Nickel Layer Crystal Orientation Control for Corrosion Resistance

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Solution Overview

Problem

Conventional nickel plating on metal sheets for battery cans and pipes faces issues with corrosion resistance due to pinholes and wear, leading to reduced mold lifetime and increased production costs, while existing solutions either compromise on corrosion resistance or economic viability.

Innovation Solution

A surface-treated metal sheet with a nickel layer where the (200) plane orientation is suppressed to 40% or less, combined with heat treatment or temper rolling, and optionally a secondary metal layer above or below the nickel layer, to enhance corrosion resistance and surface hardness, thereby reducing nickel powder generation during press forming.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If nickel plating is applied to prevent corrosion, then corrosion resistance is improved, but pinholes form in the plating layer reducing effectiveness

Engineering Contradiction:

Improvecorrosion resistanceVSAvoidpinholes

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The invention changes the crystallographic orientation parameters of the nickel plating layer by controlling the plating process to suppress (200) plane orientation and promote (111) plane orientation. This parameter change in crystal structure reduces the formation of pinholes while maintaining corrosion resistance, resolving the contradiction between protective function and structural defects.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention creates a composite plating structure with multiple metal layers having different compositions and crystal orientations. The nickel plating layer is combined with other metal layers to form a composite structure where each layer contributes specific properties, reducing pinhole formation while maintaining overall corrosion resistance.

Inventive Principle:

Principle #40Composite materials

2Reliability

If nickel plating weight is increased to reduce pinholes, then corrosion resistance is improved, but manufacturing cost increases

Engineering Contradiction:

Improvecorrosion resistanceVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

Instead of increasing nickel plating weight, the invention changes the crystallographic orientation parameters of the plating layer. By controlling the orientation to suppress (200) plane and promote (111) plane, the invention achieves reduced pinholes and improved corrosion resistance at the same or reduced material cost, resolving the contradiction between performance and manufacturing cost.

Inventive Principle:

Principle #35Parameter changes

3Productivity

If conventional nickel plating is used for press forming, then productivity is maintained, but mold wear increases due to nickel powder generation

Engineering Contradiction:

Improveproduction rateVSAvoidmold lifetime

Core Design Contradiction:

ProductivityVSDuration of action of stationary object

Solution Approach 1:

The invention changes the surface properties of the nickel plating layer by controlling crystal orientation to suppress (200) plane. This parameter change results in reduced nickel powder generation during press forming, thereby reducing mold wear and extending mold lifetime while maintaining production productivity.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention creates local quality differences in the nickel plating layer by controlling crystal orientation in specific directions. The suppressed (200) plane orientation creates a surface structure that is less prone to generating nickel powder during mechanical processing, thereby protecting the mold while maintaining overall productivity.

Inventive Principle:

Principle #3Local quality

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 achieves excellent corrosion resistance and surface hardness, minimizing pinholes and mold wear, thus improving the productivity and quality of formed articles like battery cans and pipes.

Implementation Method 1

the proportion of the (200) plane to (111) plane, (200) plane, (220) plane and (311) plane is 40% or less

Methodology Applied

Scientific EffectCrystal orientation control:

Implementation Method 2

heat treatment, temper rolling or the like may be applied to the surface-treated metal sheet

Methodology Applied

Scientific EffectHeat treatment: Heat Treatment

Data Source

PatentUS9498933B2Surface-treated metal sheet and process for producing formed article from the surface-treated metal sheet

Publication Date: 2016.11.22 TOYO KOHAN CO LTD

AI summary

Provided are a surface-treated metal sheet which includes a nickel layer having improved corrosion resistance and a method of manufacturing a formed article. In a surface-treated metal sheet where a nickel layer is formed on a substrate, the proportion of (200) planes to a total of (111) planes, (200) planes, (220) planes and (311) planes with respect to the crystal plane orientations of the nickel layer is set to 40% or less. In a method of manufacturing a formed article using a surface-treated metal sheet where a nickel layer is formed on a substrate, the surface-treated metal sheet having the nickel layer where the proportion of (200) planes to a total of (111) planes, (200) planes, (220) planes and (311) planes is set to 40% or less with respect to the crystal plane orientations of the nickel layer is worked using a mold.