Galvanizing is one of the effective ways to prevent corrosion of steel wire. There are two methods for galvanizing, one is electro-galvanized and the other is hot-dip galvanizing. A disadvantage of hot-dip galvanizing is the large loss of strength. In the production process of small-sized steel wire ropes, electroplated zinc is mostly used as a raw material coating processing method for rope-making steel wire. The advantage of electro-galvanizing is that the thickness of the steel plating layer is uniform and compact. The mechanical properties of the steel wire before and after plating are less changed, and can also be adjusted according to requirements; the disadvantage is that if the steel wire is not cleaned before plating, the bonding strength between the plating layer and the steel wire substrate is poor. Dezincification is prone to occur. Therefore, the control of the quality of the galvanized steel wire galvanized layer is very important.
The electroplating zinc production process is as follows: discharge line → pickling → water washing → electro-galvanizing → cold water washing → hot water washing → drying → take-up. The zinc sulfate salt is electroplated, the mass concentration of zinc sulfate is 400-600 g/L, and the pH of the plating solution is 2-4. In the electroplating zinc production process, the key factors affecting the quality of galvanizing are the cleanliness of the pickling of the steel wire before plating and the mass concentration of the plating solution, the pH control and the current of the monofilament. The quality of pickling directly affects the bonding strength between the coating and the substrate. The mass concentration of the plating solution directly determines the rate of ion replenishment in the solution after ion migration and eliminates the concentration polarization phenomenon.
Jiangsu Farsheng Shengsheng Group Co., Ltd. optimized the electro-galvanizing process to improve the quality of the galvanized layer.
First, adjust the plating process parameters. (1) Strictly control the pH value of the plating solution. Research shows that the pH value of the plating solution directly affects the quality of the steel plating layer. If the pH value is improperly controlled, the plating layer will be loose. When the pH value is greater than 3, the steel wire coating has fine dendrites. The burr, the surface is not smooth. (2) Strictly control the current density. From the microscopic morphology, the larger the current density, the larger the zinc layer grain deposition, and the less dense the corresponding zinc layer. On the contrary, the denser the ion deposition, the better the quality of the zinc layer. In order to ensure the surface zinc layer is dense and bright, to achieve a mass per unit area of ​​zinc level of 80g / m2, the process parameters need to be optimized as follows: current density is 16 ~ 20A / dm2, zinc sulfate solution mass concentration is 500 g / L, The pH is 2.5 to 3.0.
Second, adjust the process parameters of the tank drawing. (1) Strictly follow the multi-pass small compression ratio, the total compression ratio is 96.48%, reducing the scraping of the zinc layer. (2) The whole set of wire drawing die is made of tungsten steel die and polycrystalline die. The working angle of the wire drawing die is 12°~16°, and the length of the sizing tape is 0.15 of the wire diameter to ensure the deformation of the zinc layer and the basic of the steel wire base. Synchronize. (3) The cooling circulation system uses the spray method to cool the wire drawing die, and timely takes away a large amount of heat generated by the wire drawing machine in high-speed drawing to ensure the quality of the wire. (4) Control the drawing process parameters: take-up speed 10~12 m/s; take-up tension 8~10N; fixed length 30km; lubricant mass fraction 3.5~4.5%; lubricant pH 7~8; lubricant The temperature is 30 to 40 °C.
Through the optimization of the process, the quality of the zinc-zinc layer of the electroplated zinc wire with a diameter of 0.80 mm is controlled at 80-90 g/m2, and the mass difference of the zinc layer is small; the subsequent water tank pulls the rope to conduct the zinc layer inspection. The results show that the average zinc layer quality is 14.5 g/m2, the zinc layer loss is less than 5%, and the tensile strength of the steel wire is 2300-2500 MPa. It not only effectively controls the zinc level quality of the electroplated zinc raw material steel wire, but also reduces unnecessary waste and reduces production costs.
The electroplating zinc production process is as follows: discharge line → pickling → water washing → electro-galvanizing → cold water washing → hot water washing → drying → take-up. The zinc sulfate salt is electroplated, the mass concentration of zinc sulfate is 400-600 g/L, and the pH of the plating solution is 2-4. In the electroplating zinc production process, the key factors affecting the quality of galvanizing are the cleanliness of the pickling of the steel wire before plating and the mass concentration of the plating solution, the pH control and the current of the monofilament. The quality of pickling directly affects the bonding strength between the coating and the substrate. The mass concentration of the plating solution directly determines the rate of ion replenishment in the solution after ion migration and eliminates the concentration polarization phenomenon.
Jiangsu Farsheng Shengsheng Group Co., Ltd. optimized the electro-galvanizing process to improve the quality of the galvanized layer.
First, adjust the plating process parameters. (1) Strictly control the pH value of the plating solution. Research shows that the pH value of the plating solution directly affects the quality of the steel plating layer. If the pH value is improperly controlled, the plating layer will be loose. When the pH value is greater than 3, the steel wire coating has fine dendrites. The burr, the surface is not smooth. (2) Strictly control the current density. From the microscopic morphology, the larger the current density, the larger the zinc layer grain deposition, and the less dense the corresponding zinc layer. On the contrary, the denser the ion deposition, the better the quality of the zinc layer. In order to ensure the surface zinc layer is dense and bright, to achieve a mass per unit area of ​​zinc level of 80g / m2, the process parameters need to be optimized as follows: current density is 16 ~ 20A / dm2, zinc sulfate solution mass concentration is 500 g / L, The pH is 2.5 to 3.0.
Second, adjust the process parameters of the tank drawing. (1) Strictly follow the multi-pass small compression ratio, the total compression ratio is 96.48%, reducing the scraping of the zinc layer. (2) The whole set of wire drawing die is made of tungsten steel die and polycrystalline die. The working angle of the wire drawing die is 12°~16°, and the length of the sizing tape is 0.15 of the wire diameter to ensure the deformation of the zinc layer and the basic of the steel wire base. Synchronize. (3) The cooling circulation system uses the spray method to cool the wire drawing die, and timely takes away a large amount of heat generated by the wire drawing machine in high-speed drawing to ensure the quality of the wire. (4) Control the drawing process parameters: take-up speed 10~12 m/s; take-up tension 8~10N; fixed length 30km; lubricant mass fraction 3.5~4.5%; lubricant pH 7~8; lubricant The temperature is 30 to 40 °C.
Through the optimization of the process, the quality of the zinc-zinc layer of the electroplated zinc wire with a diameter of 0.80 mm is controlled at 80-90 g/m2, and the mass difference of the zinc layer is small; the subsequent water tank pulls the rope to conduct the zinc layer inspection. The results show that the average zinc layer quality is 14.5 g/m2, the zinc layer loss is less than 5%, and the tensile strength of the steel wire is 2300-2500 MPa. It not only effectively controls the zinc level quality of the electroplated zinc raw material steel wire, but also reduces unnecessary waste and reduces production costs.
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