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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
Foreword
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.
Features
Alstar features heat resistance, corrosion resistance at high temperature, heat reflectivity, attractive appearance, nonpolluting
properties, 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.
1
Uniform aluminum coating and free control of aluminum thickness.
2
Thin aluminum coating
40g/m2 on both sidesThis 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.
Production Processes
Figure 1 : Production Processes
8
Coil
10
12
14
Cut-length
Coil
13
2
3
11
1.
2.
3.
4.
5.
6.
7.
Uncoiler
Shear
Welder
Looper
Oxidizing, reducing, and annealing furnace
Aluminum coating bath
Gas-wiping
Cold Rolled
Steel Coils
Oxidizing, Reducing,
and Annealing Furnace
8.
9.
10.
11.
12.
13.
14.
Cut-length
Cooling tower
Skin pass mill
Tension leveller
Posttreatment tank
Shear
Recoiler
Skin pass mill
Aluminizing
Cooling
Posttreatment
Aluminum
Coated Steel
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 surface, 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.
Examples of Uses
Kerosene heater
Kerosene heater
Kerosene heater
Kerosene heater
Water heater
Examples of Uses
Kitchen utensils
Kitchen utensils
Kitchen utensils
Oven, toaster
Gas oven
Gas range
Smokestack
Examples of Uses
Muffler
Muffler
Muffler
Muffler
Heat insulator
Reactor part
Examples of Uses
Manifold cover
Manifold cover
Manifold cover
Charcoal stove
Charcoal stove
Chimney
Barbecue grill
Kerosene stove
Fireplace
Specifications
1.Types of Alstar
(1) Alstar is available in the following types which vary with the uses and the means of processing.
Table 1
Symbol
ASTM
A463
Surface Finish
Commercial Quality
Type
CQ
Dull
Drawing Quality
DQ
Dull
DQSK
Dull
C
D,E
Quality
Product
symbol
Posttreatment
Surface finish
Dull
Mass of
aluminum coating
(3) There are several kinds of posttreatment for various uses. These include ordinary chromate and oiling
and oiling nonchromate.
Table 2
Posttreatment
Symbol
N0
Oiling nonchromate
M0
Symbol
ASTM
A463
Nisshin Standard
T1-25
T1-40
MSA-40
MSA-60
MSA-80
MSA-100
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
Note : Minimum masses on both sides by the triple-spot test are based on the ASTM standards.
MSA-120
Specifications
3.Mechanical Properties
Tension and bend tests of Alstar produce the following values.
(1) Tensile strength and elongation
Table 4
Elongation
Thickness
,
mm
Tensile
Strength
N/mm2
0.4 to 0.6
excl.
0.6 to 0.8
excl.
0.8 to 1.0
excl.
1.0 to 1.6
excl.
1.6 to 2.3
incl.
Commercial Quality
270
23
26
28
30
31
Drawing Quality
270
30
32
33
34
35
270
34
36
37
38
39
Type
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.
4.Available Dimensions
Alstar is available in the dimensions shown in the chart below.
Figure 2
1,200
1,219 or under
1,150 or under
1,100
1,070 or under
Width
mm
1,000
1,000
914
900
800
700
600
700 or
over
600 or over
0.3 0.4 0.5 0.6 0.7
under
1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0 2.1 2.2 2.3
Thickness mm
Specifications
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
mm
Width
Thickness
Under 1,000
1,000 or Over
0.06
0.06
0.07
0.07
0.09
0.09
0.10
0.11
0.11
0.12
0.13
0.14
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 plus
the thicknesses corresponding to aluminum coating masses.
2.Thickness is measured at any point across the width not less than 50mm
from a side edge.
Table 7
mm
mm
Item
Tolerance
Edge
Tolerance
Length
12, 0
Mill edge
10, 0
Slit edge
0.5
Remarks
mm
Thickness
Type
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
Panel Quality
Commercial Quality
11
Specifications
Figure 4
Length
Width
Width
Camber
2,000mm
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.
Table 9
mm
Width
Cut-length
Length under 2,000
Coil
50 to 60 excl.
8 per 2,000
60 to 200 excl.
4 per 2,000
4 per 2,000
600 or more
2 per 2,000
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
Figure 5
Heating
Al
Al
Alloy layer
Alloy layer
Fe (before heating)
Heating
Fe (after heating)
Alloy layer
Properties
(2) Microscopic photographs of cross sections of MSA-40 kept at 500 for 100 hours and 1,000 hours,
respectively
Cross sectional structures of Alstar before and after heating to 500
Drawing Quality
Before heating
(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 resistanceat 500 to 600similar to stainless steel sheet, and is over 20 times more heatresistant than cold-rolled steel sheet.
(40
she
led
ste
el
teel sh
ldCo
Cold-r
40
rol
olled s
50
Oxygen Pickup (mg/dm2)
et
eet (50
60
0
)
0)
Figure 6
30
)
00
r (6
sta
Al
)
(600
eet
el sh
ste
less
stain
18-8
00)
Alstar (5
20
10
el sheet (500)
12
16
20
24
28
32
36
40
44
48
52
Properties
Temperature ()
800
600
600
400
200
12
Hours
16
20
24
600
750
100
50
TI-25CQ (MSA-80)
SUS430
SPC (Cold-rolled steel sheet)
Galvanized sheet
Galvannealed sheet
TI-25CQ
30
10
-10
-20
SUS430
2
10
Number of Cycles
-30
-50
-70
-100
-200
Galvannealed sheet
-300
-500
Galvanized sheet
SPC
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
Surface Finish
Surface Luster
Surface Roughness
Alstar
Type
Dull
15
Hmax 8 to 9
2B
15
Hmax 1.2
BA
60
Hmax
Dull
Hmax
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
120
110
100
90
80
Corrosion (g/m2/day)
130
Corrosion resistance
in pH Solutions
Alstar (60)
Galvanized sheet (room temperature)
Galvanized sheet (60)
Source : Metal Surface Technology Vol.7, No.7.
70
60
50
40
30
20
10
1
4
Acidity
7
pH
10
11
12
13
14
Alkalinity
Properties
24 Hours
72 Hours
240 Hours
360 Hours
Red rust
in 384
hours
Room temperature
25024 hours
Room temperature
25024 hours
Red rust
10%
Red rust
60%
Red rust
60%
Red rust
90%
Red rust
100%
to
zinc.
Alstar
Galvanized Sheet
Palm oil
Machine oil
Boiled oil
Spindle oil
Glycerine
Formalin
Alcohol
Acetone
Carbon tetrachloride
Coal tar
Printing ink
Phthalide
Aqueous ammonia
5 caustic soda
5 nitric acid
5 sulfuric acid
5 acetic acid
Properties
Decrease in Thickness
converted from the mass decrease
in.
mm
x
0.260
0.011
0.0007
0.018
0.191
0.035
0.0005
0.013
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 Face
Time
Thickness
mm
Electrode Force
N
0.6
16
25
1,800
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
Current
A
Shear Strength
N
Note : With a low welding current, sufficient strength cannot be expected. With an overcurrent, the aluminum coating deteriorates more
than necessary and dark gray stripes appear around welds. Suitable welding conditions between these extremes must be
selected. 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 to
minimize pickup and periodic dressing are necessary. As in the case of welding mild steel, radius-face tips or truncated cone
face
120 140
to
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
MSA-80 1.0mm
MSA-40 1.0mm
(Commercial Quality)
9,800
8
6
Diameter of Electrode
Force Mark (mm)
8,800
7,800
6,900
9,800
8,800
7,800
6,900
Shear strength
5,900
5,900
4,900
4,900
3,900
3,900
2,900
2,900
2,000
1,000
4
2
1,000
2,000
100
200
300
400
500
600
Number of Welds
700
800
900
1,000
Properties
Thickness
mm
Electrode Width
mm
Electrode Force
N
On
Off
Welding Speed
cm/min.
Current
A
0.8
3,900
150
17,000 to 19,000
0.95
4,200
150
16,000 to 18,000
0.95
4,200
230
18,000 to 21,000
1.2
4,400
150
18,000 to 20,000
1.2
4,900
230
18,000 to 21,000
JIS Rating of
X-ray Results
Tensile Strength
N/mm2
Elongation
D4313
Poor
387
24.2
Weld
D4316
Good
368
28.9
Base metal
1.2
D30816
Stainless steel
Excellent
379
28.0
Base metal
1.2
D4316
Good
327
28.4
Base metal
Thickness
mm
Welding Rod
T1-25CQ
MSA-80
Commercial
Quality
1.2
1.2
SPCC
Sheet Welded
Rupture Point
T1-25CQ
MSA-80
Commercial
Quality
1.6
Welding
Current
Weldability
JIS Rating of
X-ray Results
Tensile Strength
N/mm2
Elongation
Rupture Point
AC
Poor
380
24
Base metal
DM-2
gas-welding rod
for Si-Mn alloy
Thickness
mm
Welding Rod
GA
gas-welding rod
for mild steel
Sheet Welded
AC
Good
389
28
Base metal
D308
18-8 stainless
steel rod
AC
Good
393
24
Base metal
GA
DC
Poor
400
24
Base metal
DM-2
DC
Good
380
28
Base metal
D308
DC
Excellent
398
26
Base metal
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 and punch radii and clearances must be used where appropriate to prevent
Die
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 redrawing is necessary, a drawing ratio of more than 60 percent is
If
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
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.
Degreasing
Take note of pH.
Use trichloroethylene or other
neutral chemicals.
Chemical Treatment
Painting
(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.
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.
Steel Pipe
Alstar steel pipe is made from Alstar steel sheet by high-frequency welding. It has all the features of Alstar steel sheet. Being
highly heat resistant, Alstar steel pipe is used in large quantities in the automobile industry as exhaust pipe.
1.Features
1Evenly coated with aluminum
2Thin aluminized Alstar steel pipe is available.
3Highly heat resistant
4High workability
5Excellent weldability
6Smooth, 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 shown in Table 18.
are
Steel Pipe
Table 18
Test Piece Size
35.0 1.2mm
38.1 1.2mm
42.7 1.2mm
Number of
Test Cycles
Tensile Test
Flattening Test
2/3D
Flaring Test
Bending Test
3D
45
Good
1.39
Good
1.38
46
Good
1.39
Creases occurred
Tensile Strength
N/mm2
Elongation
366
361
Good
1.30
362
45
Good
1.37
Good
1.40
Length
mm
0.62.3
12.763.5
3,5006,100
0.82.0
16162525
Thickness
mm
Round Pipe
Sharp Edge
Square Pipe
Rounded Edge
Square
Rectangle
0.82.3
22106030
Square
0.82.3
25255050
Rectangle
0.82.3
25126030
3,5006,000
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 the
coating 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.
8. Mechanical Requirements
8.1 Base Metal Bend Test-Commercial quality
CQ
,
drawing quality
DQ or drawing quality special killed
,
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 requirements for triple- and single-spot minimum checks
prescribed 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
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 Type1
Note : 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.
Triple-Spot Test
Total Both Sides
Coating
Designation
Single-Spot Test
Total Both Sides
TI 40regular
g/m2
120
oz/ft2
0.30
g/m2
90
TI 25light
a
oz/ft2
0.40
0.25
75
0.20
60
0.0013
0.0008
Over 0.075
to 0.101, incl
Over 0.061
to 0.075, incl
Over 0.043
to 0.061, incl
Over 0.023
to 0.043, incl
0.023 and
thinner
To 32 incl
0.008
0.007
0.006
0.005
0.004
0.003
0.008
0.008
0.006
0.005
0.004
0.003
0.009
0.008
0.006
0.005
0.004
0.003
in.
mm
1/8
3.2
in.
mm
in.
0.0254
3/16
4.762
6.350
mm
Over 30 to 48
760 to 1,220incl
,
3/16
4.8
0.001
Over 48 to 60
1,220 to 1,520incl
,
1/4
6.4
0.005
0.127
1/4
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
25.400
www.nisshin-steel.co.jp
JAPAN
Registered Head Office
Shinkokusai Building, 4-1, Marunouchi 3-chome, Chiyoda-ku,
Tokyo 100-8366, Japan
Telephone:
81-3
3216-5530 Facsimile:
81-3
3216-5747
OVERSEAS
Singapore Representative Office
16 Raffles Quay #20-01, Hong Leong Bldg., Singapore 048581
Telephone:
65
6221-1277/8 Facsimile:
65
6224-2357
Subsidiary
Nisshin Steel USA, LLC
1701 Golf Road, Continental Tower3, Suite1004,
Rolling Meadows, IL 60008 U.S.A.
Telephone:
1-847
290-5100 Facsimile:
1-847
290-0826
Notice
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
change without prior notice. Please contact Nisshin Steel
office for updated information.
R-03 '07.01