strip is passed through the melting pot having a
length of about 16 feet at a speed of about 100 ft/min. The carbon
steel strip has a resident time in the melting pot of less than
about 10 seconds. The coated carbon steel strip is passed through
coating rollers and/or an air-knife to achieve a coating thickness
of about 7-77 microns. The coated carbon steel strip is rewound
into a roll of coated carbon steel strip.
EXAMPLE P
[0246] A stainless steel strip is unwound from a roll of stainless
steel strip. The stainless steel strip is continuously plated with
a tin layer of about 1-3 microns thick. The stainless steel strip
has a thickness of less than about 762 microns. A metal alloy
having a composition of at least about 98-99% tin and zinc is
heated in a melting pot at a temperature of about 301-427.degree.
C. The stainless steel strip is passed through the melting pot
having a length of about 16 feet at a speed of about 100 ft/min.
The stainless steel strip has a resident time in the melting pot of
less than about 10 seconds. The coated stainless steel strip is
passed through coating rollers and/or an air-knife to achieve a
coating thickness of about 7-77 microns. The coated stainless steel
strip is rewound into a roll of coated stainless steel strip.
EXAMPLE Q
[0247] A carbon steel strip is unwound from a roll of carbon steel
strip and is pickled with a hydrochloric acid solution and a copper
sulfate solution. Copper is plated onto the carbon steel strip
surface during the pickling process to form a copper layer of about
1-3 microns thick. The carbon steel strip has a thickness of less
than about 762 microns. A metal alloy having a composition of at
least about 95-99% tin and zinc, and less than about 0.2% lead is
coated onto the carbon steel strip. The metal in a melting pot is
heated to a temperature of about 301-482.degree. C. The carbon
steel strip is passed through the melting pot having a length of
about 16 feet at a speed of about 100 ft/min. The carbon steel
strip has a resident time in the melting pot of less than about 10
seconds. The coated carbon steel strip is passed through coating
rollers and/or an air-knife to achieve a coating thickness of about
7-77 microns. The coated carbon steel strip is rewound into a roll
of coated carbon steel strip.
EXAMPLE R
[0248] A carbon steel strip is unwound from a roll of carbon steel
strip and is pickled with a hydrochloric acid solution and
chemically activated with a zinc chloride solution prior to
coating. The carbon steel strip has a thickness of less than about
762 microns. The carbon steel strip is not pre-heated prior to
coating. A metal alloy having a composition of about 90-95% tin,
and less than about 0.5% lead is coated onto the carbon steel
strip. The metal alloy in the melting pot is heated to a
temperature of about 238-246.degree. C. The melting pot is heated
by four external gas torches directed to the outer sides of the
melting pot. The carbon steel strip is passed through the melting
pot having a length of about 16 feet at a speed of about 100
ft/min. The carbon steel strip has a resident time in the melting
pot of less than about 10 seconds. The coated carbon steel is
passed through coating rollers and/or an air-knife to achieve a
coating thickness of about 7-51 microns. The coated carbon steel
strip is then cooled and rewound into a roll of coated carbon steel
strip.
EXAMPLE S
[0249] A carbon steel strip is unwound from a roll of carbon steel
strip and is pickled with a hydrochloric acid solution and
chemically activated with a zinc chloride solution prior to
coating. The carbon steel strip has a thickness of less than about
762 microns. The carbon steel strip is plated with chromium of a
thickness of less than about 3 microns. The carbon steel strip is
not pre-heated prior to coating. A metal alloy having a composition
of about 90-99% tin, about 0.01-1% metallic stabilizer selected
from antimony, bismuth and/or copper, and less than about 0.5% lead
is coated onto the carbon steel strip. The metal alloy is heated in
a melting pot at a temperature of about 238-482.degree. C. The
melting pot is heated by four external gas torches directed to the
outer sides of the melting pot. The carbon steel strip is passed
through the melting pot having a length of about 16 feet at a speed
of about 100 ft/min. The carbon steel strip has a resident time in
the melting pot of less than about 10 seconds. The coated carbon
steel strip is passed through coating rollers and/or an air-knife
to achieve a coating thickness of about 7-51 microns. The coated
carbon steel strip is then cooled and rewound into a roll of coated
carbon steel strip.
EXAMPLE T
[0250] A copper strip is unwound from a roll of copper strip and is
pickled with a hydrochloric acid solution and chemically activated
with a zinc chloride solution prior to coating. The copper strip
has a thickness of less than about 762 microns. The copper strip is
not pre-heated prior to coating. A metal alloy having a composition
of about 90-99% tin, 0-1% metallic stabilizer, and less than about
0.1% lead is coated onto the copper strip. The metal alloy is
heated in a melting pot at a temperature of about 238-246.degree.
C. The melting pot is heated by four external gas torches directed
to the outer sides of the melting pot. The copper strip is passed
through the melting pot having a length of about 16 feet at a speed
of about 100 ft./min. The copper strip has a resident time in the
melting pot of less than about 10 seconds. The coated copper strip
is passed through coating rollers and/or an air-knife to achieve a
coating thickness of about 7-51 microns. The coated copper strip is
then cooled and rewound into a roll of coated copper strip.
EXAMPLE U
[0251] A carbon steel strip is unwound from a roll of carbon steel
strip and plated with a nickel layer of a thickness of less than
about 3 microns. The carbon steel strip has a thickness of less
than about 762 microns. The carbon steel strip is not pre-heated
prior to coating. A metal alloy having a composition of about
90-99% tin, and less than about 0.1% lead is coated onto the carbon
steel strip. The metal alloy is heated in a melting pot at a
temperature of about 238-255.degree. C. The melting pot is heated
by four external gas torches directed to the outer sides of the
melting pot. The carbon steel strip is passed through the coating
tank having a length of about 16 feet at a speed of about 100
ft/min. The carbon steel strip has a resident time in the melting
pot of less than about 10 seconds. The coated carbon steel strip is
passed through coating rollers and/or an air-knife to achieve a
coating thickness of 7-51 microns. The coated carbon steel strip is
then cooled and rewound into a roll of coated carbon steel
strip.
EXAMPLE V
[0252] A stainless steel strip is unwound from a roll of stainless
steel strip and is aggressively pickled with a dual acid solution
of hydrochloric acid and nitric acid and chemically activated with
a zinc chloride solution. The stainless steel strip is plated with
a nickel layer of about 1-3 microns thick. The stainless steel
strip has a thickness of less than about 762 microns. The stainless
steel strip is not pre-heated prior to coating. A metal alloy
having a composition of about 90-99% tin and is heated in a melting
pot at a temperature of about 238-260.degree. C. The melting pot is
heated by four external gas torches directed to the outer sides of
the melting pot. The stainless steel strip is passed through the
melting pot having a length of about 16 feet at a speed of about
100 ft/min. The stainless steel strip has a resident time in the
melting pot of less than about 10 seconds. The coated stainless
steel strip is passed through coating rollers and/or an air-knife
to achieve a coating thickness of about 7-51 microns. The coated
stainless steel strip is then cooled and rewound into a roll of
coated stainless steel strip.
EXAMPLE W
[0253] A carbon steel strip is unwound from a roll of carbon steel
strip and is pickled with a hydrochloric acid solution and a copper
sulfate solution and chemically activated with a zinc chloride
solution prior to coating. Copper is plated onto the carbon steel
strip surface during the pickling process to form a copper layer of
about 1-3 microns thick. The carbon steel strip has a thickness of
less than about 762 microns. The carbon steel strip is not
pre-heated prior to coating. A metal alloy having a composition of
about 90-95% tin and less than about 0.5% lead is coated onto the
carbon steel strip. The metal alloy is heated in a melting pot at a
temperature of about 238-250.degree. C. The melting pot is heated
by four external gas torches directed to the outer sides of the
melting pot. The carbon steel strip is passed through the melting
pot having a length of about 16 feet at a speed of about 100
ft/min. The carbon steel strip has a resident time in the melting
pot of less than about 10 seconds. The coated carbon steel strip is
passed through coating rollers and/or an air-knife to achieve a
coating thickness of about 7-51 microns. The coated carbon steel
strip is then cooled and rewound into a roll of coated carbon steel
strip.
EXAMPLE X
[0254] A carbon steel strip is unwound from a roll of carbon steel
strip and is pickled with a hydrochloric acid solution and
chemically activated with a zinc chloride solution prior to
coating. The carbon steel strip has a thickness of more than about
762 microns. The carbon steel strip is pre-heated prior to coating.
A metal alloy having a composition of about 90-99% tin and less
than about 0.1% lead is coated onto the carbon steel strip. The
metal alloy is heated in a melting pot at a temperature of about
237-246.degree. C. The melting pot is heated by four external gas
torches directed to the outer sides of the melting pot. The carbon
steel strip is passed through the melting pot having a length of
about 16 feet at a speed of about 100 ft/min. The carbon steel
strip has a resident time in the melting pot of less than about 10
seconds. The coated carbon steel strip is passed through coating
rollers and/or an air-knife to achieve a coating thickness of about
7-51 microns. The coated carbon steel strip is then cooled and
rewound into a roll of coated carbon steel strip.
EXAMPLE Y
[0255] A thin strip of carbon steel uncoiled from a roll of carbon
steel is passed through an electroplating bath to deposit an ultra
thin layer of tin on the carbon steel strip. The carbon steel strip
had a thickness of less than about 762 microns. The carbon steel
strip is then coated with a two-phase zinc-tin coating to produce
an intermetallic layer between the metal alloy and the carbon steel
strip. The tin-zinc metal alloy has a coating of tin and zinc
content at least about 75 weight percent.
EXAMPLE Z
[0256] The process of Example Y was performed with the addition of
a heating furnace to flow heat the thin tin plating and, thus, form
a heat created intermetallic layer including iron and tin prior to
the metal alloy coating process.
EXAMPLE AA
[0257] The process of Example Y was performed with copper being
plated on the carbon steel strip by an electrolytic bath.
EXAMPLE BB
[0258] A copper strip is unwound from a roll of copper strip. The
copper strip has a thickness of less than about 762 microns. The
copper strip is pickled with an acid to clean the surface of the
copper strip. The copper strip is continuously passed through an
electrolytic tank to plate nickel on the copper strip surface. The
nickel plated layer has a thickness of about 1-3 microns. The
copper strip is no preheated. A metal alloy having a composition of
at least about 95% tin and zinc, and less than about 0.5% lead is
coated onto the copper strip. The metal alloy is in a melting pot
at a temperature of about 301-454.degree. C. The copper strip is
passed through the melting pot having a length of about 16 feet at
a speed of about 100 ft/min. The copper strip has a resident time
in the melting pot of less than about 10 seconds. The coated copper
strip is passed through coating rollers and/or an air-knife to
achieve a coating thickness of about 7-77 microns. The coated
copper strip is rewound into a roll of coated copper strip.
EXAMPLE CC
[0259] A brass strip is unwound from a roll of brass strip. The
brass strip has a thickness of less than about 762 microns. The
brass strip is pickled to remove surface oxides. The brass strip is
plated with chromium having a thickness of less than about 3
microns. The brass strip is not preheated. A metal alloy having a
composition of at least about 98% tin and zinc, less than about 1%
of a metal additive, and less than about 0.1% lead is coated onto
the brass strip. The metal alloy is heated in a melting pot at a
temperature of about 301-482.degree. C. The brass strip is passed
through the melting pot having a length of about 16 feet at a speed
of about 100 ft/min. The brass strip has a resident time in the
melting pot of less than about 10 seconds. The coated brass strip
is passed through coating rollers and/or an air-knife to achieve a
coating thickness of about 7-77 microns. The coated brass strip is
rewound into a roll of coated brass strip.
EXAMPLE DD
[0260] A bronze strip is unwound from a roll of bronze strip. The
bronze strip has a thickness of less than about 762 microns. The
copper strip is continuously plated with a tin layer of about 1-3
microns thick. A metal alloy having a composition of at least about
99% tin and zinc is coated onto the bronze strip. The metal alloy
is heated in a melting pot at a temperature of about
301-482.degree. C. The bronze strip is passed through the melting
pot having a length of about 16 feet at a speed of about 100
ft./min. The bronze strip has a resident time in the melting pot of
less than about 10 seconds. The coated bronze strip is passed
through coating rollers and/or an air-knife to achieve a coating
thickness of about 7-77 microns. The coated bronze strip is rewound
into a roll of coated bronze strip.
EXAMPLE EE
[0261] A carbon steel strip is unwound from a roll of carbon steel
strip and continuously plated with a tin layer of a thickness of
less than about 3 microns. The carbon steel strip has a thickness
of less than 762 microns. A metal alloy having a composition of at
least about 98% tin and zinc, and less than about 0.1% lead is
coated onto the carbon steel strip. The metal alloy is plated and
subsequently flow heated onto the surface of the carbon steel
strip. The coated carbon steel strip is passed through an air-knife
to achieve a coating thickness of about 7-77 microns. The coated
carbon steel strip is oxidized to expose the heat created
intermetallic layer. The oxidized carbon steel strip is rewound
into a roll of oxidized carbon steel strip.
EXAMPLE FF
[0262] A stainless steel strip is unwound from a roll of stainless
steel strip. The stainless steel strip is aggressively pickled and
chemically activated to clean the stainless steel strip surface.
The stainless steel strip is continuously plated with a tin layer
of about 1-3 microns thick. The stainless steel strip has a
thickness of less than about 762 microns. The stainless steel strip
is preheated. A metal alloy having a composition of at least about
98-99% tin and zinc is heated in a melting pot at a temperature of
about 301-427.degree. C. The stainless steel strip is passed
through the melting pot having a length of about 16 feet at a speed
of about 100 ft/min. The stainless steel strip has a resident time
in the melting pot of less than about 10 seconds. The coated
stainless steel strip is passed through coating rollers and/or an
air-knife to achieve a coating thickness of about 7-77 microns. The
coated stainless steel strip is oxidized to expose the heat created
intermetallic layer. The oxidized stainless steel strip is rewound
into a roll of oxidized stainless steel strip.
EXAMPLE GG
[0263] A carbon steel strip is unwound from a roll of carbon steel
strip and is pickled with a hydrochloric acid solution and a copper
sulfate solution. Copper is plated onto the carbon steel strip
surface during pickling to form a copper layer of about 1-3 microns
thick. The carbon steel strip has a thickness of less than about
762 microns. A metal alloy having a composition of at least about
95-99% tin and zinc, and less than about 0.2% lead is coated onto
the carbon steel strip. The metal alloy is plated and subsequently
flow heated onto the carbon steel strip. The coated carbon steel
strip is passed through coating rollers and/or an air-knife to
achieve a coating thickness of about 7-77 microns. The coated
carbon steel strip is rewound into a roll of coated carbon steel
strip.
EXAMPLE HH
[0264] A brass strip is unwound from a roll of brass strip. The
brass strip has a thickness of less than about 762 microns. The
brass is continuously passed through an electrolytic tank to plate
nickel on the brass strip surface. The nickel plated layer has a
thickness of about 1-3 microns. A metal alloy having a composition
of 95-98% tin and zinc, and less than about 0.5% lead is coated
onto the brass strip. The metal alloy in a melting pot is heated to
a temperature of about 301-455.degree. C. The carbon steel strip is
passed through the melting pot having a length of about 16 feet at
a speed of about 100 ft/min. The brass strip has a resident time in
the melting pot of less than about 10 seconds. The coated brass
strip is passed through coating rollers and/or an air-knife to
achieve a coating thickness of about 7-77 microns. The coated brass
strip is rewound into a roll of coated brass strip.
EXAMPLE II
[0265] A tin strip is unwound from a roll of tin strip. The tin
strip has a thickness of less than about 762 microns. The tin strip
is plated with chromium of a thickness of less than about 3
microns. A metal alloy having a composition of about 95-98% tin and
zinc, less than about 2% of a metal additive, and less than about
0.5% lead is coated onto the tin strip. The metal alloy is heated
in a melting pot at a temperature of about 301-482.degree. C. The
tin strip is passed through the melting pot having a length of
about 16 feet at a speed of about 100 ft/min. The tin strip has a
resident time in the melting pot of less than about 10 seconds. The
coated tin strip is passed through coating rollers and/or an
air-knife to achieve a coating thickness of about 7-77 microns. The
coated tin strip is rewound into a roll of coated tin strip.
EXAMPLE JJ
[0266] A copper strip is unwound from a roll of copper strip. The
copper strip has a thickness of less than about 762 microns. The
copper strip is continuously plated with a tin layer of about 1-3
microns thick. A metal alloy having a composition of about 90-99%
tin and 0-5% lead is coated onto the copper strip. The metal alloy
is heated in a melting pot at a temperature of about
301-482.degree. C. The copper strip is passed through the melting
pot having a length of about 16 feet at a speed of about 100
ft./min. The copper strip has a resident time in the melting pot of
less than about 10 seconds. The coated copper strip is passed
through coating rollers and/or an air-knife to achieve a coating
thickness of about 7-77 microns. The coated copper strip is rewound
into a roll of coated copper strip.
EXAMPLE KK
[0267] A carbon steel strip is unwound from a roll of carbon steel
strip and continuously plated with a tin layer of a thickness of
less than about 3 microns. The carbon steel strip has a thickness
of less than about 762 microns. A metal alloy having a composition
of about 90-99% tin and zinc, and less than about 0.5% lead is
coated onto the carbon steel strip. The metal alloy is heated in a
melting pot at a temperature of about 301-482.degree. C. The carbon
steel strip is passed through the melting pot having a length of
about 16 feet at a speed of about 100 ft/min. The carbon steel has
a resident time in the melting pot of less than about 10 seconds.
The coated carbon steel strip is passed through coating rollers
and/or an air-knife to achieve a coating thickness of about 7-77
microns. The coated carbon steel strip is rewound into a roll of
coated carbon steel strip.
EXAMPLE LL
[0268] A stainless steel strip is unwound from a roll of stainless
steel strip. The stainless steel strip is continuously plated with
a tin layer of about 1-3 microns thick. The stainless steel strip
has a thickness of less than about 762 microns. A metal alloy
having a composition of about 90-99% tin and zinc is heated in a
melting pot at a temperature of about 301-482.degree. C. The
stainless steel strip is passed through the melting pot having a
length of about 16 feet at a speed of about 100 ft/min. The
stainless steel strip has a resident time in the melting pot of
less than about 10 seconds. The coated stainless steel strip is
passed through coating rollers and/or an air-knife to achieve a
coating thickness of about 7-77 microns. The coated stainless steel
strip is rewound into a roll of coated stainless steel strip.
EXAMPLE MM
[0269] A brass strip is unwound from a roll of brass strip and is
pickled with a hydrochloric acid solution and a copper sulfate
solution. Copper is plated onto the carbon steel strip surface
during pickling to form a copper layer of about 1-3 microns thick.
The brass strip has a thickness of less than about 762 microns. A
metal alloy having a composition of about 90-95% tin, and less than
about 0.5% lead is heated in a melting pot at a temperature of
about 301-482.degree. C. The brass strip is passed through the
melting pot having a length of about 16 feet at a speed of about
100 ft/min. The brass strip has a resident time in the melting pot
of less than about 10 seconds. The coated brass strip is passed
through coating rollers and/or an air-knife to achieve a coating
thickness of about 7-77 microns. The coated brass strip is rewound
into a roll of coated brass strip.
EXAMPLE NN
[0270] A copper strip is unwound from a roll of copper strip and is
pickled with a hydrochloric acid solution and chemically activated
with a zinc chloride solution prior to coating. The copper strip
has a thickness of less than about 762 microns. The copper strip is
not pre-heated prior to coating. A tin alloy having a composition
of about 90-99% tin, and less than about 2% lead is heated in a
melting pot at atemperature of about 237-246.degree. C. The copper
strip is passed through the melting pot at a speed of about 100
ft/min. The copper strip has a resident time in the coating tank of
less than about 10 seconds. The coated copper strip is passed
through coating rollers and/or an air knife to achieve a coating
thickness of about 7-51 microns. The coated copper strip is then
cooled. The coated copper strip is then oxidized to remove the
coated tin alloy and to expose and pacify the heat created
intermetallic layer. The copper strip is then wound into a roll of
copper strip.
EXAMPLE OO
[0271] A copper strip is unwound from a roll of copper strip and is
pickled with a hydrochloric acid solution and chemically activated
with a zinc chloride solution prior to coating. The copper strip
has a thickness of less than about 762 microns. The copper strip is
plated with nickel having a thickness of less than about 3 microns.
The copper strip is preheated prior to coating. A tin alloy having
a composition of about 90-99% tin, and less than about 2% lead is
heated in a melting pot at a temperature of about 237-482.degree.
C. The copper strip is passed through the melting pot at a speed of
about 100 ft/min. The copper strip has a resident time in the
melting pot of less than about 10 seconds. The coated copper strip
is passed through coating rollers and/or an air-knife to achieve a
coating thickness of 7-51 microns. The coated copper strip is
cooled and then oxidized to remove the tin alloy and to expose and
pacify the heat created intermetallic layer. The copper strip is
then wound into a roll of copper strip.
EXAMPLE PP
[0272] A copper strip is unwound from a roll of copper strip. The
copper strip has a thickness of less than about 762 microns. The
strip is not pre-heated prior to coating. A tin alloy having a
composition of about 99% tin, and less than about 0-5% lead is
applied to the copper strip by an electroplating process. The
plated copper strip is then flow heated for less than about 5
minutes. The coated copper strip is passed through coating rollers
and/or an air-knife to achieve a coating thickness of about 7-51
microns. The coated copper strip is then cooled. The coated copper
strip is then oxidized to remove the tin alloy and to expose and
pacify the heat created intermetallic layer. The copper strip is
then wound into a roll of copper strip.
EXAMPLE QQ
[0273] A copper steel strip is unwound from a roll of copper strip
and plated with a chromium layer having a thickness of less than
about 3 microns. The copper strip has a thickness of less than
about 762 microns. The copper strip is pre-heated prior to coating.
A tin alloy having a composition of about 90-99% tin, and less than
about 0-1% lead is coated onto the copper strip. The copper strip
is passed through a metal spaying process at a speed of up to about
100 ft/min. The coated copper strip is then passed through coating
rollers and/or an air-knife to achieve a coating thickness of about
7-51 microns. The coated copper strip is cooled and then oxidized
to remove the tin alloy to expose and pacify the heat created
intermetallic layer. The copper strip is then cut into sheets.
EXAMPLE RR
[0274] A copper strip is unwound from a roll of copper strip and is
pickled with an acid solution and then chemically activated with a
chemical activation solution. The copper strip is plated with a
metal layer of about 1-3 microns thick. The copper strip is not
pre-heated prior to coating. A tin alloy having a composition of
about 90-99% tin is metal sprayed onto the copper strip. The coated
copper strip is then passed through coating rollers and/or an
air-knife to achieve a coating thickness of about 7-51 microns. The
coated copper strip is then cooled and wound into a roll of copper
strip. The roll of coated copper strip is later formed into roofing
materials and installed on a building. The formed coated copper
strip is then exposed on site to an oxidizing solution to remove
the tin alloy and expose and pacify the intermetallic layer.
EXAMPLE SS
[0275] A tin strip is unwound from a roll of tin strip. The tin
strip has a thickness of less than about 762 microns. The tin strip
is continuously passed through an electrolytic tank to plate nickel
on the tin strip surface. The nickel plated layer has a thickness
of about 1-3 microns. A metal alloy having a composition of at
least about 85% tin, at least about 9 to 10% zinc, and less than
about 0.5% lead is heated in a melting pot at a temperature of
about 301-455.degree. C. The tin strip is passed through the
melting pot having a length of about 16 feet at a speed of about
100 ft/min. The tin strip has a resident time in the melting pot of
less than about 10 seconds. The coated tin strip is passed through
coating rollers and/or an air-knife to achieve a coating thickness
of about 7-77 microns. The coated tin strip is rewound into a roll
of coated tin strip.
EXAMPLE TT
[0276] A bronze strip is unwound from a roll of bronze strip. The
bronze strip has a thickness of less than about 762 microns. The
bronze strip is plated with chromium of a thickness of less than
about 3 microns. A metal alloy having a composition of at least
about 45% tin, at least about 45% zinc, less than about 1% of a
metal additive, and less than about 0.1% lead is heated in a
melting pot at a temperature of about 301-482.degree. C. The bronze
strip is passed through the melting pot having a length of about 16
feet at a speed of about 100 ft/min. The bronze strip has a
resident time in the melting pot of less than about 10 seconds. The
coated bronze strip is passed through coating rollers and/or an
air-knife to achieve a coating thickness of about 7-77 microns. The
coated bronze strip is rewound into a roll of coated bronze
strip.
EXAMPLE UU
[0277] A aluminum strip is unwound from a roll of aluminum strip.
The aluminum strip has a thickness of less than about 762 microns.
The aluminum strip is continuously plated with a tin layer of about
1-3 microns thick. A metal alloy having a composition of at least
about 45% tin and at least about 45% zinc is heated in a melting
pot at a temperature of about 301-482.degree. C. The aluminum strip
is passed through the melting pot having a length of about 16 feet
at a speed of about 100 ft./min. The aluminum strip has a resident
time in the melting pot of less than about 10 seconds. The coated
aluminum strip is passed through coating rollers and/or an
air-knife to achieve a coating thickness of about 7-77 microns. The
coated aluminum strip is rewound into a roll of coated aluminum
strip.
EXAMPLE VV
[0278] A tin strip is unwound from a roll of tin strip and
continuously plated with a tin layer of a thickness of less than
about 3 microns. The tin strip has a thickness of less than about
762 microns. A metal alloy having a composition of at least about
45% tin, at least about 45% zinc, and less than about 0.1% lead is
heated in a melting pot at a temperature of about 301-427.degree.
C. The tin strip is passed through the melting pot having a length
of about 16 feet at a speed of about 100 ft/min. The tin has a
resident time in the melting pot of less than about 10 seconds. The
coated tin strip is passed through coating rollers and/or an
air-knife to achieve a coating thickness of about 7-77 microns. The
coated tin strip is rewound into a roll of coated tin strip.
EXAMPLE WW
[0279] A brass strip is unwound from a roll of brass strip. The
brass strip is continuously plated with a tin layer of about 1-3
microns thick. The brass strip has a thickness of less than about
762 microns. A metal alloy having a composition of at least about
20% tin, and at least about 75% zinc is heated in a melting pot at
a temperature of about 301-427.degree. C. The brass strip is passed
through the melting pot having a length of about 16 feet at a speed
of about 100 ft/min. The brass strip has a resident time in the
melting pot of less than about 10 seconds. The coated brass strip
is passed through coating rollers and/or an air-knife to achieve a
coating thickness of about 7-77 microns. The coated brass strip is
rewound into a roll of coated brass strip.
EXAMPLE XX
[0280] A brass strip is unwound from a roll of brass strip and is
pickled with a hydrochloric acid solution and a copper sulfate
solution. Copper is plated onto the brass strip surface during
pickling to form a copper layer of about 1-3 microns thick. The
brass strip has a thickness of less than about 762 microns. A metal
alloy having a composition of at least about 70% tin, at least
about 25% zinc, and less than about 0.2% lead is heated in a
melting pot at a temperature of about 301-482.degree. C. The brass
strip is coated by metal strap jets. The coated brass strip is
passed through coating rollers and/or an air-knife to achieve a
coating thickness of about 7-77 microns. The coated brass strip is
rewound into a roll of coated brass strip.
EXAMPLE YY
[0281] A brass strip is unwound from a roll of brass strip and is
pickled with a hydrochloric acid solution and chemically activated
with a zinc chloride solution prior to coating. The brass strip has
a thickness of less than about 762 microns. The brass strip is not
pre-heated prior to coating. A tin alloy having a composition of
about 90-99% tin, and less than about 2% lead is heated in a
melting pot at a temperature of about 237-246.degree. C. The brass
strip is passed through the melting pot at a speed of about 100
ft/min. The brass strip has a resident time in the melting pot of
less than about 10 seconds. The coated brass strip is passed
through coating rollers and/or an air knife to achieve a coating
thickness of about 7-51 microns. The coated brass strip is then
cooled. The coated brass strip is then oxidized to remove the
coated tin alloy to expose and pacify the heat created
intermetallic layer. The brass strip is then wound into a roll of
brass strip.
EXAMPLE ZZ
[0282] A brass strip is unwound from a roll of brass strip and is
pickled with a hydrochloric acid solution and chemically activated
with a zinc chloride solution prior to coating. The brass strip has
a thickness of less than about 762 microns. The brass strip is
plated with nickel having a thickness of less than about 3 microns.
The brass strip is preheated prior to coating. A tin alloy having a
composition of about 90-99% tin, and less than about 2% lead is
heated in a melting pot at a temperature of about 237-482.degree.
C. The brass strip is passed through the melting pot at a speed of
about 100 ft/min. The brass strip has a resident time in the
melting pot of less than about 10 seconds. The coated brass strip
is passed through coating rollers and/or an air-knife to achieve a
coating thickness of about 7-51 microns. The coated brass strip is
cooled and then oxidized to remove the tin alloy to expose and
pacify the heat created interrnetallic layer. The brass strip is
then wound into a roll of brass strip.
EXAMPLE AAA
[0283] A brass strip is unwound from a roll of brass strip. The
brass strip has a thickness of less than about 762 microns. The
brass strip is pickled to clean the brass strip surface. The brass
strip is not pre-heated prior to coating. A tin alloy having a
composition of about 99% tin, and less than about 0-5% lead is
applied to the brass strip by an electroplating process. The plated
brass strip is then flow heated for less than about 5 minutes. The
coated brass strip is passed through coating rollers and/or an
air-knife to achieve a coating thickness of about 7-51 microns. The
coated brass strip is then cooled. The coated brass strip is then
oxidized to remove the tin alloy and to expose and pacify the heat
created intermetallic layer. The brass strip is then wound into a
roll of brass strip.
EXAMPLE BBB
[0284] A brass strip is unwound from a roll of brass strip and
plated with a zinc layer having a thickness of less than about 3
microns. The brass strip has a thickness of less than about 762
microns. The brass strip is pre-heated prior to coating. A tin
alloy having a composition of about 90-99% tin, and less than about
0-1% lead is passed through a metal spaying process at a speed of
up to 100 ft/min. The coated brass strip is then passed through
coating rollers and/or an air-knife to achieve a coating thickness
of about 7-51 microns. The coated brass strip is cooled and then
oxidized to remove the tin alloy and to expose and pacify the heat
created intermetallic layer. The brass strip is then cut into
sheets.
EXAMPLE CCC
[0285] A brass strip is unwound from a roll of brass strip and is
pickled with an acid solution and then chemically activated with a
chemical activation solution. The brass strip is plated with a
metal layer of about 1-3 microns thick. The brass strip is not
pre-heated prior to coating. A tin alloy having a composition of
about 90-99% tin is plated onto the brass strip and then flow
heated. The brass strip is then coated again by a spray metal
process. The coated brass strip is then passed through coating
rollers and/or an air-knife to achieve a coating thickness of about
7-51 microns. The coated brass strip is then cooled and wound into
a roll of brass strip. The roll of coated brass strip is formed
into roofing materials and installed on a building. The formed
coated strip is then exposed on site to an oxidizing solution to
remove the tin alloy and to expose and to pacify the intermetallic
layer.
EXAMPLE DDD
[0286] A metal alloy is formed into a metal strip to be formed to
various types of materials, or into a solder or a welding wire for
connecting two or more metal materials together. One general
composition of the metal strip, solder or welding wire is 20-70%
tin, 30-75% zinc, 0.0005-2% aluminum, 0.001-2% antimony, 0.0001-1%
bismuth, 0-2% copper, 0-0.5% lead, 0.0001-0.1% titanium. Another
and/or alternative formulation ofthe metal strip, solder or welding
wire is 40-60% tin, 40-60% zinc, 0.0005-0.75% aluminum, 0.001-1%
antimony, 0.0001-0.2% bismuth, 0-0.01% arsenic, 0-0.01% cadmium,
0-0.01% chromium, 0.001-1% copper, 0-0.1% iron, 0-0.1% lead;
0-0.01% manganese, 0-0.2% nickel, 0-0.01% silver, 0.0005-0.05%
titanium. Still another and/or alternative formulation of the metal
strip, solder or welding wire includes 30-70% tin; 30-70% zinc;
0.0001-0.5% aluminum; 0.001-2% antimony; 0-0.01% arsenic; 0.0001-1%
bismuth; 0-0.01% boron; 0-0.01% cadmium; 0-0.05% carbon; 0-0.05%
chromium; 0-2% copper; 0-0.1% iron; 0-0.5% lead; 0-0.01% magnesium;
0-0.01% manganese; 0-0.01% molybdenum; 0-1% nickel; 0-0.01%
silicon; 0-0.01% silver; 0-0.01% sulfur; 0-0.01% tellurium;
0.0001-0.1% titanium; and 0-0.01% vanadium; Yet another and/or
alternative formulation of the metal strip, solder or welding wire
is 40-60% tin; 40-60% zinc; 0.0005-0.4% aluminum; 0.01-0.8%
antimony; 0-0.005% arsenic; 0.001-0.05% bismuth; 0-0.005% cadmium;
0.005-0.5% copper; 0-0.05% iron; 0-0.1% lead; 0-0.05% nickel;
0-0.005% silver; and 0.0005-0.05% titanium. Still yet a further
and/or alternative formulation of the metal strip, solder or
welding wire is 48-52% tin; 48-52% zinc; 0.005-0.24% aluminum;
0.05-0.64% antimony; 0-0.001% arsenic; 0.002-0.005% bismuth;
0-0.001% cadmium; 0.01-0.3% copper; 0-0.016% iron; 0-0.08% lead;
0-0.001% nickel; 0-0.001% silver; 0.001-0.02% titanium. Another
and/or alternative formulation of the metal strip, solder or
welding wire is 5-70% tin; 30-95% zinc; 0-0.25% aluminum; 0-0.02%
chromium; 0-1.5% copper; 0-0.01% iron; 0-0.01% lead; 0-0.01%
manganese; and 0-0.18% titanium. When the metal alloy is used as a
solder metal or electrode, the metal alloy is formed into a thin
wire or thin strip by common known processes. The wire or thin
strip is typically rolled for later processing or use. The metal
alloy made for solder typically includes aluminum and/or titanium
since these two metal additives positively affect the surface
tension of the metal alloy in the molten state so that the molten
metal alloy has the desired wetting characteristics. The higher the
concentration of titanium and/or aluminum, the more the solder will
bead when applied to a workpiece. The addition of titanium and/or
aluminum to the metal alloy also causes the metal alloy to resist
flowing at temperatures near the melting point of the metal alloy.
This resistance imparts excellent soldering characteristics. The
titanium and/or aluminum are believed to cause oxide formation on
the surface of the molten solder to form a dull greyish, earth tone
colored solder. The titanium and aluminum are also believe to
assist in forming an intermetallic layer with the tin and zinc in
the metal alloy and the workpiece before solidification of the
solder to thereby form a strong bond with the workpiece. The solder
typically includes little, if any, lead additions, and such, any
lead in the solder is typically due to impurities. The solder
composition is particularly useful in soldering carbon steel,
stainless steel, copper, copper alloys, tin, tin metal alloys, zinc
and zinc alloys. However, the solder can be used on other types of
metals. If the solder is to be used to connect copper or copper
alloys, copper is typically added to the metal alloy composition.
The addition of copper reduces the reactivity of the solder with
the copper or copper alloy materials. The solder may be used with a
wide variety of fluxes. If the solder is to be used in ultrasonic
welding, a flux is typically not used.
EXAMPLE EEE
[0287] The metal alloy is used for standing seam and press fit
(mechanical joining such as shown in U.S. Pat. No. 4,987,716)
applications for roofing. In standing seam applications, the edges
of the roofing materials are folded together and then soldered to
form a water tight seal. The metal alloy inherently includes
excellent soldering characteristics. When the metal alloy is
heated, it has the necessary wetting properties to produce a tight
water resistant seal. As a result, the metal alloy acts as both a
corrosive resistive coating and a soldering agent for standing seam
roofing systems. The metal alloy coated can be also welded with
standard solders. Typical solders contain about 50% tin and about
50% lead. The metal alloy has the added advantage of being able to
be soldered with low or no-lead solders. The metal alloy coated
roofing materials also can be used in mechanically joined roofing
systems due to the malleability of the metal alloy. Mechanically
joined systems form water tight seals by folding adjacent roof
material edges together and subsequently applying a compressive
force to the seam in excess of about 1,000 psi. Under these high
pressures, the metal alloy plastically deforms within the seam and
produces a water tight seal.
[0288] The invention has been described with reference to preferred
and alternate embodiments. Modifications and alterations will
become apparent to those skilled in the art upon reading and
understanding the detailed discussion of the invention provided
herein. This invention is intended to include all such
modifications and alterations insofar as they come within the scope
of the present invention.
* * * * *