Characterisation of Fe Distribution in the Liquid-Solid Boundary of Al-Zn-Mg-Si Alloy Using Synchrotron X-ray Fluorescence Microscopy.

Al-Zn-Mg-Si alloy coatings have been developed to inhibit the corrosion of cold-rolled steel sheets by offering galvanic and barrier protection to the substrate steel. It is known that Fe deposited from the steel strip modifies the microstructure of the alloy. We cast samples of Al-Zn-Mg-Si coating alloys containing 0.4 wt% Fe and directionally solidified them using a Bridgman furnace to quantify the effect of this Fe addition between 600 °C and 240 °C. By applying a temperature gradient, growth is encouraged, and by then quenching the sample in coolant, the microstructure may be frozen. These samples were analysed using scanning electron microscopy (SEM) and energy dispersive X-ray spectroscopy (EDS) to determine the morphological effects of the Fe distribution across the experimental temperature range. However, due to the sub 1 wt% concentration of Fe, synchrotron X-ray fluorescence microscopy (XFM) was applied to quantitatively confirm the Fe distribution. Directionally solidified samples were scanned at 7.05 keV and 18.5 keV using X-ray fluorescence at the Australian Synchrotron using the Maia array detector. It was found that a mass nucleation event of the Fe-based τ6 phase occurred at 495 °C following the nucleation of the primary α-Al phase as a result of a peritectic reaction with remaining liquid.

Phase Stability of Dross Particles in Hot-Dip Zn-55wt%Al-1.6wt%Si Galvanizing Bath.

Dross in a Zn-55wt%Al-1.6wt%Si metal coating bath is a mixture of bath metal and the quaternary intermetallic phase τ5c-Al20Fe5Si2(+Zn). Understanding the properties and formation of dross in a hot-dip Al-Zn galvanizing bath at the processing temperature (~600 °C) is critical for improving the production quality of steel sheet coating. However, dross analysis is usually conducted at room temperature with dross samples taken from the hot-dip bath and it is not known how representative these samples are of the phase(s) existing at high temperature. Using in-situ synchrotron X-ray diffraction (XRD), the crystal lattice and the coefficient of thermal expansion (CTE) of the intermetallic phase have been determined in the temperature range of 30 °C to 660 °C. Phase formation and phase stability of the intermetallic phase in the dross powder have been determined, providing fundamental knowledge for optimizing the production and quality of steel sheet coating.