Ni Plating Steel Sheet Corrosion Resistance

Solution Overview

Problem

Conventional Ni plating steel sheets used for manufacturing containers face issues with piercing corrosion, especially in acidic contents, and have limited applicability due to insufficient corrosion resistance and adhesion problems during processing.

Innovation Solution

A Ni plating steel sheet with a hydroxyl Ni and Ni oxide inclusion within the Ni plating layer, combined with a chromate film layer or a Zr film layer, is developed to enhance corrosion resistance and adhesion, featuring a specific composition and formation process to reduce piercing corrosion and improve weldability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If Ni plating steel sheet is used to improve workability and adhesion, then adhesion and weldability are improved, but piercing corrosion resistance deteriorates in acidic contents

Engineering Contradiction:

ImproveadhesionVSAvoidpiercing corrosion

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The invention applies local quality by creating a dual-layer plating structure where the inner layer has different composition and properties than the outer layer. The inner plating layer contains specific alloying elements (Al, Si, P, S) at controlled concentrations to provide corrosion resistance, while the outer layer provides adhesion and weldability. This localized differentiation of material properties resolves the contradiction between adhesion and corrosion resistance.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The invention uses composite materials by combining nickel plating with specific alloying elements (Al, Si, P, S) in controlled amounts. This composite plating structure leverages the corrosion resistance of the alloyed inner layer and the adhesion/weldability of the nickel outer layer, simultaneously addressing both requirements without compromise.

Inventive Principle:

Principle #40Composite materials

2Ease of operation

If Ni plating steel sheet is used to improve workability, then workability is improved, but corrosion resistance in acidic contents deteriorates

Engineering Contradiction:

ImproveworkabilityVSAvoidcorrosion resistance

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The invention applies local quality by creating a dual-layer plating structure where the inner layer has different composition and properties than the outer layer. The inner plating layer contains specific alloying elements (Al, Si, P, S) at controlled concentrations to provide corrosion resistance, while the outer layer provides adhesion and weldability. This localized differentiation of material properties resolves the contradiction between adhesion and corrosion resistance.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The invention uses composite materials by combining nickel plating with specific alloying elements (Al, Si, P, S) in controlled amounts. This composite plating structure leverages the corrosion resistance of the alloyed inner layer and the adhesion/weldability of the nickel outer layer, simultaneously addressing both requirements without compromise.

Inventive Principle:

Principle #40Composite materials

3Object-affected harmful factors

If film is formed on Sn plating steel sheet to improve corrosion resistance, then corrosion resistance is improved, but film adhesion becomes unstable due to brittle Sn oxide

Engineering Contradiction:

Improvecorrosion resistanceVSAvoidfilm adhesion

Core Design Contradiction:

Object-affected harmful factorsVSReliability

Solution Approach 1:

The invention extracts the problematic Sn plating layer and replaces it with a Ni-based plating system. By removing the source of the adhesion problem (brittle Sn oxide) while maintaining corrosion resistance through the Ni plating with alloying elements, the contradiction between corrosion resistance and film adhesion is resolved.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The invention changes the fundamental material parameter from Sn-based plating to Ni-based plating. This parameter change fundamentally alters the properties of the plating layer, eliminating the brittle oxide formation issue while maintaining protective corrosion resistance, thereby improving film adhesion stability.

Inventive Principle:

Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution significantly reduces piercing corrosion rates by dispersing corrosion through voids within the Ni plating layer, enhancing both corrosion resistance and adhesion with resin films, while maintaining excellent weldability.

Implementation Method 1

the Ni plating layer includes one or more of a hydroxyl Ni and a Ni oxide

Methodology Applied

Scientific EffectHydroxyl Ni and Ni oxide inclusion:

Implementation Method 2

dispersing corrosion through voids within the Ni plating layer

Methodology Applied

Scientific EffectCorrosion dispersion through voids:

Implementation Method 3

a chromate film layer or a film layer including Zr, on the Ni plating layer

Methodology Applied

Scientific EffectChromate film formation:

Implementation Method 4

enhancing both corrosion resistance and adhesion with resin films

Methodology Applied

Scientific EffectAdhesion enhancement: Adhesive

Implementation Method 5

Ni plating steel sheet

Methodology Applied

Scientific EffectElectroplating: Electroplating

Data Source

PatentUS9945037B2Steel sheet used to manufacture a container and method of manufacturing the same

Publication Date: 2018.04.17 NIPPON STEEL CORPORATION

AI summary

A steel sheet used to manufacture a container, wherein the steel sheet includes a chromate film layer or a film layer including Zr on the Ni plating layer, the Ni plating layer includes one or more of a hydroxyl Ni and a Ni oxide, an adhesion amount of the Ni plating layer in terms of an amount of Ni is 0.3 g/m2 or more, a concentration of oxygen atoms of the Ni plating layer due to the hydroxyl Ni and the Ni oxide is 1 to 10 atomic %, an adhesion amount of the chromate film layer in terms of the amount of Cr is 1 to 40 mg/m2, and an adhesion amount of the film layer including Zr in terms of an amount of Zr is 1 to 40 mg/m2 or more.