aluminised coils specification

8/15/2019 Aluminised Coils Specification

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1 Nisshin Steel Quality Products

Foreword ……………………………2

Features ……………………………3

Production Processes ……………4

Examples of Uses …………………5

Specifications ………………………9

Properties …………………………13

Steel Pipe …………………………23

Standard Specification for

Steel Sheet, Cold-Rolled,

Aluminum-Coated Type 1 ………25

Contents


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2Nisshin Steel Quality Products

Nisshin Steel Co., Ltd. is Japan's sixth largest producer of iron and steel, with an annual crude

steel production capacity in excess of three million tons. The Company, a member of the

International Iron and Steel Institute, has extensive experience in the production and marketing of ordinary, specialty, and stainless steel.

Nisshin is particularly strong in coated and stainless steel and has also established a firm

position in the ordinary and specialty steel markets. The Company has maintained the highest

technological standards, developing innovative technology and marketing superior quality steel

products for industry and the home.

Nisshin Steel Co., Ltd., well-known for Moonstar brand galvanized sheet, galvannealed sheet, and

spangle-free galvanized sheet, proudly introduces Alstar, a new type of aluminized steel sheet

and coil that has more versatility than conventional aluminized steel sheet. Aluminized steel

sheet had been produced by the roll-wiping method in Japan since 1962, but the gas-wiping

method developed by Nisshin Steel in 1968 has improved the uniformity and appearance of

aluminum-coated steel sheet. This new process has also widened the scope of aluminized steel

sheet applications. Alstar metallurgically combines the strength of steel with the advantages

of aluminum, and is extensively used where heat resistance is involved. Specific uses are in

heat-resistant parts and products for automobiles, burners, and home appliances. Alstar now

enjoys the largest share of the domestic aluminized steel sheet market.

Foreword

Aerial view of the Sakai Works


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Features

1

Uniform aluminum coating and free control of aluminum thickness.

2

Thin aluminum coating（40g/m2 on both sides）. This means better weld-ability and formability and hence

better productivity.

3

Even surface finish and silvery white appearance make Alstar useful in applications where a fine finish is

important.

4

Nisshin's aluminizing line is in constant operation so Alstar is available where and when it is needed.

Alstar features heat resistance, corrosion resistance at high temperature, heat reflectivity, attractive appearance, nonpollutingproperties, and other characteristics that are unique to aluminized steel sheet. The gas-wiping method developed by Nisshin Steel

has been applied to Alstar production to offer the following additional features.


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1.Annealing process

Nonannealed cold-rolled steel strip is annealed and the oxide film formed on the surface is reduced in the furnace.

2.Coating process

After the strip is reduced to a clean sur face, it is passed through the aluminum coating bath. The weight of aluminum coating on

the strip is regulated by the gas-wiping method.

3.Posttreatment process

The aluminum-coated strip is then treated by chromate solution to make it further corrosion resistant. After thorough drying, the

sheet is wound back into a coil.

4.Skin passing process

The aluminum-coated strip is skin passed to make it suitable for specific uses, where such factors as surface conditions and age

hardening are involved.

Production Processes

8.9.

10.11.12.13.14.

Cooling towerSkin pass millTension levellerPosttreatment tankShearRecoilerSkin pass mill

1.2.3.4.5.6.7.

UncoilerShearWelderLooperOxidizing, reducing, and annealing furnaceAluminum coating bathGas-wiping

14

Coil

Coil

Cut-length

Cut-length

Cold RolledSteel Coils

Oxidizing, Reducing,and Annealing Furnace Aluminizing

Cooling Posttreatment AluminumCoated Steel

1

23

4

1

2 3

4

5

6

7

8

109 12

11

13

Figure 1 : Production Processes


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Examples of Uses

Kerosene heater Kerosene heater Kerosene heater

Large-sized kerosene heater Large-sized kerosene heater Large-sized kerosene heater

Kerosene heater Water heater


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■ Examples of Uses ■

Kitchen utensils Kitchen utensils Kitchen utensils

Oven, toaster Gas oven Two-burner gas stove

Gas range Smokestack


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Muffler and converter

Muffler

Muffler

Muffler Muffler

Heat insulator Reactor part


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Manifold cover Manifold cover Manifold cover

Charcoal stove Charcoal stove Chimney

Barbecue grill Kerosene stove Fireplace


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Specifications

1.Types of Alstar

(1) Alstar is available in the following types which vary with the uses and the means of processing.

2.Masses of Aluminum Coating

Note : Minimum masses on both sides by the triple-spot test are based on the ASTM standards.

Alstar is available in various masses of aluminum coating as shown in the following table.

Table 1

Type Symbol ASTM（A463） Surface Finish

Commercial Quality C CQ Dull

Drawing Quality D DQ Dull

Deep Drawing Quality E DQSK Dull

(2) Indication of product's standard is as follows:

MSA C（D,E） D △△ ×××

Posttreatment

Productsymbol

Quality

Surface finish（Dull）

(3) There are several kinds of posttreatment for various uses. These include ordinary chromate and oiling

and oiling nonchromate.

Table 3

T1-25 T1-40 MSA-40 MSA-60 MSA-80 MSA-100 MSA-120

ASTM（A463） Nisshin StandardSymbolItem

Minimum mass on bothsides（triple-spot test）

g/m2 （80）（120） 40 60 80 100 120

ox/ft2 0.25 0.40 （0.13）（0.20）（0.25）（0.33）（0.40）

Mass ofaluminum coating

Posttreatment Symbol

Chromate and oiling N0

Oiling nonchromate M0

Table 2


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■ Specifications ■

3.Mechanical Properties

Tension and bend tests of Alstar produce the following values.

(1) Tensile strength and elongation

Table 4

0.4 to 0.6excl.

0.6 to 0.8excl.

0.8 to 1.0excl.

1.0 to 1.6excl.

1.6 to 2.3incl.

Elongation（％）, Thickness（mm）TensileStrength

（N/mm2）Type

Commercial Quality （270）（23）（26）（28）（30）（31）

Drawing Quality （270） 30 32 33 34 35

Deep Drawing Quality （270） 34 36 37 38 39

Notes : 1. The No.5 test specimen in JIS Z2201 is used for the tension test which is conducted in conformity with JIS Z2241.2. Values in parentheses for commercial quality sheet are for reference only.

(2) Bend test

A specimen taken from the aluminized steel sheet in the direction parallel to its rolling is bent through 180°over a radius of 0.5t at

right angles to the rolling direction. The outside of the bend shall be free from flaking of the coating, and cracking and breaking in

the base metal. This does not apply to those parts of the specimen which are within 7mm of both ends.

Note : The bend test specified in the ASTM standards may be conducted on the product if requested.

4.Available Dimensions

Alstar is available in the dimensions shown in the chart below.

600

700

800

900

1,000

1,100

1,200

W i d t h （ m m ）

0.3 0.4 0.5 0.6 0.7 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0 2.1 2.2 2.3

Thickness（mm）

under 600 or over

914

700 orover

1,219 or under

1,000

1,150 or under

1,070 or under

Figure 2


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5.Dimensional Tolerances

Dimensional tolerances are as shown below.

Alstar can also be manufactured to the dimensional tolerances of the ASTM A463 standards.

(1) Thickness tolerances

Table 5

Under 1,000 1,000 or Over

WidthThickness

0.27 to 0.40 excl. ±0.06 ±0.06

0.40 to 0.60 excl. ±0.07 ±0.07

0.60 to 0.80 excl. ±0.09 ±0.09

0.80 to 1.00 excl. ±0.10 ±0.11

1.00 to 1.25 excl. ±0.11 ±0.12

1.25 to 1.60 excl. ±0.13 ±0.14

1.60 to 2.00 excl. ±0.14 ±0.15

2.00 to 2.30 ±0.16 ±0.17

Notes : 1.The thicknesses shown in the above table indicate sheet thicknesses plusthe thicknesses corresponding to aluminum coating masses.

2.Thickness is measured at any point across the width not less than 50mmfrom a side edge.

(2) Length and width tolerances

Table 6

（mm）

（mm）（mm）Table 7Item Tolerance

Length ＋12, −0

Edge Tolerance Remarks

Mill edge ＋10, −0 ─

Slit edge ±0.5 Applies to widths less than 600mmNote : The length tolerances shown in

Table 6 do not apply to coilproducts.

(3) Flatness tolerances

The flatness tolerance shall be less than the figures shown in Table 8.

Table 8

Panel Quality 5 5 3 3

Commercial Quality 8 8 5 5

Press Forming Quality 11 8 8 5

Thickness

Long Edge（maximum deviation from a horizontal flat surface）

Center Buckle（maximum deviation from a horizontal flat surface）

Under 0.5 0.5 or over Under 0.5 0.5 or over

Type

（mm）

Notes : 1. Flatness tolerances apply to cut length sheets.2. Consult us about tolerances for panel quality and commercial quality sheet when ordering.


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（mm）Table 9

(4) Camber tolerancesCamber is the greatest deviation of a side edge from a straight line. Camber measurement is taken as shown in Figure 3 for cut-

lengths and Figure 4 for coils.

The camber tolerance for sheet with a width of 50mm or over and less than 200mm, and with a length of 2,000mm or over and

less than 3,048mm, is measured as shown in Figure 4.

Figure 3 Figure 4

Length

2,000mm

Width

Width

Camber

Camber

The camber tolerance values apply to normal parts of coils and cut-lengths. Their camber tolerances must be less than the values

shown below.

Length over 2,000 to 3,658 excl.Length under 2,000CoilWidth

Cut-length

50 to 60 excl. ─ ─ 8 per 2,000

60 to 200 excl. ─ ─ 4 per 2,000

200 to 600 excl. ─ ─ 4 per 2,000

600 or more 2 4 2 per 2,000


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Properties

1.Heat Resistance

Alstar has far greater heat resistance than galvanized and cold-rolled steel sheet and thus keeps its original fine surface luster

even when used for long periods at temperatures below 450℃＊. If it is exposed to temperatures above 450℃, however, the iron

and aluminum become alloyed through mutual diffusion and the surface gradually turns from gray to a darker color. Since this

alloy layer has a high fusing point, it will not melt even if exposed to a temperature above the fusing point of aluminum.

In addition, an oxide layer is produced on the coated surface by high temperature, which suppresses scale formation so that the

sheet will not quickly become oxidized and worn until the diffusion progresses to the point where the aluminum coating becomes

unable to control scale formation (approximately 600℃). The heat-resistant characteristics of Alstar are shown below.

＊We have high grade Alstar which can be used at approximately 500℃.

(1) Heating behavior of aluminized steel sheet

………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………………

………………………………………………………………………………………………………………………………

×

×

× ×

× ×

×

× ×

××

×

× ×

×

×

×

××

×

××

Fe (before heating) Fe (after heating) Fe (after more heating)

Alloy layer

Alloy layerAlloy layer

Heating HeatingOxidized layer caused byhigh temperature

Al Al

Figure 5


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■ Properties ■

(2)Microscopic photographs of cross sections of MSA-40 kept at 500℃ for 100 hours and 1,000 hours,respectively

(3) Heat resistance comparison of aluminized steel, stainless steel, and cold-rolled steel sheet

Figure 6 shows a mass increase comparison of Alstar with 18-8 stainless steel and cold-rolled steel sheet after high-temperature

oxidation. Alstar shows good heat resistance（at 500℃ to 600℃）similar to stainless steel sheet, and is over 20 times more heat-

resistant than cold-rolled steel sheet.

Before heating After 100 hours of heating at 500℃ After 1,000 hours of heating at 500℃

Cross sectional structures of Alstar before and after heating to 500℃（Drawing Quality）

Figure 6

C o

l d - r o

l l e

d s

t e e

l s

h e e t ( 5

0 0 ℃

)

C o l d

- r o l l e

d s t e

e l s h

e e t ( 4

0 0 ℃ )

A l s t a r

( 6 0 0 ℃

)

A l s ta r ( 5 0 0 ℃ )

18-8 s tainless s teel shee t (50

0 ℃ )

1 8 - 8 s t a

i n l e s s s t

e e l s h e e

t ( 6 0 0 ℃ )

0 4 8 12 16 20 24 28 32 36 40 44 48 52Oxidation Time (hours)

Heat resistance comparision of Alstar, stainless steel, and cold-rolled steel sheet

10

20

30

40

50

60

O x y g e n P i c k u p ( m g / d m 2 )


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■ Properties ■

(4) Mass increase/decrease by oxidation through heating and cooling cyclesFigures 7 and 8 show a mass increase and decrease comparison of Alstar's different aluminum coating masses with other

materials after oxidation, and after being exposed to 10 cycles of heating to 600℃ and 750℃ and then cooled. It is clear from the

diagrams that Alstar possesses greater oxidation resistance than cold-rolled and galvanized sheet even at temperatures of 600℃

and 750℃, and can be satisfactorily used below 600℃ without any increase in oxidation.

Figure 7 : Heating and Cooling Cycle

750℃

600℃

Hours

T e m p

e r a t u r e ( ℃ )

200

400

600

800

0 4 8 12 16 20 24

Figure 8 : Oxidation Increase/Decrease by 600℃ and 750℃ Heating/Cooling Cycles

600℃ 750℃

TI-25CQ (MSA-80)

TI-25CQ

SUS430

SUS430

SPC (Cold-rolled steel sheet)

SPC

Galvanized sheetGalvannealed sheet

Galvanized sheet

Galvannealed sheet

2 5 10

Number of Cycles

O x i d a t i o n I n c r e a s e / D e c r e a s e ( g / m 2 )

10

-10

-20

-30

-50

-70

-100

-200

-300

-500

30

50

100


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■ Properties ■

2.Heat Reflectivity

Alstar possesses not only a finely finished surface, but also excellent heat reflectivity. Because Alstar has a very high thermal

efficiency, it is useful for making highly effective heat reflecting plates for toasters, ovens, driers, and other consumer durables.

For reference, here is a surface luster comparison of Alstar with other steel sheets.

Table 10

Type Surface Finish Surface Luster （％） Surface Roughness（μ）

Alstar Dull 15 Hmax 8 to 9

Stainless steel sheet 2B 15 Hmax 1.2

Stainless steel sheet BA 60 Hmax 0

Cold-rolled steel sheet coated with silver paint Dull 6 Hmax 8

Notes : 1. Surface luster measured（with gloss meter Model GM-3）in conformity with JIS 8741.2. 1/10 light filter Gs（60）is used.

3.Corrosion Resistance

Aluminum has a more active ionization trend than Mn, Mo, Cr, W, Cd, Fe, and Zn and is more easily corroded. Because aluminum

has the characteristic of easily forming a fine oxide film when exposed to air, or a hydroxide film when exposed to water, a

corrosion resistance effect by galvanic action, such as is exhibited in galvanized sheet, cannot be expected.

Because aluminum's oxide film is stable, the aluminum coated surface of Alstar is considerably more corrosion-resistant than that

of galvanized sheet except in certain environments. The corrosion resistance of Alstar under various conditions is shown in the

following pages.

(1) Corrosion resistance in various pH solutions

Unlike zinc, aluminum is relatively resistant to weak acids but not to alkalis. The corrosion resistance of aluminum in pH solutions

is as shown in Figure 9.

Figure 9

Corrosion resistancein pH Solutions

10

20

30

40

50

60

70

80

90

100

110

120

130

pHAlkalinity

Alstar (room temperature)

Alstar (60℃)

Galvanized sheet (room temperature)

Galvanized sheet (60℃)

Acidity

1 2 3 4 5 6 7 8 9 10 11 12 13 14

C o r

r o s i o n ( g / m 2 / d a y )

Source : Metal Surface Technology Vol.7, No.7.


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Pretest Treatment 24 Hours 72 Hours 240 Hours 360 Hours


■ Properties ■

(2) Saltwater spray test Aluminum shows a lower potential than iron in saltwater and, in an Fe-Al electrolyte cell with an aluminum anode and steel

cathode, the aluminum, as a sacrificial anode, protects the steel from corrosion.

Table 11 shows the results of a continuous saltwater spray test on Alstar.

TI-25DQ Alstar （MSA-80 Drawing Quality）

Room temperature250℃×24 hours

Other manufacturers'electro-galvanized sheet

Room temperature250℃×24 hours

Red rust10%

Red rust60%

Red rust60%

Red rust90%

Red rust100%

Red rustin 384hours

Table 11

Chemicals Alstar Galvanized Sheet

Light oil E G

Palm oil E E

Machine oil E G

Boiled oil E E

Spindle oil E E

Glycerine E E

Formalin F G

Alcohol G G

Acetone E E

Carbon tetrachloride E E

Coal tar E E

Printing ink E E

Phthalide E G

Aqueous ammonia P F

5％ caustic soda P F

5％ nitric acid F P

5％ sulfuric acid P P

5％ acetic acid F P

Table 12

Note : Evaluation scale : E ＝ ExcellentG＝GoodF ＝Fair P＝Poor

(3) Atmospheric exposure test

Aluminized steel sheet develops oxides on the aluminum surfaces when exposed to air, but the stable oxides protect the

aluminum layer and prevent discoloring of the surfaces. Exposed steel parts, such as cut sections and pinholes, however,

develop red rust.

If Cl− is present in a wet state, as in seawater, for example, the oxidized aluminum film is destroyed and starts a sacrificial

corrosion protection action.

Because aluminum has a lower electrolytic solubility than zinc, aluminized steel sheet has greater corrosion resistance in, for

example, coastal areas.［If the coating mass is the same, the ratio is said to be five or six（aluminum）to approximately one（zinc）］.

(4) Resistance to chemicals

Alstar has less resistance to alkaline industrial chemicals, but greater resistance to acid industrial chemicals than galvanized

sheet.


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■ Properties ■

Notes : 1. Test method:Chrysler's spec. 461H-83.

2. Test outline:（a）A mixed solution of 180°F（82℃）0.01N hydrobromic acid and 0.05N sulfuric acid was used for the test.（b）Cold muffler conditions. After immersing the test pieces in the test solution for five seconds, they were kept

over the solution surface for one hour. This was repeated 20 times（20 hours）.（c）Hot muffler conditions. Then the test pieces were heated in a furnace at 1,000°F（538℃）for two hours.（d）Steps（b）and（c）were repeated for 240 hours.

3. Test results judgment:（a）Amounts of decrease before and after the test were measured.（b）Decreased amounts were converted into decrease in sheet thickness.（c）Converted sheet thickness decrease must be less than 0.002 in.（0.051mm）.

4. Test results:

The test simulated a running Chrysler car. Sheet thickness decreased in inverse proportion to aluminum coatingmass Alstar passed this test.

(5) Resistance to automobile exhaust gas Alstar demonstrates good corrosion resistance in auto exhaust part uses. The results of an exhaust gas test by the Chrysler

Corporation of the U.S. are shown in Table 13.

Decrease in Mass（g）Decrease in Thickness

（converted from the mass decrease）

R in. mm−x

TI-25DQ Alstar （MSA-80 Drawing Quality） 0.260 0.011 0.0007 0.018

TI-25CQ Alstar （MSA-80 Commercial Quality） 0.191 0.035 0.0005 0.013

Table 13


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■ Properties ■

4.Weldability

Alstar differs slightly from cold-rolled steel sheet under welding conditions. Since aluminum is soft, flexible and has good electric

conductivity, aluminized steel sheet generates less heat at welds than cold-rolled steel sheet. Alstar does not require as high a

current as galvanized sheet due to the aluminum coating which has a higher melting point, less fluidity, and less spread of molten

area.

Conditions for spot, seam, and other kinds of welding are given below.

(1) Spot welding

Table 14 shows an example of spot welding conditions for Alstar.

Table 14 : MSA-40 Commercial Quality

Electrode Force（N）

Time（）

Current（A）

Shear Strength（N）

Thickness（mm）

Electrode FaceD R

0.6 16 25 1,800 9 8,700 1,900

0.8 16 25 2,000 10 9,500 2,500

1.0 16 50 2,500 11 10,500 4,100

1.2 16 50 3,100 12 12,000 5,900

1.4 16 50 3,900 14 13,000 7,800

2.0 16 50 5,400 18 14,000 12,700

Note : With a low welding current, sufficient strength cannot be expected. With an overcurrent, the aluminum coating deteriorates morethan necessary and dark gray stripes appear around welds. Suitable welding conditions between these extremes must beselected. The scope of correct welding conditions narrows in inverse proportion to sheet thickness. Chromium copper alloy electrode tips may be used and, as with galvanized sheet, aluminum pickup poses a problem. Good water-cooling tominimize pickup and periodic dressing are necessary. As in the case of welding mild steel, radius-face tips or truncated cone

face（120°to 140°）tips are recommended.

Figure 10 shows the results of a spot welding test on MSA-40 and MSA-80, which differ in aluminum coating mass. While MSA-40

shows a sharp drop in shear strength after approximately 900 spot welds, MSA-80 develops the same phenomenon after

approximately 600 spot welds. proximately 600 spot welds.

Figure 10 : Electrode Life in Spot Welding Alstar

1,000

0

2,000

2,900

3,900

4,900

5,900

6,900

7,800

8,800

9,800

1,000

0

2,000

2,900

3,900

4,900

5,900

6,900

7,800

8,800

9,800

S h e a r S t r e n g t h ( N )

0

2

4

6

8

0

2

4

6

8

D i a m e t e r o f E l e

c t r o d e

F o r c e M a r k ( m

m φ )

0 100 200 300 400 500 600 700 800 900 1,000

Number of Welds

Shear strength

Diameter of electrode force mark

MSA-80 1.0mm

MSA-40 1.0mm(Commercial Quality)

Notes : Welding conditions: Electrode force: 2,000NWelding current: 11,200A to 14,500A. Welding time: 7 .


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■ Properties ■

(2) Seam weldingTable 15 shows an example of seam welding conditions for Alstar.

Table 15

Thickness（mm）

Electrode Width（mm）

Electrode Force（N）

Welding Speed（cm/min.）

Current（A）On Off

Time

0.8 7 3,900 3 2 150 17,000 to 19,000

0.95 7 4,200 3 3 150 16,000 to 18,000

0.95 7 4,200 3 2 230 18,000 to 21,000

1.2 7 4,400 3 2 150 18,000 to 20,000

1.2 7 4,900 4 2 230 18,000 to 21,000

(3) Gas welding and arc welding

Gas welding is difficult and requires a certain amount of skill. It is recommended that a two-stage regulator be used for assuring

the correct gas flow. Use killed steel wire for satisfactory results. Flux for stainless steel is suitable for the purpose.

Shielded arc electrodes may be used for arc welding, but care must be taken in selecting the right kind of electrode. Ilmenite or

high titanium type electrodes produce blow holes. For the best results, select a low hydrogen type electrode. If a corrosion-

resistant characteristic is required, use stainless steel. When oxidation of welds must be reduced to a minimum, argon arc

welding（TIG）produces good results.

Tables 16 and 17 show examples of arc welding and TIG welding.

Table 16 : Example of Arc Welding

Thickness（mm）

Welding Rod WeldabilityJIS Rating of

X-ray ResultsTensile Strength

（N/mm2）Elongation

（％）Rupture PointSheet Welded

T1-25CQMSA-80CommercialQuality

SPCC

1.2 D4313 Poor 6 387 24.2 Weld

1.2 D4316 Good 1 368 28.9 Base metal

1.2 Excellent 1 379 28.0 Base metal

1.2 D4316 Good 1 327 28.4 Base metal

D30816Stainless steel

Table 17:Example of TIG Welding

Sheet WeldedThickness（mm）

Welding RodWeldingCurrent

WeldabilityJIS Rating of

X-ray ResultsTensile Strength


（％）Rupture Point

T1-25CQMSA-80

CommercialQuality

1.6

GA（gas-welding rodfor mild steel）

DM-2（gas-welding rodfor Si-Mn alloy）

D308（18-8 stainlesssteel rod）

GA

DM-2

D308

DC Poor 4 400 24 Base metal

DC Good 1 380 28 Base metal

DC Excellent 1 398 26 Base metal

AC Poor 2 380 24 Base metal

AC Good 1 389 28 Base metal

AC Good 1 393 24 Base metal

Notes : 1. Argon gas flow rate: 6 l/min2. AC power source: Pure tungsten electrode 3.2φ3. DC power source: Thorium-containing tungsten electrode 3.2φ

(4) Weld repairs

Welds and damaged aluminum coating can be repaired with silver paint or with molten aluminum spray.


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■ Properties ■

5.Formability

Aluminized steel sheet is generally said to have poor formability as compared with cold-rolled and galvanized sheet because it

has a hard alloy layer of steel and aluminum between the base metal and the aluminum coating. However, Alstar offers good

formability comparable to other steel sheets if proper consideration is taken of its characteristics.

(1) Deep drawing

（a）Die and punch radii and clearances must be used where appropriate to prevent

aluminum exfoliation on the parts pressed by deep drawing.

（b）Die radii 6t to 10t and punch radii similar to those used in cold-rolled steel

sheet drawing may be used, although the figures vary with forms to be drawn.

A clearance of about 1.2t is appropriate.

（c）If redrawing is necessary , a drawing ratio of more than 60 percent is

recommended per drawing.

A sample（0.55mm）formed by a 6

ton cushion pressure

(2) Burring

（a）The hole enlarging ratio of Alstar ranges from 0.3 to approximately 0.8, depending on the forming process

（This compares with 0.5 to 0.9 for cold-rolled steel sheet）.

（b）The hole enlarging operation can be improved by observing the following instructions:・Direct burrs inward.

・Use an enlarging punch that has a greater taper.

・Add embossing during the enlarging process.

An example of hole enlarging and drawing is shown below.

Drawn sample（1.2mm）auto muffler end plate


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■ Properties ■

6.Paintability

Alstar requires chemical treatment before painting to assure good adhesion of paint.

(1) Pretreatment

Degreasing alone is insufficient to assure good adhesion. For the best results, the following process is recommended.

・Take note of pH.

・Use trichloroethylene or other

neutral chemicals.

(2) Paint

The same paint as used in painting other steel sheets may be used for Alstar if it is pretreated. To obtain satisfactory corrosion

resistance, adhesion and other qualities, the right paint for the intended use should be selected.

The following are examples of paint that may be used for Alstar:

・Vinyl resin paint.

・Silicon resin paint.

・Polyurethane resin paint.

・Phenol resin paint.

・Alkyd resin paint.

・Lacquer.

Degreasing Chemical Treatment Painting

7.Food Sanitation

The aluminum coating consists of aluminum, silicon and iron. Tests conducted by prefectural governments in Japan, under the

Food Sanitation Law, have proved that even if these elements enter the human body, they are harmless and will be completely

discharged. An example of analysis of the aluminum coating of a utensil made from Alstar is shown below.

Aluminum（77.2％）

Silicon（7.4％）

Iron（15.4％）

Caution : Chromate treatment for preventing white rust on the aluminum surface is harmful, and therefore only oiling without

chromate is recommended.

・Chromate treatment or phosphate

treatment is recommended.


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Steel Pipe

Alstar steel pipe is made from Alstar steel sheet by high-frequency welding. It has all the features of Alstar steel sheet. Beinghighly heat resistant, Alstar steel pipe is used in large quantities in the automobile industry as exhaust pipe.

1.Features

1）Evenly coated with aluminum

2）Thin aluminized Alstar steel pipe is available.

3）Highly heat resistant

4）High workability

5）Excellent weldability

6）Smooth, aesthetically pleasing surface

2.Quality

(1) Appearance

Alstar steel pipe has an aesthetically pleasing surface peculiar to aluminum. Bare metal is exposed on the outer surface of welded

joints in an area 3mm to 5mm wide after bead cutting but can be aluminized to order. Slight beads are built on the inner surface

of welded joints but can be cut away as necessary.

(2) Workability

Alstar steel pipe has the same workability as the JIS G3445 machine-structure carbon steel pipe STKM-11A.

(3) Effect of pipe production on aluminum coats

Pipe production has little if any detrimental effect on the aluminum coating of Alstar steel sheet.

(4) Corrosion resistance of welds

Since bare metal is exposed at the welds after bead cutting, rust forms at an early stage of the salt spray test. Alstar steel pipe is

generally used unfinished after bead cutting as heat-resistant parts but has not posed any problem in such applications.

3.Mechanical properties

Typical mechanical properties of Alstar steel pipe made of MS-40（drawn material）are shown in Table 18.


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■ Steel Pipe ■

Table 18

Number ofTest Cycles

Flattening Test（2/3D）

Flaring TestBending Test

（3D）Test Piece Size Tensile Strength


（％）

Tensile Test

35.0φ×1.2mm1 366 45 Good 1.39 ─

2 ─ ─ Good 1.38 ─

38.1φ×1.2mm1 361 46 Good 1.39 Creases occurred

2 ─ ─ Good 1.30 ─

42.7φ×1.2mm1 362 45 Good 1.37 ─

2 ─ ─ Good 1.40 ─

Notes : 1. Tensile test: JIS No.11 test piece2. Flattening test: 2/3D, the welded portion is placed at right angles to the direction of compression.3. Flaring test: Using a 60°cone punch, pipe end openings are widened until cracks occur.

4. Flaring ratio: Diameter after flaring/initial diameter

Thickness（mm）

Outside Diameter or Side Length

（mm）

Length（mm）

Round Pipe 0.6∼2.3 12.7∼63.5 3,500∼6,100

Sharp EdgeSquare 0.8∼2.0 16×16∼25×25

Rectangle 0.8∼2.3 22×10∼60×303,500∼6,000Square Pipe

Rounded EdgeSquare 0.8∼2.3 25×25∼50×50

Rectangle 0.8∼2.3 25×12∼60×30

Table 19: Available Dimensions of Alstar Steel Pipe

Note : Dimensions other than those listed above can be negotiated.


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Extracts from ASTM A 463-83

Standard Specification for

Steel Sheet, Cold-Rolled, Aluminum-Coated Type 1

1. Scope1.1 This specification covers aluminum-coated steel sheet

Type 1 in coils and cut lengths coated with an aluminum-

silicon alloy by the hot-dip process. The aluminum-silicon

alloy for coating has 5％ to 11％ silicon added to promote

better adherence. It is intended principally for heat-resisting

applications and also for uses where corrosion resistance

and heat are involved. The weight of coating expressed as

the total coating on both sides may be specified in

accordance with Table 1. Aluminum-coated steel sheet is

available in the following quality designations: Commercial

Quality, Drawing Quality, Drawing Quality Special Killed, and

Structural（Physical）Quality.

Notes : 1. values stated in U.S. customary units are to beregarded as the standard.

3. Description of Terms

3.1 Quality Designations:

3.1.1 Commercial Quality -This material is intended for

parts where bending, moderate forming, or moderate

drawing may be involved.

3.1.2 Drawing Quality -This material is intended for

fabricating identified parts where drawing or severe forming

may be involved. Care should be taken to ensure that thecoating designation is compatible with the end use.

3.1.3 Drawing Quality Special Killed -This material is

intended for fabricating identified parts where particularly

severe drawing or forming may be involved or essential

freedom from aging is required. Care should be taken to

ensure that the coating designation is compatible with the

end use.

3.1.4 Structural （Physical）Quality -This material is produced

when mechanical properties are specified or required. Such

properties or values include those indicated by tension,

hardness, or other commonly accepted mechanical tests.

Care should be taken to ensure that the coating designation

is compatible with the end use.

4. General Requirements for Delivery

4.2 Aluminum-coated steel sheet shall be ordered to a

decimal thickness for both coils and cut lengths. The

thickness is the total of the base metal and the coating.

8. Mechanical Requirements8.1 Base Meta l Bend Test -Commerci al quali ty（CQ）,

drawing qua lity（DQ）, or drawing qual ity spec ial kil led

（DQSK） shall be capable of being bent at room temperature

in any direction through 180 deg. flat on itself without

fracturing of the base metal. Bend test requirements for

structural（physical）quality are subject to negotiation.

9. Coating Tests

9.1 Weight of Coating:

9.1.1 The weight of coating shall conform to the re-

quirements for triple- and single-spot minimum checksprescribed in Table 1 for the specific coating designation.

The weight of coating is the total amount on both sides of a

sheet, expressed in ounces per square foot（or grams per

square meter）of sheet.

9.2 Coating Bend Test:

9.2.1 For all qualities other than structural（physical）

quality, the bend test specimens of coated metal shall be

capable of being bent through 180 deg. over a diameter

equal to twice the thickness in any direction without flaking

of the coating on the outside of the bend only. A hand-

operated vise with smooth jaws should be used for makingthe tests, unless excessive thickness makes this impractical.

Any other method used to make the bend test should not

involve impact. Flaking of coating within 1/4 in.（6.4mm）of

the edge of the bend specimen shall not be cause for

rejection. Bend tests are not required of coils or cut lengths

ordered extra-smooth or stretcher-leveled.


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in. mm in. mm


This Standard is issued under the fixed designation A 463; the number immediately

following the designation indicates the year of original adoption or, in the case of revision,

the year of last revision. A number in parentheses indicates the year of last reapproval.

TABLE 1 Coating Designation and Minimum Coating Test Limits for Aluminum-Coated Steel Sheet Type1Note : The weight of coating in ounces per square foot and coating thickness in inches refer to the total coating on both surfaces.

The coating designation is the term by which this product is specified.

Calculated Coating ThicknessBased on Minimum

Single Spot Test,a in.

CoatingDesignation

Triple-Spot TestTotal Both Sides

Single-Spot TestTotal Both Sides

oz/ft2 g/m2 oz/ft2 g/m2

TI 40（regular） 0.40 120 0.30 90 0.0013

TI 25（light） 0.25 75 0.20 60 0.0008a Calculation based on aluminum density of 0.0975 lb/in.

11. Dimensions, Weights, and Tolerances11.1 Aluminum-coated steel sheet is produced to decimal thickness only. The density of aluminum is 0.0975 lb/in. as compared

to that of zinc which is 0.258 lb/in.; hence, the weight equivalents are different. Table 3 gives the thickness and weight equivalents

of aluminum-coated steel sheet Type1.

11.2 Thickness tolerances and all other dimensional tolerances are given in Tables 4 through 16.

TABLE 4 Thickness Tolerances of Aluminum-Coated Steel Sheet Type1

Notes : 1. Thickness is measured at any point across the width not less than 3/8 in.（9.5mm）from a side edge.2. Regardless of whether total thickness tolerance is specified equally or unequally, over and under, the total tolerance

should be equal to twice the tabular tolerance.

Over 0.101to 0.187, incl





0.023 andthinner

Thickness Tolerances for Widths and Thicknesses, Over and Under, in.

Specified Thickness, in.Specified Width, in.

To 32 incl 0.008 0.007 0.006 0.005 0.004 0.003

Over 32 to 40, incl 0.008 0.008 0.006 0.005 0.004 0.003

Over 40 to 60, incl 0.009 0.008 0.006 0.005 0.004 0.003

TABLE 5 Width Tolerances of Aluminum-Coated

Steel Sheet Type1（Coils and Cut Lengths Not

Resquared）

Tolerance Over Specified

Width, No Tolerance Under

Specified Width, in.

（mm）in. mm

Over 12（300）to 30（760）, incl 1/8 3.2

Over 30 to 48（760 to 1,220）, incl 3/16 4.8

Over 48 to 60（1,220 to 1,520）, incl 1/4 6.4

Appendix A1. Metric Equivalents

A1.1 The metric equivalents for the tolerances given in the

tables are shown in Table A1.

TABLE A1 Metric Equivalentsa

0.001 0.0254 3/16 4.762

0.005 0.127 1/4 6.350

0.010 0.254 5/16 7.938

0.050 1.270 3/8 9.525

0.100 2.540 1/2 12.700

0.200 5.080 3/4 19.050

1/16 1.588 7/8 22.225

1/8 3.175 1 25.400aConversion factor : 1 in.×25.4＝mm.


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Guangzhou 510613, P.R.China

Telephone:（86）20-3877-1054 Facsimile:（86）20-3877-1094

Subsidiary

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1701 Golf Road, Continental Tower3, Suite1004,

Rolling Meadows, IL 60008 U.S.A.

Telephone:（1-847）290-5100 Facsimile:（1-847）290-0826

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Shanghai Maxdo Centre 3208-3210, 8 Xing Yi Road,

Technical information in this booklet, while every reasonable

effort was made to ensure the accuracy at the time of this

publication, is general information relating to our products

only and is not meant as any warranty, expressed or implied.

Such technical information does not guarantee that any of our

products are suitable for your particular application or

purpose. Use of any information contained in this booklet shall

be at user's risk Any information in this booklet is subject to

Notice

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