Metastable Phases of Dross Particles Formed in a Molten Zinc Bath and Prediction of Soluble Aluminum During Galvannealing Processes

Abstract

The morphology, chemistry, and crystallographic characteristics of metastable dross particles were identified. These particles are formed during the initial stage of precipitation. The particles had aluminum concentrations of 15 to 80 mass pct, with values that decreased gradually as particle size increased. These metastable dross particles were a mixture of the crystalline phase of FeZn10, which is called the “delta phase,” and the high-aluminum amorphous phase, which covered the surface of the crystalline phase. The new “meta Q” concept was proposed to predict the amount of soluble aluminum in the zinc bath by considering nucleation kinetics and particle growth. The results calculated using the “meta Q” concept were compared with the values measured by the aluminum sensor, which were taken during the same period at the commercial galvanizing line. The mean of the absolute values of the differences between the calculated and measured values was 9.7 ppm.