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Contents

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

Nisshin Steel Quality Products

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.

Aerial view of the Sakai Works

Nisshin Steel Quality Products

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.

Nisshin Steel Quality Products

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.

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.

Nisshin Steel Quality Products

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

Nisshin Steel Quality Products

Examples of Uses

Kitchen utensils

Kitchen utensils

Kitchen utensils

Oven, toaster

Gas oven

Two-burner gas stove

Gas range

Smokestack

Nisshin Steel Quality Products

Examples of Uses

Muffler

Muffler

Muffler

Muffler

Heat insulator

Reactor part

Muffler and converter

Nisshin Steel Quality Products

Examples of Uses

Manifold cover

Manifold cover

Manifold cover

Charcoal stove

Charcoal stove

Chimney

Barbecue grill

Kerosene stove

Fireplace

Nisshin Steel Quality Products

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

Deep Drawing Quality

DQSK

Dull

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


MSA

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

Chromate and oiling

N0

Oiling nonchromate

M0

2.Masses of Aluminum Coating


Alstar is available in various masses of aluminum coating as shown in the following table.
Table 3
Item

Symbol

Minimum mass on both


sides
triple-spot test

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.

Nisshin Steel Quality Products

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

Deep Drawing Quality

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.

(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 par ts 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.
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

Nisshin Steel Quality Products 10

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

0.27 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 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.

(2) Length and width tolerances


Table 6

Table 7

mm

mm

Item

Tolerance

Edge

Tolerance

Length

12, 0

Mill edge

10, 0

Slit edge

0.5

Applies to widths less than 600mm

Note : The length tolerances shown in


Table 6 do not apply to coil
products.

Remarks

(3) Flatness tolerances


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

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

Press Forming Quality

11

Notes : 1. Flatness tolerances apply to cut length sheets.


2. Consult us about tolerances for panel quality and commercial quality sheet when ordering.

11 Nisshin Steel Quality Products

Specifications

(4) Camber tolerances


Camber is the greatest deviation of a side edge from a straight line. Camber measurement is taken as shown in Figure 3 for cutlengths 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
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

Length over 2,000 to 3,658 excl.

Coil

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 per 2,000

Nisshin Steel Quality Products 12

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)

13 Nisshin Steel Quality Products

Oxidized layer caused by


high temperature

Heating

Fe (after heating)

Alloy layer

Fe (after more heating)

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

After 100 hours of heating at 500

After 1,000 hours of heating at 500

(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)

18-8 stainless ste

12

16

20

24

28

32

36

40

44

48

52

Oxidation Time (hours)


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

Nisshin Steel Quality Products 14

Properties

(4) Mass increase/decrease by oxidation through heating and cooling cycles


Figures 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

Temperature ()

800

600

600
400
200

12
Hours

16

20

24

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

600

750

100

Oxidation Increase/Decrease (g/m2)

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

15 Nisshin Steel Quality Products

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

Stainless steel sheet

2B

15

Hmax 1.2

Stainless steel sheet

BA

60

Hmax

Cold-rolled steel sheet coated with silver paint

Dull

Hmax

Notes : 1. Surface luster measured


with gloss meter Model GM-3 conformity with JIS 8741.
in
2. 1/10 light filter Gs
60 used.
is

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

Alstar (room temperature)

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

Nisshin Steel Quality Products 16

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.
Table 11
Pretest Treatment
TI-25DQ Alstar
MSA-80 Drawing Quality
Other manufacturers'
electro-galvanized sheet

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%

(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 approximately one

to
zinc.

(4) Resistance to chemicals


Alstar has less resistance to alkaline industrial chemicals, but greater resistance to acid industrial chemicals than galvanized
sheet.
Table 12
Chemicals
Light oil

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

17 Nisshin Steel Quality Products

Note : Evaluation scale : E Excellent


G Good
F Fair
P Poor

Properties

(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.
Table 13
Decrease in Massg

Decrease in Thickness
converted from the mass decrease

in.

mm

TI-25DQ Alstar MSA-80 Drawing Quality

x
0.260

0.011

0.0007

0.018

TI-25CQ Alstar MSA-80 Commercial Quality

0.191

0.035

0.0005

0.013

Notes : 1. Test method:


Chrysler's spec. 461H-83.
2. Test outline:
aA mixed solution of 180
F
82
0.01N hydrobromic acid and 0.05N sulfuric acid was used for the test.
bCold 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
.
cHot muffler conditions. Then the test pieces were heated in a furnace at 1,000
F
538for two hours.
dSteps
b cwere repeated for 240 hours.
and
3. Test results judgment:
aAmounts of decrease before and after the test were measured.
bDecreased amounts were converted into decrease in sheet thickness.
cConverted 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 coating
mass Alstar passed this test.

Nisshin Steel Quality Products 18

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

Shear Strength (N)

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

Diameter of electrode force mark

2,000

100

200

300

400

500

600

Number of Welds

Notes : Welding conditions:


Welding current: 11,200A to 14,500A.

19 Nisshin Steel Quality Products

Electrode force: 2,000N


Welding time: 7
.

700

800

900

1,000

Properties

(2) Seam welding


Table 15 shows an example of seam welding conditions for Alstar.
Table 15
Time

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

(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 corrosionresistant 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
Weldability

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

Table 17:Example of TIG Welding

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

Notes : 1. Argon gas flow rate: 6 l/min


2. AC power source: Pure tungsten electrode 3.2
3. DC power source: Thorium-containing tungsten electrode 3.2
(4) Weld repairs
Welds and damaged aluminum coating can be repaired with silver paint or with molten aluminum spray.

Nisshin Steel Quality Products 20

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

21 Nisshin Steel Quality Products

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

Chromate treatment or phosphate


treatment is recommended.

(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.

Nisshin Steel Quality Products 22

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

23 Nisshin Steel Quality Products

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

Notes : 1. Tensile test: JIS No.11 test piece


2. 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
Table 19: Available Dimensions of Alstar Steel Pipe
Outside Diameter or
Side Length
mm

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

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

Nisshin Steel Quality Products 24

Extracts from ASTM A 463-83

Standard Specification for

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


1. Scope
1.1 This specification covers aluminum-coated steel sheet
Type 1 in coils and cut lengths coated with an aluminumsilicon 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 be
regarded 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 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.

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.

25 Nisshin Steel Quality Products

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

square meterof 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 handoperated vise with smooth jaws should be used for making
the 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.

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

Calculated Coating Thickness


Based on Minimum
Single Spot Test,a in.

60

0.0013
0.0008

Calculation based on aluminum density of 0.0975 lb/in.

11. Dimensions, Weights, and Tolerances


11.1 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.
9.5mmfrom 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.
Thickness Tolerances for Widths and Thicknesses, Over and Under, in.
Specified Width, in.

Specified Thickness, in.


Over 0.101
to 0.187, incl

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

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 Type1Coils and Cut Lengths Not
Resquared
Specified Width, in.
mm
Over 12
300 30
to 760incl
,

Tolerance Over Specified


Width, No Tolerance Under

Appendix A1. Metric Equivalents


A1.1 The metric equivalents for the tolerances given in the
tables are shown in Table A1.
TABLE A1 Metric Equivalents a

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

Conversion factor : 1 in.25.4mm.

Nisshin Steel Quality Products 26

www.nisshin-steel.co.jp
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290-5100 Facsimile:
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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.

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