Modified hot-dip galvanize coatings with low liquidus temperature, methods of making and using the same

Abstract

The present invention relates to a coated substrate material. The substrate can be a steel alloy and the microstructure in the steel alloy can be altered with a low temperature coating process. The present invention also relates to a method to coat the substrate at the low temperature. The present invention also relates to a coating wherein the melting temperature of the coating is reduced with a dopant compared to the melting temperature without the dopant. The present invention also relates to a method to make the coating with the dopant.

1 . A method of coating a metallic material at a reduced liquidus temperature, comprising:
 providing a metallic material;   coating the metallic material with a zinc-based alloy coating to form a coated metallic material, and wherein a liquidus temperature of the zinc-based alloy coating is less than the liquidus temperature of the zinc-based alloy material without the doping material; and   altering a first microstructure in the metallic material when coating the metallic material with the zinc-based coating.   
     
     
         2 . The method of  claim 1 , wherein the zinc-based alloy coating is a zinc-magnesium-aluminum coating. 
     
     
         3 . The method of  claim 1 , wherein the doping material is selected from the group consisting tin, lithium, gallium, magnesium, indium, and combinations thereof. 
     
     
         4 . The method of  claim 1 , wherein the liquidus temperature of the zinc-based alloy coating is less than 419° C. 
     
     
         5 . The method of  claim 1 , wherein the liquidus temperature of the zinc-based alloy coating is between about 300° C. and about 365° C. 
     
     
         6 . The method of  claim 1 , wherein a formula of the zinc-based alloy coating is selected from the group consisting of Zn-aAl-bMg-dopant, Zn-bMg-(x)dopant, Zn-aAl-(x)dopant, Zn-aAl-bMg-(x)dopant1-(y)dopant2, Zn-bMg-(x)dopant1-(y)dopant2, Zn-aAl-(x)dopant1-(y)dopant2, Zn-3.9Al-2.45Mg-(x)dopant, or Zn-3.9Al-2.45Mg-(x)dopant1-(y)dopant2. 
     
     
         7 . The method of  claim 6 , wherein the formula of the zinc-based alloy coating is Zn-4Al-3Mg-dopant, and wherein the dopant is selected from the group consisting of tin, gallium, bismuth, or indium, and wherein a mass fraction of the dopant is between 1 and 15. 
     
     
         8 . The method of  claim 7 , wherein the mass fraction of the dopant is between 1 and 9. 
     
     
         9 . The method of  claim 6 , wherein the formula of the zinc-based alloy coating wherein the formula is Zn-4Al-bMg-8Sn, and wherein b is between 1 and 6. 
     
     
         10 . The method of  claim 6 , wherein the formula of the zinc-based alloy coating wherein the formula is Zn-aAl-3Mg-8Sn, and wherein a is between 1 and 15. 
     
     
         11 . The method of  claim 6 , wherein the formula of the zinc-based alloy coating wherein the formula is Zn-7Al-3Mg-xSn, and wherein x is between 1 and 12. 
     
     
         12 . The method of  claim 6 , wherein the formula of the zinc-based alloy coating wherein the formula is Zn-15Al-1Mg-xSn, and wherein x is between 1 and 20. 
     
     
         13 . The method of  claim 6 , wherein the formula of the zinc-based alloy coating wherein the formula is Zn-aAl-3Mg-10Ga, and wherein a is between 1 and 10. 
     
     
         14 . The method of  claim 6 , wherein the formula of the zinc-based alloy coating wherein the formula is Zn-3.5-bMg-6In, and wherein b is between 1 and 4. 
     
     
         15 . The method of  claim 6 , wherein the formula of the zinc-based alloy coating wherein the formula is Zn-aAl-2.5Mg-6In, and wherein a is between 1 and 6. 
     
     
         16 . The method of  claim 1 , wherein the first microstructure is selected from the group consisting of martensite, ferrite, bainite and combinations thereof. 
     
     
         17 . The method of  claim 16 , wherein the alternative microstructure is selected from the group consisting of a tempered martensite, austempered bainite, and combinations thereof. 
     
     
         18 . The method of  claim 16 , wherein the alternative microstructure is a lack of carbon aging. 
     
     
         19 . A coated substrate alloy, comprising:
 a metallic material coated with a zinc-based alloy coating, wherein the zinc-based alloy coating comprises:   a zinc-based alloy; and   at least one dopant, wherein a liquidus temperature of the zinc-based alloy coating is less than 419° C.   
     
     
         20 .- 64 . (canceled) 
     
     
         65 . A method to produce a coated steel, comprising:
 providing a liquid coating, wherein a liquidus temperature of the coating is less than a quenching temperature to form an alternative microstructure in a steel, wherein the alternative microstructure is a change in at least one of martensite tempering, bainite austempering, or carbon aging of the steel;   coating the steel with the coating; and   forming the alternative microstructure in the steel during the coating.   
     
     
         66 .- 110 . (canceled)