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JOURNAL OF IRON AND STEEL RESEARCH, INTERNATIONAL. 2012, 19(6): 7@78
Influence of Air-Knife Wiping on Coating Thickness in
Hot-Dip Galvanizing
ZHANG Yanl V3, CUI Qi-peng' , SHAO Fu-qun' , WANG Jun-sheng3, ZHAO Hong-yang'
(1. College of Information Science and Engineering, Northeastern University, Shenyang 110004, Liaoning , China;
2. University of Science and Technology Liaoning, Anshan 114000, Liaoning, China; 3. Angang Steel Co Ltd,
Anshan 114021, Liaoning, China)
Abstract: In hot-dip galvanizing process, air jet wiping control is so crucial to decide the coating thickness and uni-
formity of the zinc layer on the steel strip. The mathematical models developed predict the zinc coating thickness as a
function of pressure and shear stress. The required pressure and shear stress profile on the strip surface were calcu-
lated using regression analysis, and carried out using numerical simulation as FLUENT, a finite element analysis
software. The influences of the outlet pressure, the nozzle to strip distance, the slot opening, the edge baffle plate,
as well as the tilting angle of air knife were discussed. Combining with these results and regression analysis on the
practical data, four first-order polynomial multi-parameter models were established for different targeted coating
thicknesses with better regression coefficients. The validated model was used to carry out sensitivity analysis to de-
termine the favorable controlling regime for the air jet wiping process.
Key words: hot-dip galvanizing; air knife; air jet wiping; numerical simulation; coating thickness
It is known that it is easy for the merits of air
jet wiping in hot-dip galvanizing to control the zinc
coating thickness and t o improve the productivity of
steel strip with the target coating thickness at the
highest possible line speed"'. Jet wiping process has
been the subject of the present studies, and some
analytical models have been proposed for the coating
thickness distribution at the wiping areacz1. It deems
feasible regulation of the coating thickness by con-
trolling air knife parameters. However, the gas im-
pingement may influence more than transport mech-
anism involved in the dip-coating process. Jet wiping
process is limited by rather violent strip instability
t o cope with the demand of speed-up, pressure of
nozzle increasing, and nozzle to substrate distance
shortening of galvanizing line obtaining the same
film thickness. Therefore, scientists have carried
out a lot of researches on jet wiping process of air
knife during the past few years. CHENG Ji-min
studied the effects of various factors on the pressure
distribution upon strip surface. CHANG Tie-zhu
provided technological countermeasures of strip edge
over coating control for uniformity of zinc layer.
Kim investigated the mechanism of the edge over
coating through a numerical analysis. Ki Jang AHN
found that when the two opposing jets collided at an
angle much less than 180", the alternating vortices
disappeared and the impinging pressure on the strip
surface became nearly uniform. Gilchrist demonstra-
ted that a j et , discharged tangentially to a cylindrical
surface, flowed along the surfacer31. D Lacanette
defined the governing parameters of the process and
proposed a description of the flow using a large eddy
simulation
The modern application of closed-loop computer
control requires a fundamental understanding of the
flow field and mass transfer mechanisms over a sub-
strate that is withdrawn from zinc liquid bathCs1. In
the present study, the 3D simulation with compres-
sible turbulent flow was employed by using FLUENT,
t o find out how the operating parameters affect the
flow behavior of the wiping gas. The combined
Foundation Item: Item Sponsored by National Natural Science Foundation of China (50604006) ; National Development and Reform Commission
Biugraphy:ZHANG Yan(1973-), Male, Doctor, Engineer; E-mail: wu_kunkui@163. corn; Received Date: April 3, 2011
of China (2009-354)
Issue 6 Influence of Air-Knife Wiping on Coating Thickness in Hot-Dip Galvanizing 71
effects of t he outlet pressure, the nozzle t o strip dis-
tance, t he slot opening, t he edge baffle plate, as
well as t he tilting angle of air knife were studied. I t
shows that uniformity of coating thickness can be
improved by optimizing important parameters and
t he design of nozzle. Furthermore, the practical
production data of t he continuous galvanizing line
(CGL) are analyzed with regression method. The sam-
ples of t he galvanizing steel are selected to measure
the thickness of zinc deposition on t he steel surface
by metallographic method. All the results made it
possible t o establish four first-order polynomial
models that gave coating thickness as a function of
all those parameters. Using these models, the most
optimal operating conditions can be predicted.
1 Experimental Procedure
The study object and all of data and samples
were from No. 4 CGL at Angang Steel. The prehea-
ted strip comes from t he annealing furnace and zinc
bath with molten zinc of 99. 77% is heated at 460 "C.
The jet pressure is controlled by a digital pressure
regulator. Stepping motors control both horizontal
and vertical distance between t he strip and nozzle.
As illustrated in Fig. 1, air jet injected normally onto
t he surface of moving strip is divided into two differ-
ent wall jets. In t he upper region ( y>O) , since t he
strip moves upward, t he molten zinc moves in the
same direction at both wall boundary and free
boundary. In the lower region ( y<O) , t he molten
zinc moves upward near t he strip surface while it
moves downward near t he free boundary. Gas wi-
ping process mainly depends upon t he impact pres-
sure gradient and shear stress distribution of impin-
ging jet at t he liquid zinc surface. The experiments
were conducted using low-carbon steel samples
which consist of C 0.06%, Si 0.04%, P 0.015%, and
2-Nozzle to strip distance:
Va,-Jet exit velocity;
V,-Strip velocity;
D-Nozzle slot opening;
P.-Nozzle exit dynamic pressure:
V P,.,-Impact pressure gradient:
r,,,-Shear stress distribution.
Fig. 1 Schematic diagram of jet wiping process presenting
Mn 0. 25 XL6].
The galvanizing strip samples are selected t o
measure the thickness of zinc deposition on the steel
surface by metallographic method. The sample at
0. 58 mm of thickness were cut into thin rectangular
slices (10 mmX10 mm) and sealed t o hold the sec-
tion being vertical t o t he surface. After grinding and
fine polishing, the sampled were observed by optical
microscope and t he thickness at various positions is
measured as shown in Fig. 2. In [Fig. 2 ( a) ] , during
operation t he line speed is often changed according
t o t he furnace capacity and production constraints.
It may cause serious film thickness variance and non-
uniformity by adjusting improperly air knife position
and chamber pressure. As shown in [Fig. 2 ( b) ] ,
coating thickness is uniform when adjusting the pa-
rameters properly. The goal of this study is to find
out t he favorable control method to achieve the opti-
mal thickness and uniformity. To accomplish this
objective, following methodology is adoptedC7'.
1) Develop a mathematical model which relates
to t he coating thickness CW on the strip velocity V,,
jet nozzle pressure P , nozzle to strip distance 2, nozzle
+ -
( a) Non-uniform zinc coating: (b) Uniform zinc coating.
Fig. 2 Metallographic analysis of coating thickness distribution
72 Journal of Iron and Steel Research, International VOl. 19
slot opening D.
2) Run numerical simulation of an impinging jet
using the FLUENT and correlate the obtained pres-
sure and shear stress profile on the strip surface.
3) Compare the predicted coating thickness through
t he developed model, with the actual measured coat-
ing thickness in the plant.
2 Mathematical Modeling
The mathematical model is developed based on
the following assumptions :
1) The fluid flow on the liquid coating layer can
be described by the steady state, two dimensional equa-
tions of incompressible, constant viscosity creep flow.
2) The pressure across the relatively thin incom-
pressible coating layer is assumed to be constant.
3) There is no slip between the liquid zinc layer
and the strip on the strip-fluid interface.
The coating thickness, based on the assumptions
made, is determined by the following equation.
Motion equation:
(1)
where, u is t he velocity in the zinc film; P is the
pressure in the liquid zinc due to impinging air jet; ,u
is viscosity of liquid zinc at 460 'C ; p is density of
zinc; and g is gravitational constant.
Conservation of mass: the zinc withdrawal rate
q can be expressed as,
Boundary conditions :
u=V, at x=O and ,u -=r at x=h, ( 3 )
' where, V, is the strip velocity; r is the shear stress.
The non-dimensional coating thickness T , non-
dimensional shear stress S , and the effective gravita-
tional acceleration G are given as,
du
dx
Introduce the non-dimensional withdrawal rate
flux Q in Eqn. ( 2) as
dQ
d T
And by setting - = 0, the non-dimensional
coating thickness is obtained as
St
2G
T= ( 6 )
From Eqn. ( 4 ) and Eqn. ( 6 ) , it is clear that if
the pressure and shear stress profile on the strip sur-
face are known, the coating thickness can easily be
calculated.
3 Numerical Analysis Model
Numerical simulations were carried out using
FLUENT, a finite element analysis software, t o
generate pressure and shear stress profile on the
strip surface. In numerical analysis, the equations of
continuity, two-dimensional time dependent Navier-
Stokes, energy, and state equation were used as
governing equations. When Reynolds number is
greater than 4 000, realizable KE turbulent models
are used t o solve t he turbulent stress. The schemat-
ic computational domains and each boundary condi-
tion are shown in Fig. 3. The grid in the regions
having more possibility of changing in pressure, ve-
locity and others, makes the exit grid of air knife
denser. The numbers of mesh and mesh type are about
2. 6 X l o5 and hexahedral, respectivelyC8'. The inlet
pressure and outlet pressure boundary are located at
the entry and outside of air knife. A non-equilibrium
wall function on wall boundary of air knife and strip
surface was used. Strip velocity was set at 1.67 m/s.
and the media for gas wiping is compressed air. In
discrimination function, pressure-velocity coupling
used SIMPLEC algorithm, and pressure correction
inferior-relaxation factor is 1. 0. The pressure, mo-
mentum equation, and KE equation are second-order
upwind format.
ship
\
V
'*
t
Pressure-outlet
Air knife outlet
1' Pressure-outlet
Grid system and boundary condition Fig. 3
4 Results and Discussion
In the air jet wiping process, in order t o opti-
mize t he pressure and shear stress, it is necessary to
Issue 6 Influence of Air-Knife Wiping on Coating Thickness in Hot-Dip Galvanizing
-
study the influences of the important parameters and
nozzle geometry. The regression analysis is carried
out to develop the correlations which relate t o the
pressure and shear stress profile on a moving strip
surface. The numerical analysis model is used t o
study the effect of different operating parameters
such as nozzle pressure, nozzle t o strip distance,
nozzle slot opening, edge baffle plate, and tilting
angle of air knife.
4. 1
jet pressure is gauss distribution.
Pressure distribution of strip surface
Based on the jet wiping force theory, impinging
( 7 )
The correlation for the shear stress on the verti-
cal moving strip due to the impinging air jet is given by
r=r,.,[erf(O. 8337) -0. Z7e-0.6g3;] (8)
where, P,,, is maximum value of impinging pres-
sure; v=z / b, 1 is strip coordinate; b is the half-val-
ue width of pressure distribution; rmax is maximum
value of shear stress; erf ( p ) = - e dy is error
f un~t i on[ ~l .
The distributions of impinging jet pressure and
shear stress are shown in Fig. 4. As long as it is
within the range of the process parameters impin-
ging pressure maximum value half-value width
of pressure b and shear stress maximum value rmax of
strip surface can be achieved. According t o Eqn. ( 7 )
and Eqn. ( 8) , strip surface pressure distribution can
be got. The three parameters quantify the ability of
air knife impinging jet. The greater the peak value
of impinging pressure is, the stronger ability of air
knife impinging jet is; The smaller pressure half-
value width of pressure is, the more air flow concen-
trated and stronger impinging ability is. The greater
p = p
x e-O. 693;
max
2 p - 2
73
-0.02 -0.01 0 0.01 0.02
Length of striplm
Fig. 4 Impinging jet pressure and shear stress distribution
the maximum value of shear stress is, the stronger
the ability of blowing is. As a result, the maximum
values of impinging pressure and shear stress reflect
the magnitude of strip surface pressure, and half-
value width determines the pressure distribution.
Reaching f 2. 5 mm distance to the entrance of
strip, jet pressure attenuates to 0 and shear stress
increases to maximum value.
4. 2 Influence of air knife outlet pressure
The influence of the outlet pressure on max
pressure and shear stress is shown in Fig. 5. The out-
let pressure of air knife ranges from 40 to 80 kPa, at
5 kPa interval. With the same nozzle slot, influence
of the outlet pressure on the strip surface is linear
with peak value of pressure and shear stress. The
peak value of pressure and shear stress increase with
the increase in outlet pressure, and under the same
outlet pressure condition they decrease with the in-
crease in the nozzle t o strip distance. But it is non-
linear for pressure distribution and mostly decided
by the distance between nozzle and strip. When the
distance is more than 16 mm from strip surface, the
half-value pressure width is smaller and the pressure
40 50 60 70 80 40 50 60 70 80
Air-knife outlet pressure/kPa
Influence of outlet pressure on (a) impinging jet pressure and (b) shear stress Fig. 5
' 74 Journal of Iron and Steel Research, International Vol. 19
on the strip is more concentrated by increasing the
pressure. When the distance is less than 16 mm, in-
fluence of t he outlet pressure on pressure distribu-
tion becomes less important.
4. 3 Influence of nozzle to strip distance
The influence of the nozzle to strip distance on
maximum pressure and shear stress is shown in Fig. 6.
The nozzle to strip distance is set from 8 to 21 mm, in-
flection point obtained for 11.4 mm The peak value of
pressure decreased with t he distance increasing, but
the rules are different. When the distance is less
than 11. 4 mm, peak values of pressure and shear
stress are more stable. As t he distance exceeds a
critical value 11. 4 mm, peak value of pressure and
shear stress attenuations rapidly, but half-value
pressure width increases. The numerical analysis re-
sults show that the influence of nozzle t o strip dis-
tance on pressure field is segmentation differences.
The reason is that when the distance is less than
11. 4 mm, the impact of high-speed air flow to liquid
zinc has not been fully developed. With the distance
increasing, air flow develops entirely and impinging
pressure and shear stress begins to attenuate"".
P=80 kPa
70
A 6 0
8 10 14 18 22
I
550 (b)
2001 I I
8 10 14 18 22
Nozzle to strip distancehnm
Influence of nozzle to strip distance on (a) impinging jet pressure and ( b) shear stress Fig. 6
4.4
The influence of t he nozzle slot opening on max
pressure and shear stress is shown in Fig. 7. The
nozzle slot width is taken from 1. 0 to 2. 0 mm, at
0. 2 mm interval. This is an important process pa-
rameter. The slot opening directly affects ability of cop-
ing with liquid zinc. It can be clearly seen that when the
slot opening is less than 1. 2 mm it would lead to pres-
sure and shear stress attenuate rather largely. But when
the slot opening is more than 1. 3 mm, it will result in
Influence of nozzle slot opening divergence, which reduces air jet wiping t o scrape
liquid zinc. The slope of the curve for peak value of
pressure increasing is less than steep slope of the
curve for shear stress decreasing when slot opening
is more than 1. 3 mm. So reasonable slot opening
should be less than 1. 3 mm. The pressure half-value
width has relation with nozzle slot opening. When t he
distance is closer, and slot opening increases, the
impinging pressure has higher degree of convergence.
When the distance is further away, and slot opening
1.0 1.2 1.4 1.6 1.8 2.0 1.0 1.2 1.4 1.6 1.8 2.0
Nozzle slot widthlm
Fig. 7 Influence of nozzle slot width on (a) impinging jet pressure and (b) shear stress
Issue 6 Influence of Air-Knife Wiping on Coating Thickness in Hot-Dip Galvanizing 75 '
increases, the impinging pressure is more divergent["'.
It is easy t o see the edge effect in Fig. 8, be-
cause of easiness of jet flowing t o the surrounding.
As a result, the impinging pressure at the neigh-
bourhood of the strip edge becomes small to compare
with that in the strip centre area.
To obtain good uniformity of coating thickness,
it is necessary to design air knife with the variable
nozzle slot opening. Based on numerical analysis of
nozzle slot, the current designed wedge nozzle slot is
placed 6 centre parallel gaps at distance of 110 mm,
having an opening of 1. 1 mm. And nozzle edges ex-
tend 5 gaps at distance of 110 mm which increase
0. 025 mm every slot shown as Fig. 9.
8.0~10' 7.00~10'
5.00~10'
< 6.00x104
P 2.00x10'
3.00x10'
4.00~10'
g
l.OOXlO*
n
0
0 0.1 0.2 0.3 0.4 0.5 0.6 0 0.1 0.2 0.3 0.4 0.5 0
Length of strip/m
(a) Wedge nozzle slot; ( b) Constant nozzle slot.
Fig. 8 Influence of nozzle slot on edge impinging pressure
1.225mm 1.lOmm l.10mm 1.225mm
Fig. 9 Wedge nozzle slot design
4. 5 Influence of edge baffle plate of air knife
The nozzle slot's impact of strip transverse pressure
shows that increasing slot opening in the strip edge re-
gion can restrain over-galvanized. Because different strip
width will lead to different nozzle positions, over-galva-
nized usually occurred in the area of 40 mm away
from the edge. Nozzle slot design can not avoid over-
will cause liquid zinc splashing. The control should
be based on the reasonable nozzle slot, and emphasis
on optimization and design of edge baffle plate.
Shown as Fig. 10, edge pressure distribution has lit-
tle attenuation with baffle plate, but it can be clearly
seen pressure decreasing at distance of 1 2 mm away
from the edge without baffle plate. The simulation
shows that the wider the baffle and the more narrow
the gap between strip and baffle is, the less outward
deflection flow of strip edge affected region is. The
regional pressure of strip edge can be enhanced with
the baffle, so it can effectively control over-galvani-
zing at the edge by adjusting the gap about 2 mm and
galvanized at the edge of different widths. Over opening by increasing baffle dimension properly.
t
' 4.00~10~
l ! i
3 2.00~104
-1.00~104 I I
0 0.05 0.10 0.15 0.20 0.25 0.30 0.:
I .
0 0.05 0.10 0.15 0.20 0.25 0.30 0.:
Length of shiplm
(a) With baffle plate; ( b) Without baffle plate.
Fig. 10 Influence of edge baffle plate
4.6 Influence of tilting angle of air knife
Fig. 11 shows t he distributions of impinging
pressure and shear stress with the variation deflec-
tion angle +O", 5", l o", 15"used in the current nu-
76 Journal of Iron and Steel Research, International VOl. 19
'
400
70 000
s 60000 f 300
I ta
g 200
8 0 d o
&
2 10000
30000
0
B
2 100
B
P
E
-10 000
-0.006 0 0.006 -0.010 -0.006 0 0.006 0.010
Length of strip/m
Fig. 11 Distributions of impinging pressure (a) and shear stress (b) with variation deflection angle 6
' y4o =-7. 596 9 f O. 130 1x1 -0. 034 1x2 f
6. 830 8x3-0.037 5x4 f 0 . 2 5 6 255
y50 = - 95. 575 8 f O. 080 8x1 -0.016 7x2 +
yG0=-32. 7535+0. 8704x1-0. 0 0 9 l x ~ f
(11)
2.364 8x3 -0. 151 lx4 -23.072 Ox5
9. 404 9x3 -0.342 5x4 -4. 921 4x5
y ~o =- 1 7 2 . 6 5 1 8 +1 . 8 6 1 6 ~~- 0 ~ 0635Xzf
17. 324 6x3 -0. 440 5x4 f 2 . 638 3x5
merical analysisC123. The inlet pressure is 80 kPa,
nozzle slot opening is 1. 2 mm and the nozzle to strip
distance is 10 mm, respectively. The result shows
that the larger the deflection angle is, the lower the
peak value of the pressure and shear stress is. The
location of t he peak value moves toward downward
direction of the strip. Because of the increasing of
traveling distance of flow from t he nozzle lip to strip
surface with the increase of deflection angle, the im-
pact pressure decreases with increase of deflect angle.
The reduction of max impinging pressure which may
relate directly to t he problem of splashing is about
18%, and the increase of coating thickness for the
same conditions at most is 11%. But the coating
thickness for 6= 5"is smaller than that of 6=Oode-
spite of its largeness in max impinging pressure.
This may be caused by the fact that the shear stress
acting for 6=5"at the region of half value width of
pressure distribution is larger than that of 6=0". So
there exists the optimum deflection angle 6= 5" be
very effective to prevent splashing for the given inlet
pressure and slot size.
5 Predictive Model Design
Based on these results, the developed model
predicts the coating mass as function of different op-
erating parameters. The result of galvanizing opera-
tion is expressed in g/m2 as the mean mass of the
zinc deposited per unit of area.
CW= kKZbPcDd ( 9)
Taking into account of the distance between the
knives and bath as well, to improve regression coef-
ficients, the conventional model which has a log-lin-
ear structure is as follows"3' :
logCW= logk +alogV, +bl ogZ+cl ogPf
dlogD+elogH (10)
where, CW is coating mass; V, is strip velocity; Z is
Issue 6 Influence of Air-Knife Wiping on Coating Thickness in Hot-Dip Galvanizing 77
Table 1 Experimental parameters matrix of coating thickness regression
Test CW.i,/(g * m- Z) CW,,.,/(g * m- z) V, / ( m * s-l) H/ mm Z/mm P,,.,lkPa D/ mm CW,.i
1 40 49.82 110.00 500 11 39.513 1. 20 53.38
2 40 47.52 115.02 300 9 32.016 1. 20 47.54
3 40 46.35 100.02 300 9 27.008 1. 20 45. 83
4 40 43. 14 79.98 550 10 26.005 1. 20 51.73
5 40 44.35 100.02 500 10 32.515 1. 20 45.61
6 50 56.04 70.02 350.00 8 13.016 1. 15 57.09
7 50 58.11 70. 98 500 11 21.020 1. 15 60. 61
8 50 51. 58 130.02 400 8 30.008 1. 15 56.67
9 50 53. 23 103. 02 400 10 27.008 1. 15 55.26
10 50 52.42 61.02 400 9 11.618 1. 15 57.25
11 60 62.60 139. 98 500 10 32.608 1. 10 64.50
12 60 59.99 79.98 550 10 17. 026 1. 10 66.57
13 60 62.09 115.02 600 10. 5 27.023 1. 10 64. 57
14 60 61.06 94.98 450 10 20.530 1. 10 63.52
15 60 71. 95 64.98 650 11 11. 519 1. 10 68. 55
16 90 97.55 97. 98 550 10 14.018 1. 10 95. 03
17 90 93.20 120.00 400 10 18.017 1. 10 96.13
18 90 94.97 120.00 280 9 16. 516 1. 10 93.68
19 90 95.38 90.00 500 12 16.013 1. 10 97.64
20 90 95.97 111.00 500 10 16.315 1. 10 97.87
'E
1 40
44
. 8 Measuredcurve
- Target mass
I I I I I
5 10 15 20
( a) CW.,,=40 g/ mZ; ( b) CW,,,=50 g/ m2; (c) CWa,,=60 g/ m2; (d) CWa,,=90 g/ mZ.
Fig. 12 Result of regression model fitting curve
target coating mass is 50 g/m2. This value correspond-
ing to coating thickness is approximately 53 pm. Con-
sidering the difficulties to change the parameters in an
industrial environment, especially the regulation of
the impinging jet pressure, the optimum thickness is
expected to remain in the same range. When strip
velocity changed from 70 t o 120 m/min, the models
predicted coating mass variation of less than f 1 2 g/m"
* 78 ' Jour nal of I r on and Steel Resear ch, International Vol. 19
~
that translated t he coating thickness variation should
be less than +1. 68 pm.
Y
6 Conclusions
1) The mathematical models were developed to
predict t he coating mass. The models consist of pa-
rameters of strip velocity, the jet nozzle pressure,
the nozzle to strip distance, nozzle slot opening and
distance between the knives and bath. The coating
mass predictions which have multiple correlation co-
efficients R2 more than o. 9483 are within f14% of
the measured coating mass.
2 ) The pressure and shear stress profile re-
quired in model were calculated through regression
analysis, carried out using numerical simulation.
The effect of the outlet pressure on the strip surface
is linear with peak value of pressure and shear
stress. But it is nonlinear with pressure distribution
and mostly decided by the nozzle to strip distance.
3 ) The numerical simulation using FLUENT
results show that nozzle to strip distance should be
controlled under a critical value 11. 4 mm in order to
improve the stability of coating thickness and uni-
f ormi ty.
4 ) A new air knife system with variable nozzle
slot opening and edge baffle plate are recommended
t o deal with t he edge over-galvanized problem. Un-
der t he same nozzle condition, slight tilting around
6= 5" of air knife is the most effective to control
coating thickness and reduce possibility of splashing
at No. 4 CGL of Angang Steel.
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