Al-Zn-Si Base alloy coated product and method of making the same

Abstract: An Al-Zn-Si base alloy coat including an Al-Zn-Si-Fe alloy layer which has remarkable high corrosion resistance is formed on an article. A ferrous base material is used as the article to provide Fe to the alloy layer. The alloy layer of the present invention consists of 55 to 65 wt% of Al, 25 to 35 wt% of Zn, 5 to 10 wt% of Fe, and 2 to 4 wt% of Si, and also has a cross sectional area of 15 to 90 % of the entire cross sectional area of the alloy coat. A process for forming the alloy coat of the present invention comprises the step of dipping the article into a molten bath of Zn to form, on the article, an undercoat which results from a reaction between Fe of the article and Zn in the molten bath, and then dipping the undercoat into an alloy molten bath of Al, Zn and Si to form the alloy coat of the present invention on the undercoat.

Description: TECHNICAL FIELD The present invention is directed to a corrosion resistant article comprising a ferrous base and an alloy coat covering a surface of said ferrous base and a process for making said article. BACKGROUND ART A zinc coating is generally used to provide corrosion resistance to a ferrous-base material. However, higher corrosion resistance is required in order to use the ferrous material in severe corrosive environments, e.g., a salt comprising area such as a seaside, an area having an acid rain and the like. Thus, many kinds of Al-Zn alloy coats were developed. The demands of the Al-Zn alloy coats are increasing because the Al-Zn alloy coats have more excellent corrosion resistance than Zn coats. Japanese Patent Publication [KOKOKU] No. 63-63626 describes a steel wire coated with an Al-Zn alloy containing 3 to 10 wt% of Al. Suzuki et al., Japanese patent early publication [KOKAI] No. 1-263255, also describes a method of Al-Zn alloy coating, which comprises the steps of dipping a base into a molten bath of Zn at a bath temperature in a range of 480 to 560°C to form an undercoat on the base and subsequently dipping the base with the undercoat into an alloy molten bath containing at least 1 wt% of Al at a bath temperature in a range of 390 to 460°C to form an Zn-Al alloy coat on the undercoat. The alloy molten bath preferably includes 0.1 to 10 wt% of Al. In case that the Al content is less than 0.1% the desired effect of Al, which is to greatly enhance corrosion resistance of the alloy coat, is not obtained. On the other hand, when the alloy molten bath includes more than 10 wt% of Al, a typical ferrous metal bath container and the undercoat base are given a harmful attack from molten metals of the alloy molten bath. However, when we think about a corrosion protective coat used under more severe corrosive conditions in the future, an alloy coat having more excellent corrosion resistance as compared with the Zn-Al alloy coat will be requested. It is therefore an object of the present invention to improve the corrosion resistant article described in the first paragraph of this specification such that it has an excellent corrosion resistance. This object is solved by a corrosion resistant article according to claim 1 of the present invention. The subclaims 2 to 8 describe preferred embodiments of the article of the present invention. The article according to the invention is made from ferrous base material to provide Fe to the alloy coat. The alloy coat consists preferably of three layers, that is, an interface layer, an intermediate layer and an outer layer. The Al-Zn-Si-Fe alloy layer of the present invention, which is the intermediate layer, includes about 55 to 65 wt% of Al, about 5 to 10 wt% of Fe, about 2 to 4 wt% of Si and about 25 to 35 wt% of Zn, and is also formed into a granular structure or a fine and zonal structure. The intermediate layer has a cross sectional area of 15 to 90% of the entire cross sectional area of the alloy coat of the present invention. It is a further object of the present invention to provide an unique and reproducible process for forming an article as described in the first paragraph of this specification having excellent corrosion resistance. This object is solved by a process according to claim 9 of the present invention. The subclaims 10 to 21 describe preferred embodiments of the process of the present invention. The process for forming the alloy coat of the present invention comprises dipping the base into a molten bath of Zn to form, on the base, an undercoat as a reaction layer between Fe of the base and Zn in the molten bath, and then dipping the undercoated base into an alloy molten bath of Al, Zn and Si to form the alloy coat on the undercoat. It is also preferred that the alloy coat is cooled at an optimum cooling rate in order to obtain a smooth surface and uniformity of the alloy coat after being withdrawn from the alloy molten bath. The article and the process for forming the article of the present invention will be described in detail hereinafter. DETAILED DESCRIPTION OF THE INVENTION An Al-Zn-Si base alloy coat including an Al-Zn-Si-Fe alloy layer which has excellent corrosion resistance is made according to a process of the present invention. A steel or a cast iron is used as a base. Before the base is dipped into a Zn molten bath, pre-treatments are performed on a surface of the base in accordance with the following order: alkali cleaning, water cleaning, acid cleaning, water cleaning and a flux treatment. Each of the pre-treatments is the same as for a general hot-dip Zn coating. For example, the base is cleaned in an alkali solution bath comprising NaOH or NaOH + Na₂O 2SiO₂ nH₂O at a temperature of 70 to 80°C. The water cleaning is done at ambient temperature, and then the base is cleaned in aqueous solution containing hydrochloric acid at ambient temperature. Subsequently, the flux treatment is done in aqueous solution containing zinc chloride and ammonium chloride at a temperature of 80 to 90°C. A hot-dip coating of the present invention essentially consists of first and second hot dipping steps. The most important reason for adopting the two steps of the hot-dip coating is to prevent appearance of the alloy coat of poor quality and also to stably obtain a smooth surface and uniformity of the alloy coat. The first hot dipping step is performed under the conditions described below. After the above pre-treatments have been completed, the base is dipped into the Zn molten bath to form an undercoat on the base. The formation of the undercoat is very important to obtain the smooth surface and the uniformity of the alloy coat. Because the alloy coat is basically formed through a substitutional reaction between the undercoat and molten metals in an alloy molten bath. By the way, the Zn molten bath includes at least one metal selected from a group consisting of Al, Si, Mg, Ti, In, Tl, Sb, Nb, Co, Bi, Mn, Na, Ca, Ba, Ni, and Cr. When the Zn molten bath includes 0.1 to 5.0 wt% of Al, an uniform undercoat is formed on the base because the reaction between Fe of the base and Zn of the Zn molten bath is suitably controlled by Al in the Zn molten bath. The Zn molten bath also includes desirably 0.03 to 2.0 wt% of Ni to obtain the uniform undercoat. An addition of 0.01 to 0.5 wt% of Mg into the Zn molten bath is more effective to obtain the uniform undercoat. And besides, a small amount of addition of Ti, Ni, Al and Si, for example, 0.1 to 2.0 wt% of Ti, 0.1 to 1.6 wt% of Ni, 0.1 to 1.6 wt% of Al and 0.01 to 0.03 wt% of Si, is preferable to obtain the uniform undercoat. The Zn molten bath is used at a temperature of 430 to 560°C, and preferably 440 to 460°C. In the case that the bath temperature is higher than 560°C, it is difficult to obtain the uniform undercoat. The base is dipped into the Zn molten bath for 10 to 600 seconds and preferably 15 to 60 seconds. When the undercoat is formed by dipping the base into the Zn molten bath for more than 600 seconds, the smooth surface of the alloy coat is not obtained on the undercoat in the second hot dipping step. The base with the undercoat is withdrawn from the Zn molten bath at a withdrawal velocity of 1.0 to 10 m/min and preferably 2 to 4 m/min. In the case that the withdrawal velocity is slower than 1.0 m/min, the smooth surface of the alloy coat is not formed on the undercoat in the second hot dipping step. The base with the undercoat is also transported from the Zn molten bath to the alloy molten bath within 90 seconds or less and preferably in a range of 10 to 30 seconds. When the base is transported from the Zn molten bath to the alloy molten bath within more than 90 seconds, the smooth surface and the uniformity of the alloy coat is not obtained in the second hot dipping step. The second hot dipping step of the present invention is performed under the conditions described below. The base with the undercoat is dipped into the alloy molten bath essentially consisting of 20 to 70 wt% of Al and preferably 30 to 60 wt% of Al, 0.5 to 4.0 wt% of Si and preferably 2.0 to 3.5 wt% of Si and a balance of Zn, so that the alloy coat is formed on the undercoat. When the Si content in the alloy molten bath is less than 0.5 wt%, or more than 4 wt%, it is difficult to form, on the undercoat, the alloy coat having remarkable high corrosion resistance. The alloy molten bath is used at a temperature of 570 to 670°C and preferably 580 to 610°C. In the case that the bath temperature is lower than 570°C, a large amount of dross is generated in the alloy molten bath. When the bath temperature is higher than 670°C in the second hot dipping step, an alloy coat having a rough surface is formed on the undercoat. The base with the undercoat is dipped into the alloy molten bath for 5 to 600 seconds and preferably 15 to 45 seconds. When the base with the undercoat is dipped into the alloy molten bath for more than 600 seconds, an alloy coat having the rough surface is formed on the undercoat. It is further preferred that the alloy molten bath is continuously vibrated to prevent adherence of a floating dross to the alloy coat during the second hot dipping step. When the undercoated base with the alloy coat is withdrawn from the alloy molten bath at a withdrawal velocity of 1.0 to 10 m/min and preferably 6 to 9 m/min, no adherence of the floating dross to the alloy coat is observed. The alloy coat is cooled at a particular cooling rate between 670°C and 370°C, and preferably between 610°C and 370°C. The particular cooling rate is -15°C/sec or less and preferably in a range of -3 to -7°C/sec in order to obtain the smooth surface and the uniformity of the alloy coat. When the base with the alloy coat is cooled at a rapid cooling rate, for example, more than -30°C/sec, the article is depreciated by discoloration of the alloy coat. Thus obtained alloy coat of the present invention substantially consists of an interface layer, an intermediate layer and an outer layer as shown in FIGS. 1 and 2. As the alloy coat is basically formed through the substitutional reaction between the undercoat and molten metals in the alloy molten bath, the undercoat is not observed on the base until after the second hot dipping step has been completed. The intermediate layer is an Al-Zn-Si-Fe alloy layer having a remarkable high corrosion resistance. That is to say, the intermediate layer essentially consists of 25 to 35 wt% of Zn, 55 to 65 wt% of Al, 5 to 10 wt% of Fe and 2 to 4 wt% of Si, and has a cross sectional area of 15 to 90 % of the entire cross sectional area of the alloy coat. The intermediate layer also has a granular structure as shown in FIG. 1, or a fine and zonal structure as shown in FIG. 2. For example, when the Si content in the alloy molten bath is in a range of 1.8 to 2.1 wt%, the intermediate layer is formed into the granular structure. On the other hand, when the Si content in the alloy molten bath is in a range of 2.1 to 2.8 wt%, the intermediate layer is formed into the fine and zonal structure. The fine and zonal structure of the intermediate layer can be also formed by cooling the alloy coat at an optimum cooling rate after the alloy coated article has been withdrawn from the alloy molten bath. The hardness of the intermediate layer measured by micro Vickers hardness tests is about 150 to 200 Hv. On the other hand, the interface layer is an Al-Zn-Fe-Si alloy layer having a different composition compared with the intermediate layer, that is, the interface layer includes a large amount of Fe and Si and a small amount of Zn compared with the intermediate layer. The interface layer which has a hardness of about 450 to 500 Hv is much harder than the intermediate layer. The outer alloy layer is a solidification layer essentially consisting of Al, Zn, and Si. However, the outer layer is not always needed to obtain an excellent corrosion resistance according to the present invention. For example, in the case of making an alloy coated bolt according to the present invention, the outer layer of the alloy coat is peeled off to keep an allowance of the bolt by a centrifugation method. Thus, the alloy coat then essentially consists of the interface layer and the intermediate layer. Further details of the present invention are described with respect to the following examples 1 to 24. However, the examples only illustrate the invention, but are not to be construed as to limiting the scope thereof in any manner. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 illustrates a schematic cross section of an alloy coat having an intermediate layer of a granular structure of the present invention; FIG. 2 illustrates a schematic cross section of an alloy coat having an intermediate layer of a fine and zonal structure of the present invention; FIG. 3 is a cross section of an alloy coat of example 1 of the present invention observed by an electron microscope; FIG. 4 is a cross section of an alloy coat of example 2 observed by the electron microscope; FIG. 5 is a cross section of an alloy coat of example 3 observed by the electron microscope; FIG. 6 is a cross section of an alloy coat of example 4 observed by the electron microscope; FIG. 7 is a cross section of an alloy coat of example 5 observed by the electron microscope; FIG. 8 is a cross section of an alloy coat of example 6 observed by the electron microscope; FIG. 9 is a cross section of an alloy coat of example 7 observed by the electron microscope; FIG. 10 is a cross section of an alloy coat of example 8 observed by the electron microscope; FIG. 11 is a cross section of an alloy coat of example 9 observed by the electron microscope; FIG. 12 is a cross section of an alloy coat of example 10 observed by the electron microscope; FIG. 13 is a cross section of an alloy coat of example 11 observed by the electron microscope; FIG. 14 is a cross section of an alloy coat of example 12 observed by the electron microscope; FIG. 15 is a cross section of an alloy coat of example 13 observed by the electron microscope; FIG. 16 is a cross section of an alloy coat of example 14 observed by the electron microscope; FIG. 17 is a cross section of an alloy coat of example 15 observed by the electron microscope; FIG. 18 is a cross section of an alloy coat of example 16 observed by the electron microscope; FIG. 19 is a cross section of an alloy coat of example 17 observed by the electron microscope; FIG. 20 is a cross section of an alloy coat of example 18 observed by the electron microscope; FIG. 21 is a cross section of an alloy coat of example 19 observed by the electron microscope; FIG. 22 is a cross section of an alloy coat of example 20 observed by the electron microscope; FIG. 23 is a cross section of an alloy coat of example 21 observed by the electron microscope; FIG. 24 is a cross section of an alloy coat of example 22 observed by the electron microscope; FIG. 25 is a cross section of an alloy coat of example 23 observed by the electron microscope; and FIG. 26 is a cross section of an alloy coat of example 24 observed by the electron microscope. EXAMPLES 1 TO 6 Each of the alloy coats of examples 1 to 6 of the present invention, which is an Al-Zn-Si base alloy coat including an Al-Zn-Si-Fe alloy layer, was formed on a ferrous base. The Al-Zn-Si base alloy coat consists essentially of an interface layer, an intermediate layer having excellent corrosion resistance and an outer layer. Therefore, the corrosion resistance of the alloy coat, which varies relative to the ratio of the cross sectional area of the intermediate layer against the entire cross sectional area of the alloy coat, was examined in examples 1-6. The ratio was determined by observing a cross section of the alloy coat. For example, the alloy coat of example 1 having a ratio of the cross sectional area of the intermediate layer against the entire cross sectional area of the alloy coat of about 5 % was produced through the following process. A steel sheet, which is 100 mm wide, 450 mm long, 3.2 mm high, was used as the ferrous base. Before the base was dipped into a Zn molten bath, pre-treatments such as alkali cleaning, water cleaning, acid cleaning and flux treatment were performed on a surface of the base. The treatments were based on the same process as for a general hot-dip Zn coating. Subsequently, the base was dipped into the Zn molten bath including 0.005 wt% of Al at a bath temperature of 460°C for 60 seconds to form, on the base, an undercoat, which results from a reaction between Fe of the base and Zn in the molten bath. The base with the undercoat was then transported from the Zn molten bath to an alloy molten bath within 30 seconds. The base with the undercoat was then dipped into the alloy molten bath consisting of 55 wt% of Al, 1.5 wt% of Si and a balance of Zn at a bath temperature of 590°C for 40 seconds to form, on the undercoat, the alloy coat including the Al-Zn-Fe-Si alloy layer. The undercoated base with the alloy coat was thereafter cooled from 590°C to 370°C at a cooling rate of -10°C/sec by air after being withdrawn from the alloy molten bath. Similarily, alloy coats of examples 2-6 were respectively produced by controlling hot-dip coating conditions such as chemical compositions of the Zn molten bath and/or the alloy molten bath, the dipping time or the cooling rate, etc.. The cross sectional area of the intermediate layer can be increased by cooling the alloy coat at a slower cooling rate after the undercoated base with the alloy coat has been withdrawn from the alloy molten bath. On the other hand, a comparative example was formed by the following process. The pre-treatments were performed on the base, and then the base was dipped into the Zn molten bath concluding 0.005 wt% of Al at the bath temperature of 480°C for 90 seconds. Therefore, the base of the comparative example was coated only with the undercoat essentially consisting of Zn and Fe. The ordinary undercoat has a plurality of crystal phases, e.g., η phase consisting of a pure Zn and δ phase consisting of a Zn-Fe alloy, etc.. More details about the hot-dip coating conditions for producing examples 1-6 and comparative example are shown in TABLE 1. TABLE 2 shows the chemical composition of each layer of the examples 1-6 analyzed by electron probe micro analysis (EPMA). The results of the EPMA indicate that the chemical composition of the intermediate layer essentially consists of about 55 to 65 wt% Al, 25 to 35 wt% of Zn, 5 to 10 wt% of Fe, and 2 to 4 wt% of Si. The results also indicate that the the Al-Zn-Fe-Si interface layer has a different composition compared with the intermediate layer, that is, the interface layer includes a large amount of Fe and Si and a small amount of Zn compared with the intermediate layer. Therefore, it suggests that the interface layer results from a preferential alloy reaction between Fe, which is included in the base and the undercoat, and Al and Si, which are included in the molten metals of the alloy molten bath. On the other hand, the outer layer includes a small amount of Fe and Si compared with the intermediate layer. It suggests that the outer layer is formed by a solidification of molten metals of the alloy molten bath without the preferential alloy reaction. The cross sections of the alloy coats of examples 1-6 observed by electron microscope are alos shown in FIGS. 3-8, respectively. The observations show that each of the alloy coats has a smooth surface. Three corrosion tests based on Japanese Industrial Standard (JIS) were performed with examples 1-6. One of the corrosion tests was performed in the environment of a sulfurous acid gas in accordance with JIS H8502 test. The sulfurous acid gas concentration was 100 ppm. The environment was also held at a temperature of 40°C and at a relative humidity of more than 90 %. The another one was a salt spray test based on JIS Z2371 test. The salt spray was 5 percent salt water. The last one was the same salt spray test except that acetic acid was added in the salt spray such that the salt spray has an acidity in a range of pH 3.0 to pH 3.3. The results of the corrosion tests of JIS H8502 and the salt spray test with the acetic acid are shown on TABLES 3 and 4, respectively. The results indicate that the corrosion resistance of the alloy coat of the present invention depends on the ratio of the cross sectional area of the intermediate layer against the entire cross sectional area of the alloy coat, that is, as the ratio increases, the alloy coat shows more excellent corrosion resistance. The results also indicate that no red rust is generated on the alloy coat having the ratio of more than 40 %, even after the alloy coat is exposed to the sulfurous acid gas for 1200 hours, or on the salt spray with the acetic acid for 3000 hours. On the other hand, the salt spray test of JIS Z2371 is in progress. However, no red rust is observed on all examples 1-6, even after the alloy coat was exposed to the salt spray for 5000 hours. Contents of Al, Zn, Fe, and Si, of alloy coats of examples 1 to 6 analyzed by electron probe micro analysis (EPMA). Division of alloy coat Al (wt%) Zn (wt%) Fe (wt%) Si (wt%) Example 1 Outer layer 73.7 24.5 0.20 0.85 Intermediate layer 63.3 32.0 8.28 3.16 Interface layer 52.1 12.0 25.9 9.37 Example 2 Outer layer 72.4 26.1 0.25 0.77 Intermediate layer 63.7 27.5 9.40 3.60 Interface layer 51.9 11.8 26.1 9.31 Example 3 Outer layer 73.4 26.1 0.26 0.68 Intermediate layer 62.4 29.9 8.41 2.95 Interface layer 53.6 12.2 25.3 9.01 Example 4 Outer layer 76.5 26.2 0.32 0.32 Intermediate layer 58.9 33.2 5.18 2.15 Interface layer 51.9 10.7 28.2 9.26 Example 5 Outer layer 75.5 29.0 0.30 0.68 Intermediate layer 61.3 31.8 4.77 1.95 Interface layer 53.0 10.5 27.9 9.16 Example 6 Outer layer 73.5 25.7 0.23 0.82 Intermediate layer 60.2 32.4 5.84 2.42 Interface layer 53.5 10.4 29.3 8.46 EXAMPLES 7 TO 14 The surface roughness of the alloy coat is improved by utilizing a Zn molten bath including a small amount of an additive element. Therefore, the effect of the additive element in the Zn molten bath for improving the surface roughness of the alloy coat was examined in examples 7-14. After the pre-treatments were performed on the bases, the undercoats of examples 7-14 were formed on the bases by dipping the bases into Zn molten bathes, respectively, including different additive elements such as Ni, Ti, Al and Mg. Then, each of the undercoated articles was dipped into an alloy molten bath to form the alloy coat on the undercoat. More details about the hot-dip coating conditions for producing examples 7-14 are shown in TABLE 5. The cross sections of the alloy coats of examples 7-14 observed by the electron microscope are also shown in FIGS. 9-16, respectively. The observations indicate that each of the alloy coats of examples 8-14 has a smooth surface equal to, or better than, the alloy coat, which was formed through dipping the base into a Zn molten bath including 0.01 wt% of Al of example 7. The three corrosion tests of examples 1-6 were also performed with examples 7-14. All alloy coats of examples 7-14 demonstrated excellent corrosion resistance without generation of red rust, even after being exposed to the sulfurous acid gas for 480 hours, or to the salt spray test for 5000 hours, or to the salt spray test with the acetic acid for 2500 hours. EXAMPLES 15 TO 20 The surface roughness of the alloy coat is also improved by varying the hot-dip coating conditions. Therefore, bath temperature and bath composition of the Zn molten bath for improving the surface roughness of the alloy coat were examined in examples 15-20. After the pre-treatments were performed on the bases, the undercoats of examples 15-17 were formed on the bases by dipping the bases into a Zn molten bath including 0.01 wt% of Al at different bath temperatures, respectively. Then, each of the undercoated articles was dipped into an alloy molten bath consisting of 55 wt% of Al, 1.6 wt% of Si and a balance of Zn to form the alloy coat on the undercoat. More details about the hot-dip coating conditions for producing the examples 15-17 are shown in TABLE 6. The cross sections of the alloy coats of examples 15-17 observed by the electron microscope are shown in FIGS. 17-19, respectively. The observations of examples 15-17 indicate that the surface roughness of the alloy coat depends on the bath temperature of the Zn molten bath, that is, higher the bath temperature, more rough the surface of the alloy coat, as shown in FIGS. 18 and 19. Therefore, when the Zn molten bath including 0.01 wt% Al is utilized to form the undercoat, the bath temperature of the Zn molten bath of about 450°C is prefeable to obtain the alloy coat having the smooth surface. On the other hand, the undercoats of examples 18-20 were formed by dipping the bases into a Zn molten bath including 0.5 wt% of Al and 0.5 wt% of Ni at different temperatures, respectively. Then, each of the undercoated articles was dipped into the alloy molten bath of examples 15-17 to form the alloy coat on the undercoat. More details about the hot-dip coating conditions for producing examples 18-20 are shown in TABLE 6. When the Zn molten bath including 0.5 wt% of Al and 0.5 wt% Ni was utilized to form the undercoats, the bath temperature of the Zn molten bath between 450°C and 520°C was useful to obtain the smooth surface of the alloy coat. Therefore, a practical range of bath temperature of a Zn molten bath for forming the smooth surface of the alloy coat is extended by adding a small amount of optimum additive element into the Zn molten bath. The three corrosion tests of examples 1-6 were also performed in examples 15-20. All alloy coats of examples 15-20 demonstrated excellent corrosion resistance without generation of red rust, even after being exposed to the sulfurous acid gas for 480 hours, or to the salt spray test for 5000 hours, or to the salt spray test with the acetic acid for 2500 hours. EXAMPLES 21 TO 24 The micro structure of the intermediate layer of the alloy coat is controlled by the cooling rate of the alloy coat. Therefore, the effect of the cooling rate for controlling the micro structure of the intermediate layer was examined in examples 21-24. After the pre-treatments were performed on the bases, the undercoats were formed on the bases by dipping the bases into a Zn molten bath including 0.3 wt% of Al at 480°C for 60 seconds. The alloy coats of examples 21-24 were formed on the undercoated articles by dipping the same into an alloy molten bath including 55 wt% of Al, 2.3 wt% of Si and a balance of Zn at 590°C for 30 seconds, and then they were cooled at four different cooling rates, respectively, after being withdrawn from the alloy molten bath. More details about the hot-dip coating conditions for producing examples 21-24 are also shown in TABLE 7. The cross sections of the alloy coats of examples 21-24 observed by the electron microscope are shown in FIGS. 23-26, respectively. The observations indicate that the intermediate layer was formed into a fine and zonal structure, when the cooling rate was in a range between -3 and -7°C/sec, however, when the cooling rate was more than -7°C/sec, the intermediate layer was mostly formed into a granular structure. Therefore, the cooling rate of the alloy coat, which is -7°C/sec or less, is preferable to form the fine and zonal structure of the intermediate layer. The three corrosion tests of examples 1-6 were also performed in examples 21-24. All alloy coats of examples 21-24 demonstrated excellent corrosion resistance without generation of red rust, even after being exposed to the sulfurous acid gas for 480 hours, or to salt spray test for 5000 hours, or to the salt spray test with the acetic acid for 2500 hours. The features disclosed in the foregoing description, in the claims and/or in the accompanying drawings may, both, separately and in any combination thereof, be material for realising the invention in deverse forms thereof. LIST OF REFERENCE NUMRERALS 1 ferrous base article 2 intermediate layer 3 alloy coat 4 interface layer 5 outer layer

Claims: A corrosion resistant article comprising a ferrous base and an alloy coat covering a surface of said ferrous base, wherein said alloy coat comprises a first Al-Zn-Fe-Si layer disposed on said ferrous base and a second Al-Zn-Fe-Si layer disposed on said first layer, said second layer consisting essentially of 55 to 65 wt% Al, 5 to 10 wt% Fe, 2 to 4 wt% Si and 25 to 35 wt% Zn. A corrosion resistant article according to claim 1, wherein said alloy coat also comprises as a third layer an outer layer disposed on said second layer and consisting essentially of Al, Zn and Si. A corrosion resistant article according to claim 1, wherein said second layer is formed into a granular structure. A corrosion resistant article according to claim 1, wherein said second layer is formed into a fine and zonal structure. A corrosion resistant article according to claim 1, wherein said second layer has a cross sectional area of 15 to 90 % of the entire cross sectional area of said alloy coat. A corrosion resistant article according to claim 1, wherein the amount of Fe included in said second layer is less than that in said first layer. A corrosion resistant article according to claim 1, wherein the amount of Si included in said second layer is less than that in said first layer. A corrosion resistant article according to claim 1, wherein the amount of Zn included in said second layer is more than that in said first layer. A process for making a corrosion resistant article, which comprises dipping a ferrous base into a first bath consisting essentially of Zn and at least one element selected from the group consisting of Al, Si, Mg, Ti, In, Tl, Sb, Nb, Co, Bi, Mn, Na, Ca, Ba, Ni and Cr, to form an undercoat comprising Fe and Zn, removing the undercoated article from said first bath, dipping the undercoated article into a second bath consisting essentially of 20 to 70 wt% Al, 0.5 to 4 wt% of Si and a balance of Zn to form an Al-Zn-Fe-Si alloy coat on the undercoated article, and removing the alloy-coated article from the second bath to obtain said corrosion resistant article. A process according to claim 9, wherein said first bath includes at least one selected from Al, Ni, Mg, Ti, and Si. A process according to claim 9, wherein said first bath includes 0.1 to 5.0 wt% of Al. A process according to claim 9, wherein said first bath includes 0.003% to 2 wt% of Ni. A process according to claim 9, wherein said first bath includes 0.01 to 0.5 wt% of Mg and 0.01 to 0.2 wt% of Ni. A process according to claim 9, wherein said first bath includes 0.1 to 2.0 wt% of Ti, 0.1 to 1.6 wt% of Ni, 0.1 to 1.6 wt% of Al and 0.01 to 0.03 wt% of Si. A process according to claim 9, wherein said second bath includes 2.0 to 3.5 wt% of Si. A process according to claim 9, wherein said second bath includes 30 to 60 wt% of Al. A process according to claim 9, in which said first bath is used at a temperature of between 430 and 560°C, and said second bath is used at a temperature of between 570 and 670°C. A process according to claim 9, in which said alloy-coated article is cooled at a cooling rate of about 15°C per second or less after being withdrawn from said second bath. A process according to claim 17, in which said undercoated article is withdrawn from said first bath at a withdrawal velocity of 1.0 to 10 m/min, and said alloy-coated article is withdrawn form said second bath at a withdrawal velocity of 1.0 to 10 m/min. A process according to claim 17, in which said ferrous base is dipped into said first bath for 10 to 600 seconds, and said undercoated article is dipped into said second bath for 5 to 600 seconds. A process according to claim 17, in which said undercoated article is transported from said first bath to said second bath within 90 seconds or less.

Inventors: HAYAKAWA KUNIO, SUZUKI YOUICHIRO, TAKEDA MASANORI, HAYAKAWA, KUNIO, SUZUKI, YOUICHIRO, TAKEDA, MASANORI, C/O DAIDO STEEL SHEET CORP.
Applicants: S TEM LIMITED, S-TEM LIMITED
Application year: 1992
Main classification: C23C2
IPC codes: C23C2, C23C30, C23C28