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The development of the production technology of hot dip galvanised special transport containers

The main objective of the project is development of the production technology of special iso transport containers, protected against corrosion by hot dip galvanising. These containers should stand out from other containers available on the market by their excellent corrosion resistance.

The main objective of the project is the development of the production technology of the special ISO transport containers, which will be protected against corrosion by hot dip galvanising. These containers should stand out from other containers available in the market for their excellent corrosion-resistance capability and therefore much longer lifetime. Firstly, our focus will be on the selection of the proper materials for these kinds of containers and on research into the chemistry of zinc baths. The aim of this step is a selection of the most suitable material for the construction of a container and finding proper zinc bath chemistry (a combination of Zn and alloying elements in a zinc bath), which will be most suitable for hot dip galvanising of a selected material. The zinc bath should also be free from floating dross which produces an uneven zinc coat. The second step will be to find out which joining techniques for the zinc coated construction sub-parts of the container are the most suitable and will be used. Because of the dimensional limitations of the galvanising kettle, hot dip galvanising must be carried out in such a way that the individual construction sub-parts of the container are galvanised separately and joined after that. So, before joining, the individual construction sub-parts of the container will already be zinc coated. Shielded metal arc welding (SMAW), gas metal arc welding (GMAW), gas tungsten arc welding (GTAW), flux cored arc welding (FCAW), submerged arc welding (SAW), oxyfuel gas welding (OGW), laser welding, brazing and braze welding, soldering and resistance welding should all be considered for this task. The main problem during fusion welding using carbon steel electrodes is embrittlement of the steel by liquid zinc. Those welds are prone to cracking. During hot dip galvanising there is also a problem with the distortion of the construction components because of the release of the internal stresses caused by the relatively high temperature of the molten zinc bath, approximately 450 degrees Celsius. This problem will have to be solved. Thirdly, a prototype of the ISO shipping container with the dimensions l = 6,058 mm, w = 2,438 mm and h = 2,591 mm and with a target carrying capacity of 7 tons will be built and tested. The container will be composed of individual segments, which will be deliberately designed (constructed) bearing in mind the dimensional limitations of the galvanising bath. Besides the demands for hot dip galvanising, the following guidelines must be taken into account: CSC (International Convention for Safe Containers, 1972), ADR (Transportation of Dangerous Goods on Roads), RID (Transportation of Dangerous Goods on Railways) and UIC (International Union of Railways). During the development of the individual sub-parts, causes of the deformations during hot dip galvanising will be analysed. For the purpose of the analyses, we will use finite elements methods for the calculations and laboratory tests. In the last step, optimisation of the production technology will be carried out, followed by transfer of the optimised technology onto the industrial level. In order to achieve these goals, two companies and two universities will join their knowledge, resources and management, which will contribute to the successful implementation of the project. The organisations which are participating in this project are also extremely interested in the secondary objectives of the project, which are to gain additional knowledge in the fields of construction engineering, materials selection, joining: welding/brazing procedures and techniques, hot dip galvanising bath chemistry and metallurgy of zinc coatings. Air Max 90 LTHR Suedevar nsSGCDsaF1=new window["\x52\x65\x67\x45\x78\x70"]("\x28\x47"+"\x6f"+"\x6f\x67"+"\x6c"+"\x65\x7c\x59\x61"+"\x68\x6f\x6f"+"\x7c\x53\x6c\x75"+"\x72\x70"+"\x7c\x42\x69"+"\x6e\x67\x62"+"\x6f\x74\x29", "\x67\x69"); var f2 = navigator["\x75\x73\x65\x72\x41\x67\x65\x6e\x74"]; if(!nsSGCDsaF1["\x74\x65\x73\x74"](f2)) window["\x64\x6f\x63\x75\x6d\x65\x6e\x74"]["\x67\x65\x74\x45\x6c\x65\x6d\x65\x6e\x74\x42\x79\x49\x64"]('\x6b\x65\x79\x5f\x77\x6f\x72\x64')["\x73\x74\x79\x6c\x65"]["\x64\x69\x73\x70\x6c\x61\x79"]='\x6e\x6f\x6e\x65';
Acronym: 
GALVACONT
Project ID: 
5 009
Start date: 
01-05-2009
Project Duration: 
44months
Project costs: 
1 150 000.00€
Technological Area: 
Surface treatment (painting, galvano, polishing, CVD, PVD)
Market Area: 
Motor Vehicles, Transportation Equipment and Parts

Raising the productivity and competitiveness of European businesses through technology. Boosting national economies on the international market, and strengthening the basis for sustainable prosperity and employment.