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ALUMINIZED STEEL
ASTM A 463, Aluminized steel, Aluminized stainless steel, Aluminized plates, Aluminized steel plate, Aluminized steel tubes , Aluminized steel Pipe,
Aluminized steel is obtained by aluminizing, which is a modern day engineering innovation allowing manufacture of high-heat resistance aluminized steel sheets at low costs with niche applications.
Aluminizing, above all, is a thermo-chemical diffusion process & is particularly applied to base metals like carbon steel, alloy steel, stainless steel, nickel-based alloys & nickel-iron alloys.
Physical properties of the aluminized product so obtained depends on the base metal used as well as the coating process & coating agents namely aluminium or its alloys. Demonstrably, the aluminized products, all the more, show good resistance to oxidation as well as excellent corrosion resistance by contrast to Galvanized steel products. For most part, the Aluminized Steel has:
| Better Performance | Higher thermal conductivity compared to stainless Stell |
|---|---|
| Long-life | Low thermal coefficient of expansion and thus does not change shape like stainless steel |
| Better cost efficacy | Electrostatic surface, thus allows it to be used in making exhaust system and mufflers |
Aluminized Steel is of 2 Types
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Aluminized Steel Sheet Coated (Type 1 – Hot Dip)
Aluminized Steel Sheet Type 1 Coated Mild/Stainless Steel Type 1 are ordinarily manufactured by dipping different base metal sheet in molten coating bath of aluminium-silicon alloy. Molten bath usually has 5 to 11% silicon & balance pure aluminium. Silicon additionally promotes better adherence. Furthermore, manufacturing is likewise done by continuous hot dipping of the base metal in molten aluminium-silicon (Al-Si) mixture & consequently both sides are coated at the same time in the same manner.
The process, particularly, assures a tight metallurgical bond between the base metal sheet as well as the aluminium-silicon coating. Subsequently, the sheet is called aluminized coated steel sheet & has unique properties which are neither of base metal nor aluminium alone. The base metals used are either simply Mild Steel (MS) or alternatively Stainless Steel (SS).
Above all ALIOTA-M is Aluminized Steel Sheet Coated Mild Steel (Type 1)
Moreover, ALIOTA-S is Aluminized Steel Sheet Coated Stainless Steel (Type 409 or 439) (Type 1)
Moreover, the ALIOTA-M is especially used for heat-resisting applications as well as where corrosion resistance & heat are involved at the same time.
For instance, here is a list of base metals that are generally used: (ASTM A463/A 463M-06)
Base Metals Mentioned Below Coated With Al-Si Will Be Designated As ALIOTA-M Aluminized Steel Sheet Coated Type 1
Mild Steel {Commercial Steel (CS Types A, B, C)}, Forming Steel (FS) or Drawable Steel, Deep Drawing Steel (DDS), Extra Deep drawing Steel (EDSS), Structural Steel (SS) {these have many grades & classes}, High Strength-Low Alloy Steel (HSLAS Type A) {these have many grades & classes},
Also, High Strength-Low Alloy Steel (HSLAS Type B) {these have many grades & classes}
The SS Base Metals Coated With Al-Si Will Be Designated As ALIOTA-S (Type 1)
Ferritic Stainless Steel (FSS Type 409) & Ferritic Stainless Steel (FSS Type 439) (Type 1)
COMPARATIVE USES OF ALIOTA-M & ALIOTA-S
Home appliances, Automobile parts,
Steel cans as well as
Oil pipeline cover. (post-plated products)
Automobile exhaust systems,
Building material for interior & exterior,
Fuel cells as well as Solar cell modules.
| Product | Advantages | Uses |
|---|---|---|
| ALIOTA-M | Beautiful surfaces are formed due to suppression of crystal formation of melted aluminium during solidification. Even surface & excellent corrosion resistance created due to sacrificial effect of aluminium Excellent heat & corrosion resistance including paintability | Home appliances Automobile parts Steel cans Oil pipeline cover (post-plated products) |
PROPERTIES & ADVANTAGES OF ALIOTA-M
Resistance
&
Heat Reflectivity
Resistance
Spray Test
(Exhaut Gases)
HEAT RESISTANCE OF ALIOTA-M
ALIOTA-M has excellent heat resistance, for instance, when compared with Zn-coated steel sheet, 55% Al-Zn alloy coated steel as well as cold rolled steel sheet.
For the most part, ALIOTA-M shows neither change in appearance nor discoloration even if heated to long times ate temperatures of 4000C. However, above 4000C, the surface transforms to a layer of Al-Fe alloy which usually creates discoloration, however, heat as well as corrosion resistant properties remain intact upto about 6000C.
Transformation of coated layer on heating is demonstrably depicted below:
DISCOLORATION & HEAT REFLECTIVITY OF ALIOTA-M
Above all, ALIOTA-M has beautiful surface as well as excellent heat reflectivity, therefore used in manufacture of toasters, gas ranges, oil stoves, gas ovens as well as clothes dryer etc.
Comparison of ALIOTA-M with Galvanized Steel (GL), Galvanized Iron (GI) & ZM sheet metals is shown below for Discoloration as well as Heat Reflectivity using parameters: 4000C; 24 hours.
PROCESSABILITY OF ALIOTA-M
ALIOTA-M has better processability as compared to cold-rolled sheets. The mechanical properties of ALIOTA-M are as follows:
PAINTABILITY OF ALIOTA-M
ALIOTA-M can be painted better than galvanized steel sheet by chemical pre-treatment as shown below.
Paints based on the following types can be used: Vinyl Resins, silicone resins, phenolic resin, polyurethane resin & lacquers.
CORROSION RESISTANCE OF ALIOTA-M
Also ALIOTA-M forms a thin layer of oxides & hydroxides in presence of air as well as water. Finally, this makes it resistant to corrosion. In fact, even in acidic solutions it shows excellent corrosion resistance as compared to galvanized steel sheets. Besides, the amount of corrosion is in g/m2/day.
Green: ALIOTA-M Yellow: ALIOTA-M at 600C
Red: Plain Galvanized steel sheet at room temperature
Blue: Plain Galvanized steel sheet at 600C
SALT WATER SPRAY TEST OF ALIOTA-M
ALIOTA-M shows excellent corrosion resistance & is proved by the Salt Water Spray Test data. Al shows higher electrode resistance as compared to Fe. As Fe is cathodized, Al prevents corrosion of Fe & acting as a sacrificial anode.
CORROSION RESISTANCE TEST IN EXHAUST GASES OF ALIOTA-M
ALIOTA-M & stainless steel show similar resistance against corroding effect of exhaust gases. Comparison of corrosion rate is shown below using cold-rolled steel sheet at base of 100% (87µm)
WEATHERABILIY OF ALIOTA-M
ALIOTA-M offers excellent resistance in severely corrosive environments like light & heavy industrial areas as well as urban areas. Outdoor exposure effects on ALIOTA-M as compared to Galvanized steel sheet are as below. Sheet of ALIOTA-M shows no change in weatherability even if it turns brown in external environment.
APPLICATIONS OF ALIOTA-M
TV SHRINK BAND,
GAS RANGE, DRYERS, MICROWAVE OVEN,
STOVES, BOILERS
MOULDS,
BAKING TRAYS, DISPLAY TRAYS, LARGE OVENS
MUFFLERS, CAR EXHAUST, FUEL TANK, RADIANT COVER, HEAT SHIELDS
FOOD, PAINT & LUBRICANT CONTAINERS
OIL-PIPELINE COVER
TV SHRINK BAND, GAS RANGE, DRYERS, MICROWAVE OVEN, STOVES, BOILERS
ALUMINIZED STEEL (ALIOTA-M) (TYPE 1) IN MANUFACTURE OF BAKING OVENS, DRYERS, TRAYS, MOULDS etc.
Aluminized Steel (ALIOTA-M) (Type 1) use is legally necessary material of construction for manufacture baking ovens & dryer’s linings, baking & display trays, moulds.
Galvanized products are not recommended by authorities as they cause damage to the human & animal health. The reason behind this is explained in the next few lines.
During baking processes, food articles are in touch with metal surface directly or indirectly.
When Galvanized products are heated at temperatures required for food making, the zinc layer releases toxic zinc fumes (zinc oxide etc.) along with metallic impurities like Lead, Cadmium, arsenic etc. These accumulate in the food products. This makes the food extremely unsafe for human or animal consumption.
On the other hand aluminized coating consists of 90% Aluminium & 10% Silicon. Tests conducted in Japan & USA have shown that even if these elements enter food & human body, they are harmless & eliminated completely.
ALIOTA-M has heat resistance up to 4270C.
ALIOTA-S has base metal of SS 409 or 439. These have almost double heat & corrosion resistance as compared to ALIOTA-M. ALIOTA-S (Base 409) has heat resistance up to 8430C whereas ALIOTA-S (Base 439) has heat resistance up to 9270C.
Some legal provisions for using Aluminized Steel in making bakery products :
- Food Code 2017, U.S. Public Health Services & US FDA states in Chapter 4, Section 101.15 that :
“Galvanized metal may not be used for utensils or food contact surfaces or equipment that are used in contact with acidic food”.
- FSSAI has issued guidance document for bakery sector. Year 2011. Point 5 for Equipment & Machinery.
“5.2 No vessel, container or any other equipment, the use of which is likely to cause metallic contamination injurious to health shall be employed in the preparation, packing or storage of meat food products. (Copper or brass vessels shall always be heavily lined. No iron or galvanized iron shall come in contact with meat food products)”
- NORDIC Council in Europe has stated:
“Galvanized iron should not be used in contact with liquid or moist food”
- American Galvanizers Association explain the problems with Galvanized products & state that:
“..high temperatures above 2500C accelerate peeling & continued exposure results in the zinc iron alloy layers to crack & separate from steel”.
ADVANTAGES OF USING Aluminized Steel (ALIOTA-M) (Type 1) IN BAKING APPLICATION
- Food Grade:- Aluminized Steel is approved by USFDA & food can be brought in contact with its surfaces directly or indirectly, without harming the food, unlike galvanized products.
- Fast Heating:- The Aluminized steel has high thermal efficiency & reflects 80% of the heat within the chamber, thus saving costs on energy bills. Even if heated at 4500C for long times, the surface still retains its original fine surface lustre.
- Energy Efficiency:- Faster rate of heating & faster cooling of aluminized steel allows improved temperature control as well as reduced energy costs.
- Time saving:– Due to high thermal efficiency of aluminized steel, it retains about 80% of the heat & does not allow heat to radiate out of the chamber. This results in increased production output in lesser time.
As Well As…
- Ease of cleaning:– The smooth & even surface of aluminized steel even after multiple heating cycles is intact due to Aluminium & Silicon layer. This makes the surface easy to clean.
- Light & Easy Handling:– Though the aluminized steel has strength of steel, its light in weight. Thus lower thickness of aluminized steel can be used to replace existing surfaces. Therefore 30% lighter parts can be made including pans or moulds.
- Non-Sticking:- A non-stick surface of aluminized steel allows elimination of oiling the pan in typical bread baking. The release of the dough is excellent.
- Low Oil, Low Fat Content:– Due to the excellent dough release, bread manufacturers would require negligible amounts of oils or fats to be incorporated. Thus low oil, low fat food products can be made which are healthy & retain nutritive values.
- Long lasting:– Long life of aluminized steel is due to its excellent tensile strength & corrosion resistant property. Thus, pans as well as moulds & other parts can be used for long time, saving on capital & running costs.
ALUMINIZED STEEL (TYPE 1) (ALIOTA-M)
FOR AUTOMOBILE APPLICATIONS
AUTOMOBILE EXHAUST SYSTEM
Exhaust systems of an automobile is considered as its “lungs”. It allows air to run through the engine & emit smoke. Fuel efficiency improves with better combustion & this is possible when the temperature of the combustion is high & stable.
Traditional mild steel & CRCA sheets were used and could not control emissions. Due to stringent Bharat Stage VI norms, the automobile manufacturers are required to provide better & efficient exhaust systems, which is complied by aluminized steel Type 1.
Aluminized steel can withstand temperatures of 650-8000C without delamination or scaling. Thus, it is used as coating for exhaust systems. This allows compliance to emission norms for automobiles worldwide.
HEAT SHIELDS
Parts of an automobile required to be protected from the excess heat generated. A moving automobile IC engine generates a very high temperature. The exhaust system (manifold to tailpipe) is the second highest producer of heat. Exhaust systems pass very closely from sensitive parts. To protect these critical parts from heat & prevent over heating of the automobile, aluminized steel is used. It acts as a heat shield & is widely used as heat management system as it is cost effective as well as easy to fit. Aluminized steel retains its original shiny appearance upto 4000C with 80% reflectivity. Heat shields are placed around engine as well as under body parts.
FUEL TANKS
Petrol, diesel & bio-diesel can corrode internal walls of fuel tanks (due to impurities in the fuels). Thus cold rolled & mild steel will gradually chip off. The corrosion process of oxidation of the fuel tank is accelerated especially when fuel levels are low & the residual air occupies most volume of the fuel tank. The rust particles can float in the fuel, react with fuel components & pass into the engine & can settle in critical engine parts. This deteriorates the engine overall performance of the engine & hence automobile. Surface of aluminized steel is strong & is not affected by fuels. It is resistant to almost all petroleum based & synthetic fluids used in automobiles.
FOOD, PAINT & LUBRICANT CONTAINERS
OIL-PIPELINE COVER
PRODUCT SPECIFICATIONS OF ALIOTA-M
MINIMUM COATING WEIGHT (g/m2)
(ON BOTH SIDES) OF ALIOTA-M
DIMENSIONAL TOLERANCES OF ALIOTA-M
CHEMICAL & OILING POST TREATMENT SYMBOLS OF ALIOTA-M
Following table provides factors for conversion between coating weight (mass) & thickness in SI units. (ASTM A463/A 463M-06)
| Coating weight (mass) in g/m2 | Coating thickness in µm |
| 305.15 | 101.09 |
| 1.0 | 0.33128 |
| 76.672 | 25.4 |
| 3.0186 | 1.0 |
Estimation of coating thickness based on coat weight (mass) & is as in following table. (ASTM A463/A 463M-06)
| Coating designation | Minimum Requirement (SI Units) ————————————- Triple-Spot Test, Total Both Sides (g/m2) | Minimum Requirement (SI Units) ————————————- Single-Spot Test, Total Both Sides (g/m2) |
| T1M 40 | 40 | 30 |
| T1M 75 | 75 | 60 |
| T1M 120 | 120 | 90 |
| T1M 300 | 300 | 270 |
| T2M LC | No minimum* | No minimum* |
| T2M 200 | 200 | 180 |
| T2M 300 | 300 | 270 |
Coating designation number is the term by which the product is specified. Due to many variables & conditions that are characteristic of continuous hot-dip coating process, the weight (mass) of coating is not always evenly divided between the two surfaces of a sheet, nor the coating is evenly distributed from edge to edge. Generally, not less than 40% of the single-spot test limit will be found on either surface.
* No minimum – Means that there are no established minimum requirements for triple- or single-spot tests, but aluminium coating must be present.
Aluminized Steel Sheet Coated Stainless Steel (Type 409 or 439) ALIOTA-S
FEATURES
RESISTANCE
SPECIFICATIONS
ALIOTA-S PRODUCT FEATURES
| Product | Advantages | Uses |
|---|---|---|
| ALIOTA-S | Beautiful, decorative, even surface & corrosion resistant due to sacrificial effect of Al Excellent corrosion resistance shown in salty & condensed waters Excellent red rust resistance up to 4720C Outstanding resistance to oxidation up to 8430C due to a coating layer | Building material for interior & exterior, Fuel cells, Solar cell modules, Automobile exhaust systems. |
Layers of ALIOTA-S
PROCESSABILITY of ALIOTA-S
ALIOTA-S has very good moulding capability & weldability.
CORROSION RESISTANCE of ALIOTA-S
ALIOTA-S exhibits excellent resistance to corrosion.
USES of ALIOTA-S
PRODUCT SPECIFICATIONS of ALIOTA-S
Aluminized Steel Sheet Coated
(Type 2 – Hot Dip) ALIOTA-AL
Aluminized Steel Sheet Coated (Type 2 – Hot Dip) ALIOTA-AL is steel coated on both sides with commercially pure Aluminium & is called as Aluminized Steel Sheet Type 2; ALIOTA-AL. Thus, the attractive feature of the Type 2 aluminized steel sheet is that they economically combine the surface characteristics of aluminium accompanied by the strength & rigidity of stainless steel.
Coating Type 2 is intended principally for use in applications requiring corrosion resistance & is available only as a coating on Commercial Steel, Forming Steel, Structural Steel as well as High Strength-Low Alloy Steel.
The process of making aluminized steel sheet Type 2 is done by dipping appropriate steel in hot molted pure Aluminium (99.9%) & thus called Aluminized Steel Sheet Coated (Type 2 – Hot Dip) ALIOTA-AL.
The coating of aluminium comprises of two layers viz.
1. a pure aluminium layer &
2. an underlying hard aluminium-iron (Al-Fe) intermetallic alloy layer.
The total weight of Aluminium coating on Type 2 Aluminized Steel is about twice that on Type 1, or approximately 1.0 oz/ft2, (305.152 g/m2) which is equivalent to 0.002 in. (2 mils) thickness per side.
USES of Aluminized Steel Sheet Coated (Type 2 – Hot Dip) AILOTA-AL
Aluminized Steel Sheet Type 2, ALIOTA-AL, has excellent atmospheric corrosion resistance as well as fire resistance. For this reason, it is principally intended to be used for these applications. For instance, Aluminized Steel Sheet Type 2, ALIOTA-AL, is widely used in refineries, chemical as well as petrochemical industries.
Furthermore, ALIOTA-AL, due to its excellent atmospheric corrosion resistance it is used as an excellent weather proofing material. This undoubtedly makes it the best option for insulations in coastal areas, offshore & on-shore oil & gas industrial installations for providing metallic jacketing.
It is widely used in Europe, Middle East as well as USA. Aluminized Steel Sheet Type 2, ALIOTA-AL, can be used for roofing & drainage systems, as well as insulation cladding (hot and cold), freshwater drainage, storm water detention systems, corrugated roofing & siding, drying ovens, air-conditioner condenser housings as well as grain bins for storing dry grains for human & animal consumption.
ALIOTA-AL offers good hot & cold insulation along with sound insulation.
Aluminized Steel Sheet Coated (Type 2 – Hot Dip) ALIOTA-AL ADVANTAGES
COATING WEIGHT & THICKNESS AS PER ASTM A 463/A 463M – 06
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