DE102023119937A1 - Process for hot-dip galvanizing of components - Google Patents

Abstract

The present invention relates to a method for hot-dip galvanizing (hot-dip galvanizing) an iron or steel component, in particular for producing a hot-dip galvanized iron or steel component with increased corrosion protection performance and/or with increased ductility, preferably in a two-stage hot-dip galvanizing process, as well as a corresponding plant and a hot-dip galvanized iron or steel component obtainable in this way and the uses of such a hot-dip galvanizing process.

Description

The present invention relates to the technical field of galvanizing iron-based or iron-containing components, in particular steel-based or steel-containing components (steel components), preferably for the automotive or motor vehicle industry, the construction industry, the field of general mechanical engineering, the electrical industry and other technical fields of application, by means of hot-dip galvanizing (hot-dip galvanizing).

In particular, the present invention relates to a method and a plant for hot-dip galvanizing (hot-dip galvanizing) an iron or steel component, in particular for producing a hot-dip galvanized iron or steel component with increased corrosion protection performance and/or with increased ductility, preferably in a two-stage hot-dip galvanizing process, and furthermore to the products obtainable by the method according to the invention or in the plant according to the invention (i.e. hot-dip galvanized iron or steel components) and the corresponding uses, in particular of a two-stage hot-dip galvanizing process.

Metallic components of any kind made of ferrous material, especially components made of steel, often require efficient protection against corrosion due to their application. In particular, components made of steel for motor vehicles (motor vehicles), such as cars, trucks, commercial vehicles, etc., but also for other technical areas (e.g. construction industry, mechanical engineering, electrical industry, etc.), require efficient corrosion protection that can withstand long-term stress.

In this context, it is known to protect steel-based components against corrosion by means of galvanizing (galvanizing). During galvanizing, the steel is provided with a generally thin zinc layer to protect the steel from corrosion. Various galvanizing processes can be used to galvanize steel components, i.e. to cover them with a metallic zinc coating, in particular hot-dip galvanizing (also known as hot-dip galvanizing), spray galvanizing (flame spraying with zinc wire), diffusion galvanizing (Sherard galvanizing), electrolytic galvanizing, non-electrolytic galvanizing using zinc flake coatings and mechanical galvanizing. There are major differences between the aforementioned galvanizing processes, particularly with regard to the process implementation, but also with regard to the nature and properties of the zinc layers or zinc coatings produced.

The most important method for protecting steel from corrosion using metallic zinc coatings is hot-dip galvanizing (hot-dip galvanizing). Steel is dipped continuously (e.g. strip and wire) or piece by piece (e.g. components) into a heated tank filled with liquid zinc at temperatures of around 400 °C to 600 °C (melting point of zinc: 419.5 °C; zinc alloys can have a higher or lower melting point), so that a resistant alloy layer of iron and zinc forms on the steel surface, with a very firmly adhering pure zinc layer on top.

Hot-dip galvanizing has been a recognized and proven method for protecting parts and components made of iron materials, especially steel materials, from corrosion for many decades. As previously described, the typically pre-cleaned or pre-treated component is immersed in a liquid-hot zinc bath, where it reacts with the molten zinc and, as a result, forms a relatively thin zinc layer that is metallurgically bonded to the base material.

In hot-dip galvanizing, a distinction is made between discontinuous batch galvanizing (cf. e.g. DIN EN ISO 1461 and DIN 50997) and continuous strip and wire galvanizing (cf. e.g. DIN EN 10143 and DIN EN 10346). Both batch galvanizing and strip and wire galvanizing are standardized processes. Continuously galvanized steel strip and continuously galvanized wire are each a preliminary or intermediate product (semi-finished product) which is further processed after galvanizing, in particular by forming, punching, cutting, etc., whereas components to be protected by batch galvanizing are usually first completely or at least partially manufactured and only then hot-dip galvanized (which protects the components all around against corrosion). Depending on the application conditions, batch galvanizing and strip/wire galvanizing differ in terms of the phase structure and the thickness of the resulting zinc coatings, which can result in different protection periods - also depending on the zinc layer. The zinc layer thickness of strip galvanized sheets is usually in the range of 10 to 35 micrometers, whereas the zinc layer thickness of batch galvanized steel parts is usually in the range of 50 to 200 micrometers and even more.

Hot-dip galvanizing provides both active and passive corrosion protection. Passive protection is provided by the barrier effect of the zinc coating. Active corrosion protection is provided by the cathodic effect of the zinc coating. Compared to more noble metals in the electrochemical series, such as iron, zinc serves as a sacrificial anode, which protects the iron underneath from corrosion until it is completely corroded itself.

In the so-called batch galvanizing according to DIN EN ISO 1461, the hot-dip galvanizing of mostly larger steel components and structures takes place. Steel-based blanks or (semi-)finished workpieces (components) are dipped into the molten zinc bath after pretreatment. By dipping, inner surfaces, weld seams and hard-to-reach areas of the workpieces or components to be galvanized can be easily reached.

Conventional hot-dip galvanizing, particularly dip galvanizing, is based on dipping iron or steel components into a zinc melt to form a zinc coating on the surface of the components. To ensure the adhesion, integrity and uniformity of the zinc coating, careful surface pretreatment and, if necessary, preparation of the components to be galvanized is generally required beforehand, which usually includes degreasing followed by rinsing, subsequent acid pickling followed by rinsing and finally flux treatment (i.e. so-called fluxing) followed by drying.

For reasons of process economy and cost-effectiveness, when galvanizing identical or similar components (e.g. series production of automotive components), these are typically brought together or grouped for the entire process (in particular by means of a common product carrier, for example designed as a crossbeam or frame, or a common holding or fastening device for a large number of these identical or similar components). For this purpose, a plurality of components are attached to the product carrier using holding devices, such as slings, tie wires or the like. The components are then fed in a grouped state via the product carrier to the individual treatment steps or stages of hot-dip galvanizing.

• Zunächst werden die Bauteiloberflächen der betreffenden Bauteile einer Entfettung unterzogen, um Rückstände von Fetten und Ölen zu entfernen, wobei als Entfettungsmittel üblicherweise wässrige alkalische oder saure Entfettungsmittel zur Anwendung kommen können. Nach der Reinigung im Entfettungsbad schließt sich üblicherweise ein Spülvorgang an, typischerweise durch Eintauchen in ein Wasserbad, um ein Verschleppen von Entfettungsmitteln mit dem Verzinkungsgut in den nachfolgenden Prozessschritt des Beizens zu vermeiden, wobei dies insbesondere bei einem Wechsel von alkalischer Entfettung auf eine saure Beize von hoher Bedeutung ist.

The typical process sequence for conventional hot-dip galvanizing is usually as follows:

• First, the surfaces of the components in question are degreased to remove residues of grease and oil, whereby aqueous alkaline or acidic degreasing agents can usually be used as degreasing agents. After cleaning in the degreasing bath, a rinsing process usually follows, typically by immersion in a water bath, in order to prevent degreasing agents from being carried over with the galvanized material into the subsequent process step of pickling, whereby this is particularly important when changing from alkaline degreasing to acidic pickling.

This is followed by a pickling treatment (pickling), which is used in particular to remove inherent contaminants such as rust and scale from the steel surface. Pickling is usually carried out in diluted hydrochloric acid, whereby the duration of the pickling process depends, among other things, on the state of contamination (e.g. degree of rust) of the galvanized material and the acid concentration and temperature of the pickling bath. To avoid or minimize the carryover of acid and/or salt residues with the galvanized material, a rinsing process (rinsing step) usually takes place after the pickling treatment.

This is followed by what is known as fluxing (also known as flux treatment), in which the previously degreased and pickled steel surface is treated with a flux, which typically comprises an aqueous solution of inorganic chlorides, most frequently a mixture of zinc chloride (ZnCl ₂ ) and ammonium chloride (NH ₄ Cl). On the one hand, the purpose of the flux is to carry out a final, intensive, fine cleaning of the steel surface before the steel surface reacts with the molten zinc, to dissolve the oxide skin of the zinc surface and to prevent further oxidation of the steel surface until the galvanizing process. On the other hand, the flux is intended to increase the wettability between the steel surface and the molten zinc. After the flux treatment, drying usually follows in order to create a solid flux film on the steel surface and to remove adhering water, so that subsequent undesirable reactions (in particular the formation of water vapor) in the liquid zinc dip bath are avoided.

The components pretreated in the above-mentioned manner are then hot-dip galvanized by immersing them in the liquid zinc melt. When hot-dip galvanizing with pure zinc, the zinc content of the melt is at least 98.0 wt.% in accordance with DIN EN ISO 1461. After immersing the item to be galvanized in the molten zinc (or zinc alloy), it remains in the zinc melt bath for a sufficient period of time, in particular until the item to be galvanized has assumed its temperature and is coated with a zinc layer. Typically, the surface of the zinc melt is cleaned of oxides, zinc ash, flux residues and the like, in particular, before the item to be galvanized is then removed from the zinc melt. The component hot-dip galvanized in this way is then subjected to a cooling process (e.g. in air or in a water bath). Finally, any holding devices for the component, such as slings, tie wires or the like, are removed.

Following the galvanizing process, the galvanized components are usually subjected to post-processing. This involves removing, as far as necessary, excess zinc bath residues, particularly drips from the zinc solidifying on the edges, as well as oxide or ash residues that adhere to the component.

One criterion for the quality of hot-dip galvanizing is the thickness of the zinc coating in µm (micrometers). The DIN EN ISO 1461 standard specifies the minimum values of the required coating thicknesses that must be delivered during batch galvanizing depending on the material thickness. In practice, the coating thicknesses are significantly higher than the minimum coating thicknesses specified in DIN EN ISO 1461. In general, zinc coatings produced by batch galvanizing have a thickness in the range of 50 to 200 micrometers and even more.

During the galvanizing process, a coating of iron/zinc alloy layers of various compositions forms on the steel part as a result of mutual diffusion of the liquid zinc with the steel surface. When the hot-dip galvanized objects are removed, a layer of zinc - also known as the pure zinc layer - remains on the top alloy layer, which corresponds in composition to the zinc melt. Due to the high temperatures during hot-dip dipping, a relatively brittle layer based on an alloy (mixed crystals) between iron and zinc initially forms on the steel surface, and only then does the pure zinc layer form on top of that. The relatively brittle iron/zinc alloy layer improves the adhesion to the base material, but makes it more difficult to form the galvanized steel. This leads to the formation of relatively large total layer thicknesses. Although this allows for a very long period of corrosion protection, the risk of the layer chipping off under mechanical stress, particularly local impacts, and the corrosion protection effect being impaired thereby increases with the thickness of the zinc layer. The zinc layer formed is also not ductile and thus the possibilities for further processing are limited, especially while maintaining the corrosion protection effect.

In order to counteract the problem described above of the occurrence of the rapidly growing, brittle and thick iron/zinc alloy layer and to enable thinner layer thicknesses with simultaneously high corrosion protection during galvanizing, it is known from the state of the art to add additional aluminum to the zinc melt or the liquid zinc bath. For example, by adding 5% by weight of aluminum to a liquid zinc melt, a zinc/aluminum alloy with a lower melting temperature than pure zinc is produced. By using a zinc/aluminum melt (Zn/Al melt) or a liquid zinc/aluminum bath (Zn/Al bath), on the one hand, significantly thinner layer thicknesses can be achieved for reliable corrosion protection (generally below 50 micrometers); On the other hand, the formation of the brittle iron/zinc alloy layer is avoided because the aluminium - without committing to a specific theory - first forms a barrier layer on the steel surface of the component in question, onto which the actual zinc layer is then deposited.

Components hot-dip galvanized with a zinc/aluminium melt can therefore be easily formed, but still have improved corrosion protection properties - despite the significantly lower layer thickness compared to conventional hot-dip galvanizing with a virtually aluminum-free zinc melt.

A zinc/aluminium alloy used in a hot-dip galvanizing bath has improved fluidity properties compared to pure zinc. In addition, zinc coatings produced by hot-dip galvanizing using such zinc/aluminium alloys have greater corrosion resistance (which is two to six times better than that of pure zinc), better appearance, better improved formability and better paintability than zinc coatings made from pure zinc. In addition, lead-free zinc coatings can also be produced using this technology.

Such a hot-dip galvanizing process using a zinc/aluminium melt or using a zinc/aluminium hot-dip galvanizing bath is known, for example, from WO 2002/042512 A1 and the relevant publication equivalents to this patent family (e.g. EP 1 352 100 B1 , DE 601 24 767 T2 and US 2003/0219543 A1 ). Suitable fluxes for hot-dip galvanizing using zinc/aluminium molten baths are also disclosed there, since flux compositions for zinc/aluminium hot-dip galvanizing baths must be different from those for conventional hot-dip galvanizing with pure zinc. The process disclosed there can be used to produce corrosion protection coatings with very low layer thicknesses (generally well below 50 micrometers and typically in the range of 2 to 20 micrometers) and with very low weight and high cost efficiency, which is why the process described there is used commercially under the name microZINQ ^® process.

With regard to the formation of the zinc layer and its properties, it has been shown that these can be significantly influenced by alloying elements in the zinc melt. One of the most important elements here is aluminum: It has been shown that with an aluminum content in the zinc melt of just 100 ppm (weight-based), the appearance of the resulting zinc layer can be improved to a brighter, shinier appearance. As the aluminum content in the zinc melt increases up to 1,000 ppm (weight-based), this effect increases steadily. Furthermore, it has been shown - as already described - that from an aluminum content in the zinc melt of 0.12 wt.%, an intermetallic Fe/Al phase forms between the iron material and the zinc layer, which leads to the otherwise usual diffusion processes between iron and zinc melt being inhibited and thus the growth of the Zn/Fe phases being significantly reduced; as a result, significantly thinner zinc layers result from this aluminum content in the zinc melt. Finally, it has been shown that the anti-corrosive effect of the resulting zinc layer increases with increasing aluminum content in the zinc melt; the basis for this is that the Zn/Al compounds form significantly more stable covering layers more quickly.

Well-known examples of the commercial use of aluminum-containing zinc melts are the so-called Galfan ^® process and the aforementioned microZINQ ^® process with an aluminum content in the zinc melt typically in the range of 4.2 wt.% to 6.2 wt.%. The advantage of this alloy is, among other things, that around the average value of 5 wt.% there is a eutectic composition of the Zn/Al system with a melting point of 382 °C, which enables a reduction in the operating temperature in the galvanizing process.

The disadvantage of using aluminum-alloyed or aluminum-containing zinc melts (Zn/Al melts) is that the formation of deliberately thicker or individually adjustable zinc layers is not possible within the framework of the known processes. This is because as soon as the maximum layer thickness of the aluminum-alloyed galvanizing layer has been reached according to conventional processes, even a longer residence time in the zinc/aluminum melt does not lead to a further increase in the zinc layer thickness, since the formation of the Fe/Al phase in the form of a barrier layer blocks the kinetics of the zinc layer growth, which in turn limits the layer growth and a maximum layer thickness cannot be exceeded.

This maximum layer thickness is disadvantageous, for example, when cold forming a hot-dip galvanized component, as the corrosion protection performance at the forming points can decrease significantly due to the relatively thin layer thickness. A thicker zinc layer is therefore necessary for high corrosion protection performance after forming. In addition, a thicker zinc layer may also be necessary for applications where long corrosion protection duration under high loads is required.

However, the use of the pure zinc layers described above does not represent a good alternative either, even if the layer thickness is adjustable and not limited, since such a zinc layer, as previously stated, is brittle and thus essentially not formable, especially not without significantly reducing the corrosion protection performance.

In the previously described state of the art, there is therefore no possibility of providing a hot-dip galvanized layer which is simultaneously ductile and in which the layer thickness is adjustable so that an overall increased corrosion protection performance can be provided. In particular, the State of the art on a hot-dip galvanized layer which is formable or cold-formable, in particular bendable by 90°, essentially without loss or reduction of the corrosion protection performance.

Particularly in connection with the galvanization of steel strips (“strip galvanization”), the so-called double-dip process is used in the prior art as a wet-on-wet process, whereby the steel strip to be galvanized passes through two galvanizing baths with different compositions in direct succession, i.e. the second galvanizing step immediately follows the first, whereby the first galvanizing layer still has (partially) liquid or not yet (at least fully) solidified phases. For this purpose, the two galvanizing baths must be located directly one after the other at one location, since the zinc layer formed in the first hot-dip galvanizing bath must not yet have solidified (i.e. must still be “wet”, so to speak) when the steel strip is introduced into the second zinc bath. In particular, the zinc layer formed in the first hot-dip galvanizing bath must not oxidize before the second hot-dip galvanizing, so that a protective gas atmosphere, for example a forming gas atmosphere, is often present. Overall, such a wet-on-wet process, which is also occasionally used as a batch galvanizing process, is very energy-intensive, particularly since two galvanizing baths have to be operated in combination and cannot be used independently of one another. In addition, with the wet-on-wet process, the time between the galvanizing baths is critical; in particular, this must not vary in order to achieve a consistent galvanizing quality. The temperature of the component that has been given the first hot-dip galvanizing when immersed in the second galvanizing bath is also critical and this affects the second hot-dip galvanizing. In addition, when used in the batch galvanizing process, the layer thickness and layer structure are difficult or impossible to control and monitor. In addition, in the second hot-dip galvanizing bath, the surface tension of the first zinc layer, which is still liquid, on the steel strip must be overcome. Another disadvantage is that due to uncontrollable diffusion processes, the layer structure can only be reproduced to a very limited extent and an optimal adhesion to the component is not always achieved, which can be associated with limited corrosion protection.

The problem underlying the present invention therefore consists in providing a method for hot-dip galvanizing (hot-dip galvanizing) an iron or steel component, in particular for producing a hot-dip galvanized iron or steel component with increased corrosion protection performance and/or with increased ductility, preferably in a two-stage hot-dip galvanizing process, as well as a corresponding system for carrying out this method, wherein the previously described disadvantages of the prior art are to be at least largely avoided or at least mitigated.

In particular, such a process or such a system is to be provided which, compared to conventional hot-dip galvanizing processes or systems, enables an individually or specifically adjustable zinc layer thickness and provides a more ductile hot-dip galvanizing layer.

In addition, such a process or such a system is to be provided which, compared to conventional hot-dip galvanizing processes, provides increased corrosion protection performance and increased ductility of the resulting hot-dip galvanizing layer.

Furthermore, such a process or such a system is to be provided with which a hot-dip galvanized layer with improved formability, in particular cold formability, is provided while maintaining a high corrosion protection performance.

Furthermore, an aluminum-containing or aluminum-alloyed hot-dip galvanizing layer with increased layer thickness is to be provided, as well as a plant and a method for producing such an aluminum-containing or aluminum-alloyed hot-dip galvanizing layer with increased layer thickness.

Furthermore, a hot-dip galvanizing layer with increased ductility compared to a classic batch galvanizing layer according to DIN EN ISO 1461 or pure zinc layer is to be provided, as well as a plant and a process for producing such a hot-dip galvanizing layer with increased ductility.

The aim is also to provide such a method or such a system which enables improved process economy and/or a more efficient, in particular more flexible and/or more reliable, in particular less error-prone process flow and/or improved business compatibility and/or improved cost and resource utilization.

Finally, uncontrollable diffusion processes should be avoided during the formation of the layer structure, so that a reproducible and consistent layer formation is achieved with simultaneous optimal adhesion to the component, which should be accompanied by improved corrosion protection.

To solve the problem described above, the present invention - according to a first aspect of the present invention - proposes a method for hot-dip galvanizing (hot-dip galvanizing) an iron or steel component according to claim 1; further, in particular special and/or advantageous embodiments of the method according to the invention are the subject of the relevant method subclaims.

Furthermore, the present invention - according to a second aspect of the present invention - relates to a plant (system) for hot-dip galvanizing (hot-dip galvanizing) an iron or steel component according to the relevant independent plant claim (claim 52); further, in particular special and/or advantageous embodiments of the plant according to the invention are the subject of the relevant plant subclaims.

Furthermore, the present invention - according to a third aspect of the present invention - relates to a hot-dip galvanized (hot-dip galvanized) iron or steel component according to the relevant independent product claims (claims 66, 67 and 69); further, in particular special and/or advantageous embodiments of the product according to the invention are the subject of the relevant product subclaims.

Finally, the present invention - according to a fourth aspect of the present invention - relates to the uses of a two-stage hot-dip galvanizing process according to the relevant independent use claims (claims 74 to 79); further, in particular special and/or advantageous embodiments of the uses according to the invention are the subject of the relevant use subclaims.

It goes without saying that the embodiments, embodiments, advantages and the like which are described below only for one aspect of the invention in order to avoid repetition also apply accordingly to the other aspects of the invention without this requiring separate mention.

With regard to all relative or percentage weight-related information mentioned below, in particular relative quantity or weight information, it should also be noted that these are to be selected by the person skilled in the art within the scope of the present invention in such a way that, when taken together, including all components or ingredients, in particular as defined below, they always add up to 100% or 100% by weight; however, this is self-evident to the person skilled in the art.

Furthermore, the person skilled in the art may, if necessary - depending on the application or the individual case - deviate from the range specifications given below without departing from the scope of the present invention.

In addition, all values or parameter specifications or the like mentioned below can in principle be determined using standardized or explicitly specified determination procedures or, if not, using determination or measurement methods that are familiar to a person skilled in the art.

Furthermore, for the description of the present invention, the features of the present invention cited in connection with the specific configurations, embodiments, advantages, examples or the like are also deemed to be disclosed in their combination. Thus, higher-level combinations of individual or multiple features which are cited for respective configurations, embodiments, application examples or the like are also deemed to be disclosed.

In particular, for the features characterizing the invention, all possible combinations of these features are deemed to be disclosed, whereby embodiments of comparable or corresponding preference of the various features in their combination are preferred (e.g. amounts or ranges of amounts of the relevant active ingredients and ingredients of the same preference or the like).

In particular, it also applies that for the following quantitative information relating to the various ingredients, in particular active ingredients, of the composition according to the invention or the like, in particular relative quantitative information or absolute quantitative information with the same preference or the same level of preference, respective combinations relating to the various ingredients, in particular active ingredients, with corresponding preference or preference are also disclosed. Likewise, all other combinations (ie combinations based on different preferences or different levels of preference) are also disclosed.

Having said that, the present invention will now be explained in detail below.

The subject matter of the present invention - according to a first aspect of the present invention - is thus a process for hot-dip galvanizing (hot-dip galvanizing) an iron or steel component, in particular for producing a hot-dip galvanized iron or steel component with increased corrosion protection performance and/or with increased ductility, preferably in a two-stage hot-dip galvanizing process,
wherein firstly the iron or steel component is subjected to a first hot-dip galvanizing in a zinc melt (“Zn melt”), in particular in a galvanizing bath containing a zinc melt, and wherein subsequently the iron or steel component obtained after the first hot-dip galvanizing is subjected to a second hot-dip galvanizing in an aluminum-containing and/or aluminum-alloyed zinc melt (“Zn/Al melt”), in particular in a galvanizing bath containing an aluminum-containing and/or aluminum-alloyed zinc melt.

• Denn, wie die Anmelderin nun vollkommen überraschend herausgefunden hat, kann durch das erfindungsgemäße Verfahren, insbesondere zweistufige Feuerverzinkungsverfahren, ein höherer Korrosionsschutz bei gleicher Dicke der Feuerverzinkungsschicht im Vergleich zu einer konventionellen Zinkschicht bzw. Reinzinkschicht bzw. quasi aluminiumfreien Zinkschicht bereitgestellt werden.

As explained below, the present invention is associated with a multitude of completely unexpected advantages, special features and surprising technical effects, the following description of which makes no claim to completeness, but illustrates the inventive character of the present invention:

• This is because, as the applicant has now discovered completely surprisingly, the process according to the invention, in particular the two-stage hot-dip galvanizing process, can provide a higher level of corrosion protection with the same thickness of the hot-dip galvanizing layer compared to a conventional zinc layer or pure zinc layer or quasi aluminum-free zinc layer.

In connection with the present invention, the expression conventional zinc layer or pure zinc layer or quasi aluminum-free zinc layer refers to a zinc layer which is obtainable in a conventional hot-dip galvanizing process described above, in particular where the zinc content of the melt is at least 98.0% by weight according to DIN EN ISO 1461. In particular, a conventional zinc layer (i.e. pure zinc layer or quasi aluminum-free zinc layer) in connection with the present invention must be distinguished from an aluminum-containing or aluminum-alloyed zinc layer. In connection with the present invention, an aluminum-containing or aluminum-alloyed zinc layer has in particular an aluminum content of at least 2% by weight. With regard to the corresponding zinc baths (i.e. pure zinc baths on the one hand and aluminum-containing or aluminum-alloyed zinc baths on the other), these statements and definitions apply accordingly.

In particular, the method according to the invention, in particular the two-stage hot-dip galvanizing method, provides an at least partially layered (total) hot-dip galvanizing layer which consists of Zn/Al/Fe phases. The thickness of this (total) hot-dip galvanizing layer is adjustable and, in addition, it has high corrosion protection properties and high ductility. In addition, this (total) hot-dip galvanizing layer is very bright and therefore optically of particularly high quality.

Furthermore, the applicant has discovered, completely surprisingly, that the (total) layer thickness can be adjusted by the method according to the invention, in particular the two-stage hot-dip galvanizing method, even though an aluminum-containing or aluminum-alloyed zinc bath is used; in particular, the maximum layer thickness is not limited, as is otherwise usual when using aluminum-containing or aluminum-alloyed zinc baths.

In addition, the process according to the invention, in particular the two-stage hot-dip galvanizing process, allows the formation of the aluminum-containing layer to be better controlled. In particular, for example, by controlling the galvanizing time, the proportion of aluminum and the distribution can be controlled, whereby the properties, in particular corrosion protection, optical and mechanical properties, can be adjusted.

Surprisingly, in the process according to the invention, in particular the two-stage hot-dip galvanizing process, a hot-dip galvanizing layer containing Zn/Al/Fe phases is formed, which in particular cannot be obtained by known single-stage processes. In the second hot-dip galvanizing, an aluminum-containing zinc layer is not formed on the layer formed in the first hot-dip galvanizing, which typically consists of a hot-dip galvanizing layer with Zn/Fe phase on the base material and a pure zinc layer or pure zinc phase arranged above it, but an at least partially layered hot-dip galvanizing layer is formed which contains Zn/Al/Fe phases. The second hot-dip galvanizing thus not only applies another layer, but forms a completely new layer, in particular because the aluminum from the second hot-dip galvanizing bath diffuses at least partially into the already existing hot-dip galvanizing layer. Thus, other hot-dip galvanizing layers can be obtained which are not available in known single-stage processes and which have properties which cannot be achieved by single-stage processes.

In particular, the hot-dip galvanizing layer obtainable by the process according to the invention, in particular the two-stage hot-dip galvanizing process, is more ductile and thus less brittle than a pure zinc layer and can therefore be formed or cold-formed, for example bent by 90°, without the corrosion protection properties being lost or significantly impaired.

Furthermore, the hot-dip galvanizing layer obtainable by the method according to the invention, in particular a two-stage hot-dip galvanizing process, can be provided with at least essentially any desired layer thickness, in contrast to an aluminum-containing or aluminum-alloyed hot-dip galvanizing layer that is customary in the prior art and obtainable by a single-stage hot-dip galvanizing process. The hot-dip galvanizing layer obtainable by the method according to the invention, in particular a two-stage hot-dip galvanizing process, is thus not limited by a maximum achievable layer thickness (as in the case of an aluminum-containing or aluminum-alloyed hot-dip galvanizing layer that is customary in the prior art by the formation of an Fe/Al barrier layer).

In particular, the layer thickness of the hot-dip galvanizing layer obtainable by the method according to the invention, in particular the two-stage hot-dip galvanizing process, is not limited, as is the case with an aluminum-containing or aluminum-alloyed hot-dip galvanizing layer that is customary in the prior art and obtainable by a single-stage hot-dip galvanizing process. In particular, hot-dip galvanizing layers with a high aluminum enrichment with a thickness of significantly more than 25 µm can thus also be provided. At the same time, the hot-dip galvanizing layer obtainable by the method according to the invention, in particular the two-stage hot-dip galvanizing process, also has the advantages of an aluminum-containing or aluminum-alloyed hot-dip galvanizing layer, such as gloss, ductility and high corrosion protection properties.

In addition, the process according to the invention, in particular the two-stage hot-dip galvanizing process, is more economical than the aforementioned double-dip process carried out as a wet-on-wet process, which is carried out in particular in connection with strip galvanizing.

In particular, in the process according to the invention, in particular the two-stage hot-dip galvanizing process, the galvanizing baths used can be operated separately, in particular at different locations. This allows both galvanizing baths to be optimally and, above all, fully utilized.

In addition, the galvanizing baths in the process according to the invention, in particular the two-stage hot-dip galvanizing process, can also be operated and used independently of one another, in particular can be used individually, which enables optimal and complete utilization.

The layer thicknesses and layer structures can also be better controlled by the process according to the invention, in particular the two-stage hot-dip galvanizing process, than with a double-dip process carried out as a wet-on-wet process.

In particular, in connection with the method according to the invention, in particular the two-stage hot-dip galvanizing method, neither the time between the hot-dip galvanizing steps or hot-dip galvanizing nor the temperature of the component is critical, in particular in contrast to a double-dip method carried out as a wet-on-wet method.

Furthermore, compared to a double-dip process carried out as a wet-on-wet process, the wettability in the second hot-dip galvanizing is improved; in particular - without wishing to be bound by this theory - the affinity between the surface of the component resulting from the first hot-dip galvanizing and the second hot-dip galvanizing bath increases due to the intermediate activation treatment.

In addition, there is no need to overcome the surface tension in the second hot-dip galvanizing because the layer resulting from the first hot-dip galvanizing is not liquid; in a double-dip process carried out as a wet-on-wet process, the surface tension of the still liquid zinc layer from the first hot-dip galvanizing must first be overcome.

Furthermore - in contrast to a double-dip process carried out as a wet-on-wet process - in the two-stage hot-dip galvanizing process carried out according to the invention, complete diffusion of the aluminum in the second hot-dip galvanizing or through the second hot-dip galvanizing layer can be prevented by targeted process control. This is due - without wishing to be bound to this theory - to the fact that the hot-dip galvanizing layer resulting from the first hot-dip galvanizing is preferably no longer liquid in the process according to the invention or only the top layer is liquid and/or dissolved and/or activated when the second hot-dip galvanizing is carried out. This makes it more difficult for the aluminum to diffuse through, so that a completely different layer structure results than in the case of a conventional double-dip process carried out as a wet-on-wet process. In particular, at least one hot-dip galvanizing layer with Zn/Fe phase, which originates from the first hot-dip galvanizing and is at least substantially free of aluminum, remains on the base material of the iron or steel component, in particular below (below) the outer hot-dip galvanizing layer or the outer layer, whereby a particularly strong adhesion of the (total) hot-dip galvanizing layer to the base material is achieved.

Overall, the process according to the invention, in particular the two-stage hot-dip galvanizing process, is thus more economical, more flexible and easier to control than a double-dip process carried out as a wet-on-wet process. The hot-dip galvanizing layer resulting from the process according to the invention, in particular the two-stage hot-dip galvanizing process, is more ductile and less brittle than a commercial pure zinc layer and, in addition, the layer thickness is adjustable despite the use of an aluminum-containing or aluminum-alloyed zinc bath. In particular, in the process according to the invention, in particular the two-stage hot-dip galvanizing process, a hot-dip galvanizing layer is formed that cannot be provided in a commercial single-stage process, which combines high ductility and an adjustable or controllable layer thickness and layer structure as well as high corrosion protection performance.

In particular, in comparison to conventional hot-dip galvanizing processes, the process according to the invention can enable an individually or specifically adjustable zinc layer thickness and provide a more ductile hot-dip galvanizing layer.

In addition, the process according to the invention can provide increased corrosion protection performance and increased ductility of the resulting hot-dip galvanizing layer compared to conventional hot-dip galvanizing processes.

Furthermore, in the process according to the invention, a hot-dip galvanized layer with improved formability, in particular cold formability, can be provided while maintaining a high corrosion protection performance.

Furthermore, an aluminum-containing or aluminum-alloyed hot-dip galvanizing layer with increased layer thickness can be provided.

Furthermore, a hot-dip galvanized layer with increased ductility can be provided compared to a classic pure zinc layer.

The method according to the invention also enables improved process economy and/or a more efficient, in particular more flexible and/or more reliable, in particular less error-prone process flow and/or improved business compatibility and/or improved cost and resource utilization.

Finally, uncontrollable diffusion processes during the formation of the layer structure will be avoided, so that a reproducible and consistent layer formation is achieved with simultaneous optimal adhesion to the component, which is accompanied by improved corrosion protection.

The present invention thus provides - as previously described - a method for hot-dip galvanizing (hot-dip galvanizing) an iron or steel component, in particular for producing a hot-dip galvanized iron or steel component with increased corrosion protection performance and/or with increased ductility, preferably in a two-stage hot-dip galvanizing process,
wherein firstly the iron or steel component is subjected to a first hot-dip galvanizing in a zinc melt (“Zn melt”), in particular in a galvanizing bath containing a zinc melt, and wherein subsequently the iron or steel component obtained after the first hot-dip galvanizing is subjected to a second hot-dip galvanizing in an aluminum-containing and/or aluminum-alloyed zinc melt (“Zn/Al melt”), in particular in a galvanizing bath containing an aluminum-containing and/or aluminum-alloyed zinc melt.

The zinc melt (“Zn melt”) used in the first hot-dip galvanizing process within the scope of the present invention is in particular a so-called pure zinc melt or pure zinc melt, as described above in particular; i.e. a zinc melt which consists essentially of zinc, in particular contains at least 98% by weight of zinc. An overall relatively brittle galvanizing layer is formed in which intermetallic iron/zinc phases are present on the iron or steel component and on these a pure zinc layer which essentially corresponds to the composition of the zinc melt.

In this context, it is preferred if the zinc melt used in the first hot-dip galvanizing (“Zn melt”) contains at least substantially no aluminum and/or is at least substantially free of aluminum.

This means that no so-called aluminum-containing or aluminum-alloyed zinc melt is used, especially for the first hot-dip galvanizing. This means that particularly intensive fine cleaning is not necessary before the first hot-dip galvanizing; when using an aluminum-containing or aluminum-alloyed zinc melt, the iron or steel surface to be galvanized is much more difficult to wet with the liquid-hot Zn/Al melt and the reaction is much more sensitive and difficult to handle than when using a so-called pure zinc melt, which means that special pre-treatment and cleaning is necessary before hot-dip galvanizing. In addition, the use of a pure zinc melt or a virtually aluminum-free zinc melt does not form an Fe/Al phase in the form of a barrier layer that blocks the kinetics of the zinc layer growth, so that the layer growth is not limited.

Furthermore, within the scope of the method according to the invention, it is preferred if the zinc melt used in the first hot-dip galvanizing (“Zn melt”) contains, based on the zinc melt, at most 1,000 ppm, in particular at most 900 ppm, preferably at most 800 ppm, of aluminum. In other words, within the scope of the present invention, it is preferred if the zinc melt used in the first hot-dip galvanizing (“Zn melt”) contains, based on the zinc melt, at most 0.1% by weight, in particular at most 0.09% by weight, preferably at most 0.08% by weight, of aluminum.

With such small amounts of aluminium, the specific difficulties listed above and the associated requirements of an aluminium-containing or aluminium-alloyed zinc melt do not typically arise.

Furthermore, it is preferred if, in the context of the process according to the invention, the zinc melt used in the first hot-dip galvanizing (“Zn melt”), based on the zinc melt, contains aluminum in amounts in the range from 0 wt.% to 0.1 wt.%, in particular in the range from 0.000001 wt.% to 0.09 wt.%, preferably in the range from 0.00001 wt.% to 0.08 wt.%.

Unlike the first hot-dip galvanizing, the second hot-dip galvanizing of the process according to the invention specifically uses an aluminum-alloyed or aluminum-containing zinc melt (“Zn/Al melt”).

In particular, and without wishing to be limited to this theory, the aluminum-alloyed or aluminum-containing zinc melt (“Zn/Al melt”) diffuses into the first hot-dip galvanizing layer during the second hot-dip galvanizing and a completely new layer is formed; i.e., in the context of the method according to the invention, not only are two hot-dip galvanizing layers with different compositions formed on top of one another. As already explained above, after carrying out the method according to the invention, a special multi-layer or multi-phase layer structure is present, wherein the hot-dip galvanized iron or steel component has an at least partially layered hot-dip galvanizing layer with Zn/Al/Fe phases, in particular as an outer hot-dip galvanizing layer and/or in particular as an outer layer, and wherein the hot-dip galvanized iron or steel component has a hot-dip galvanizing layer with Zn/Fe phases, which optionally contains aluminum, on the base material of the iron or steel component, in particular below (below) the outer hot-dip galvanizing layer and/or the outer layer. In addition, the (total) hot-dip galvanized layer in particular has an aluminum concentration gradient.

The base material referred to above and below is the material from which the iron or steel component itself consists or is formed or on which it is based; the base material is therefore in particular iron, iron-based material or steel.

Within the scope of the method according to the invention, it is therefore particularly provided that the aluminum-alloyed and/or aluminum-containing zinc melt (“Zn/Al melt”) used in the second hot-dip galvanizing contains, based on the zinc melt, at least 2% by weight, in particular at least 3% by weight, preferably at least 4% by weight, of aluminum.

Furthermore, it has proven advantageous in this context if the aluminum-alloyed and/or aluminum-containing zinc melt (“Zn/Al melt”) used in the second hot-dip galvanizing contains, based on the zinc melt, at most 10 wt. %, in particular at most 8 wt. %, preferably at most 6 wt. %, of aluminum.

It is preferred within the scope of the present invention if the aluminum-alloyed and/or aluminum-containing zinc melt (“Zn/Al melt”) used in the second hot-dip galvanizing contains, based on the zinc melt, aluminum in amounts in the range from 1 wt.% to 25 wt.%, in particular in the range from 2 wt.% to 10 wt.%, preferably in the range from 3 wt.% to 8 wt.%, particularly preferably in the range from 4 wt.% to 6 wt.%.

Within the scope of the present invention, it can be provided in particular that the zinc melt used in the first hot-dip galvanizing (“Zn melt”) contains, based on the zinc melt, aluminum in amounts in the range from 0 wt.% to 0.1 wt.% and the aluminum-alloyed and/or aluminum-containing zinc melt used in the second hot-dip galvanizing (“Zn/Al melt”) contains, based on the zinc melt, aluminum in amounts in the range from 2 wt.% to 10 wt.%.

It can also be provided within the scope of the present invention that the zinc melt used in the first hot-dip galvanizing (“Zn melt”) contains, based on the zinc melt, aluminum in amounts in the range from 0 wt.% to 0.09 wt.% and the aluminum-alloyed and/or aluminum-containing zinc melt used in the second hot-dip galvanizing (“Zn/Al melt”) contains, based on the zinc melt, aluminum in amounts in the range from 3 wt.% to 8 wt.%.

Furthermore, according to the present invention, it can be provided that the zinc melt used in the first hot-dip galvanizing (“Zn melt”) contains, based on the zinc melt, aluminum in amounts in the range from 0 wt.% to 0.08 wt.% and the aluminum-alloyed and/or aluminum-containing zinc melt used in the second hot-dip galvanizing (“Zn/Al melt”) contains, based on the zinc melt, aluminum in amounts in the range from 4 wt.% to 6 wt.%.

Consequently, within the scope of the method according to the invention, it is particularly provided that the zinc melt used in the first hot-dip galvanizing process (“Zn melt”) is a pure zinc melt or conventional zinc melt or virtually aluminum-free zinc melt and the aluminum-alloyed and/or aluminum-containing zinc melt used in the second hot-dip galvanizing process (“Zn/Al melt”) contains aluminum and is therefore not a pure zinc melt or conventional zinc melt or virtually aluminum-free zinc melt. Two different zinc melts are therefore preferably used, which differ in particular in the amount of aluminum they contain.

According to a particular embodiment of the present invention, the present invention relates to a method for hot-dip galvanizing (hot-dip galvanizing) an iron or steel component, in particular for producing a hot-dip galvanized iron or steel component with increased corrosion protection performance and/or with increased ductility, preferably in a two-stage hot-dip galvanizing process, in particular a method as described above, wherein the iron or steel component is first subjected to a first hot-dip galvanizing in a zinc melt (“Zn melt”), in particular in a galvanizing bath containing a zinc melt, and wherein the iron or steel component obtained after the first hot-dip galvanizing is subsequently subjected to a second hot-dip galvanizing in an aluminum-containing and/or aluminum-alloyed zinc melt (“Zn/Al melt”), in particular in a galvanizing bath containing an aluminum-containing and/or aluminum-alloyed zinc melt, wherein the zinc melt used in the first hot-dip galvanizing (“Zn melt”), based on the zinc melt, contains aluminium in amounts in the range from 0 wt.% to 0.1 wt.%, in particular in the range from 0.000001 wt.% to 0.09 wt.%, preferably in the range from 0.00001 wt.% to 0.08 wt.%,
wherein the aluminum-alloyed and/or aluminum-containing zinc melt (“Zn/Al melt”) used in the second hot-dip galvanizing contains, based on the zinc melt, aluminum in amounts in the range from 1 wt.% to 25 wt.%, in particular in the range from 2 wt.% to 10 wt.%, preferably in the range from 3 wt.% to 8 wt.%, particularly preferably in the range from 4 wt.% to 6 wt.%.

In the context of the present invention, it can be advantageous if the aluminum-alloyed and/or aluminum-containing zinc melt (“Zn/Al melt”) used in the second hot-dip galvanizing contains magnesium.

The aluminum-alloyed and/or aluminum-containing zinc melt (“Zn/Al melt”) used in the second hot-dip galvanizing can contain, based on the zinc melt, at most 10 wt. %, in particular at most 3 wt. %, preferably at most 2 wt. %, of magnesium.

In particular, according to the present invention, it can be provided that the aluminum-alloyed and/or aluminum-containing zinc melt (“Zn/Al melt”) used in the second hot-dip galvanizing contains, based on the zinc melt, magnesium in amounts in the range from 0.1 wt.% to 10 wt.%, in particular in the range from 0.1 wt.% to 3 wt.%, preferably in the range from 0.1 wt.% to 2 wt.%.

According to a particular embodiment of the present invention, the aluminum-alloyed and/or aluminum-containing zinc melt (“Zn/Al melt”) used in the second hot-dip galvanizing can contain, based on the zinc melt, 5 wt.% aluminum and 2 wt.% magnesium, in particular 5 wt.% aluminum and 3 wt.% magnesium.

By combining aluminum and magnesium in the second hot-dip galvanizing layer, the optical and mechanical properties, especially gloss and ductility, as well as corrosion protection properties can be particularly well controlled and adjusted.

Within the scope of the method according to the invention, it can be provided in particular that the zinc melt used in the first hot-dip galvanizing ("Zn melt") according to a particular embodiment, based on the zinc melt, contains aluminum in amounts in the range from 0 wt.% to 0.1 wt.%, in particular in the range from 0.000001 wt.% to 0.09 wt.%, preferably in the range from 0.00001 wt.% to 0.08 wt.%, and optionally at least one further metal, in particular in amounts of up to 10 wt.% and/or in particular selected from the group of bismuth (Bi), lead (Pb), tin (Sn), nickel (Ni), silicon (Si), magnesium (Mg) and combinations thereof, and the remaining portion of the aluminum-alloyed and/or aluminum-containing zinc melt is formed by zinc, wherein all of the above-mentioned quantities are to be selected in such a way that a total of 100 wt.% results.

1. (i) Zink (Zn), insbesondere in Mengen im Bereich von 92 bis 100 Gew.-%, insbesondere im Bereich von 80 bis 99,999 Gew.-%, bevorzugt im Bereich von 85 bis 99,995 Gew.-%, besonders bevorzugt im Bereich von 90 bis 99,99 Gew.- %,
2. (ii) gegebenenfalls Aluminium (AI), insbesondere in Mengen im Bereich von 0 Gew.-% bis 0,1 Gew.-%, insbesondere im Bereich von 0,000001 Gew.-% bis0,09 Gew.-%, bevorzugt im Bereich von 0,00001 Gew.-% bis 0,08 Gew.-%,
3. (iii) gegebenenfalls mindestens ein weiteres Metall, insbesondere in (Gesamt-) Mengen von bis zu 10 Gew.-% und/oder insbesondere ausgewählt aus der Gruppe von Bismut (Bi), Blei (Pb), Zinn (Sn), Nickel (Ni), Silizium (Si), Magnesium (Mg) sowie deren Kombinationen.

According to a further particular embodiment, the zinc melt (“Zn melt”) used in the first hot-dip galvanizing can have the following composition, wherein all the quantities given below are based on the zinc melt (“Zn melt”) and are to be selected such that a total of 100% by weight results:

1. (i) zinc (Zn), in particular in amounts in the range from 92 to 100% by weight, in particular in the range from 80 to 99.999% by weight, preferably in the range from 85 to 99.995% by weight, particularly preferably in the range from 90 to 99.99% by weight.
2. (ii) optionally aluminium (AI), in particular in amounts in the range from 0 wt.% to 0.1 wt.%, in particular in the range from 0.000001 wt.% to 0.09 wt.%, preferably in the range from 0.00001 wt.% to 0.08 wt.%,
3. (iii) optionally at least one further metal, in particular in (total) amounts of up to 10 wt.% and/or in particular selected from the group of bismuth (Bi), lead (Pb), tin (Sn), nickel (Ni), silicon (Si), magnesium (Mg) and combinations thereof.

The use of a zinc melt in the first hot-dip galvanizing with the composition described above leads to particularly good galvanizing results and the resulting hot-dip galvanizing layer is particularly well suited to be further processed in the subsequent second hot-dip galvanizing.

Within the scope of the method according to the invention, it can be provided in particular that the aluminum-alloyed and/or aluminum-containing zinc melt (“Zn/Al melt”) used in the second hot-dip galvanizing process, according to a particular embodiment, based on the zinc melt, contains aluminum in amounts in the range from 1 wt.% to 25 wt.%, in particular in the range from 2 wt.% to 10 wt.%, preferably in the range from 3 wt.% to 8 wt.%, particularly preferably in the range from 4 wt.% to 6 wt.%, optionally magnesium, in particular in amounts in the range from 0.1 wt.% to 10 wt.%, in particular in the range from 0.1 wt.% to 3 wt.%, preferably in the range from 0.1 wt.% to 2 wt.%, and optionally at least one further metal, in particular in amounts of up to 10 wt.% and/or in particular selected from the group of bismuth (Bi), lead (Pb), tin (Sn), nickel (Ni), silicon (Si) and combinations thereof, and the remaining portion of the aluminum-alloyed and/or aluminum-containing zinc melt is formed by zinc, whereby all of the above-mentioned quantities are to be selected such that a total of 100 wt.% results.

1. (i) Zink (Zn), insbesondere in Mengen im Bereich von 75 bis 99 Gew.-%, insbesondere im Bereich von 80 bis 98 Gew.-%, bevorzugt im Bereich von 85 bis 97 Gew.-%, besonders bevorzugt im Bereich von 90 bis 96 Gew.-%,
2. (ii) gegebenenfalls Aluminium (AI), insbesondere in Mengen im Bereich von 1 Gew.-% bis 25 Gew.-%, insbesondere im Bereich von 2 Gew.-% bis 10 Gew.-%, bevorzugt im Bereich von 3 Gew.-% bis 8 Gew.-%, besonders bevorzugt im Bereich von 4 Gew.-% bis 6 Gew.-%,
3. (iii) gegebenenfalls Magnesium (Mg), insbesondere in Mengen im Bereich von 0,1 Gew.-% bis 10 Gew.-%, insbesondere im Bereich von 0,1 Gew.-% bis 3 Gew.-%, bevorzugt im Bereich von 0,1 Gew.-% bis 2 Gew.-%;
4. (iii) gegebenenfalls mindestens ein weiteres Metall, insbesondere in (Gesamt-) Mengen von bis zu 10 Gew.-% und/oder insbesondere ausgewählt aus der Gruppe von Bismut (Bi), Blei (Pb), Zinn (Sn), Nickel (Ni), Silizium (Si) sowie deren Kombinationen.

According to a further particular embodiment, the aluminum-alloyed and/or aluminum-containing zinc melt (“Zn/Al melt”) used in the second hot-dip galvanizing can have the following composition, wherein all the quantities given below relate to the aluminum-alloyed and/or aluminum-containing zinc melt (“Zn/Al melt”) and are to be selected such that a total of 100% by weight results:

1. (i) zinc (Zn), in particular in amounts in the range from 75 to 99% by weight, in particular in the range from 80 to 98% by weight, preferably in the range from 85 to 97% by weight, particularly preferably in the range from 90 to 96% by weight,
2. (ii) optionally aluminium (AI), in particular in amounts in the range from 1 wt.% to 25 wt.%, in particular in the range from 2 wt.% to 10 wt.%, preferably in the range from 3 wt.% to 8 wt.%, particularly preferably in the range from 4 wt.% to 6 wt.%,
3. (iii) optionally magnesium (Mg), in particular in amounts in the range from 0.1 wt.% to 10 wt.%, in particular in the range from 0.1 wt.% to 3 wt.%, preferably in the range from 0.1 wt.% to 2 wt.%;
4. (iii) optionally at least one further metal, in particular in (total) amounts of up to 10 wt.% and/or in particular selected from the group of bismuth (Bi), lead (Pb), tin (Sn), nickel (Ni), silicon (Si) and combinations thereof.

The use of a zinc melt with the composition described above is particularly suitable for the second hot-dip galvanizing, in particular to form an at least partially layered hot-dip galvanizing layer with Zn/Al/Fe phases.

In the context of the present invention, it can be advantageous if the zinc melt (“Zn melt”) used in the first hot-dip galvanizing has a temperature in the range from 330 °C to 750 °C, in particular in the range from 340 °C to 650 °C, preferably in the range from 430 °C to 600 °C, particularly preferably in the range from 435 °C to 455 °C.

When using a so-called pure zinc melt, the thickness of the hot-dip galvanizing layer formed depends on the duration or time of the hot-dip galvanizing, in particular on the immersion time of the component to be galvanized in the zinc melt. The zinc layer to be achieved in the first hot-dip galvanizing can thus be individually adjusted, in particular by adjusting the immersion time. Since the total layer thickness of the total hot-dip galvanizing layer resulting from the second hot-dip galvanizing is also determined by the layer thickness of the hot-dip galvanizing layer resulting from the first hot-dip galvanizing layer is influenced or dependent on it, the total layer thickness of the entire hot-dip galvanizing layer can be adjusted by adjusting the immersion time in the first hot-dip galvanizing.

In the context of the method according to the invention, it has proven to be particularly advantageous if the iron or steel component is dipped into the zinc melt (“Zn melt”) used in the first hot-dip galvanizing, in particular dipped therein and moved, in particular for a period of time which is sufficient to ensure effective hot-dip galvanizing (hot-dip galvanizing), in particular for a period of time in the range from 0.1 to 90 minutes, in particular in the range from 0.75 to 60 minutes, preferably in the range from 1 to 45 minutes, particularly preferably in the range from 1.25 to 30 minutes.

In particular, it is advantageous if the iron or steel component is dipped into the zinc melt (“Zn melt”) used in the first hot-dip galvanizing, in particular dipped and moved therein, in particular for a period of time which is sufficient to ensure effective hot-dip galvanizing (hot-dip galvanizing), in particular for a period of time of at least 0.1 minutes, in particular at least 0.75 minutes, preferably at least 1 minute, particularly preferably at least 1.25 minutes. With this minimum galvanizing time, a hot-dip galvanizing layer is formed which already provides good corrosion protection on its own (i.e. even without a subsequent second hot-dip galvanizing) and which has a sufficient thickness to form the special multi-layer or multi-phase structure according to the invention in the subsequent second hot-dip galvanizing according to the invention.

It can also be advantageous if, within the scope of the method according to the invention, the iron or steel component is dipped into the zinc melt (“Zn melt”) used in the first hot-dip galvanizing, in particular dipped therein and moved, in particular for a period of time which is sufficient to ensure effective hot-dip galvanizing (hot-dip galvanizing), in particular for a period of time of at most 90 minutes, in particular at most 60 minutes, preferably at most 45 minutes, particularly preferably at most 30 minutes. The zinc layers formed in the aforementioned galvanizing period can be further processed in the second hot-dip galvanizing according to the invention in such a way that an overall ductile hot-dip galvanizing layer with high corrosion protection performance is formed, which in particular also provides high corrosion protection performance after forming, for example after bending by 90°. In addition, the zinc layers of the first hot-dip galvanizing process formed during the previously mentioned galvanizing period already provide good corrosion protection; in particular, this hot-dip galvanizing layer protects the component against corrosion before the second hot-dip galvanizing process takes place.

In connection with the aluminum-alloyed and/or aluminum-containing zinc melt (“Zn/Al melt”) used in the second hot-dip galvanizing, it has proven particularly useful within the scope of the present invention if the aluminum-alloyed and/or aluminum-containing zinc melt (“Zn/Al melt”) used in the second hot-dip galvanizing has a temperature in the range from 330 °C to 750 °C, in particular in the range from 340 °C to 600 °C, preferably in the range from 350 °C to 450 °C, particularly preferably in the range from 410 °C to 425 °C.

According to the present invention, it can be provided that the iron or steel component is dipped into the aluminum-alloyed and/or aluminum-containing zinc melt ("Zn/Al melt") used in the second hot-dip galvanizing, in particular dipped therein and moved, in particular for a period of time which is sufficient to ensure effective further hot-dip galvanizing (hot-dip galvanizing), in particular for a period of time in the range of 0.0001 to 60 minutes, in particular in the range of 0.001 to 45 minutes, preferably in the range of 0.5 to 30 minutes, particularly preferably in the range of 4 to 8 minutes.

Furthermore, according to the present invention, it can also be provided that the iron or steel component is dipped into the aluminum-alloyed and/or aluminum-containing zinc melt (“Zn/Al melt”) used in the second hot-dip galvanizing, in particular dipped therein and moved, in particular for a period of time which is sufficient to achieve effective further hot-dip galvanizing (hot-dip galvanizing), in particular for a period of time of at least 0.0001 minutes, in particular at least 0.001 minutes, preferably at least 0.5 minutes, particularly preferably at least 4 minutes.

Furthermore, according to the present invention, it can also be provided that the iron or steel component is dipped into the aluminum-alloyed and/or aluminum-containing zinc melt (“Zn/Al melt”) used in the second hot-dip galvanizing, in particular dipped and moved therein, in particular for a period of time which is sufficient to ensure effective further hot-dip galvanizing (hot-dip galvanizing), in particular for a period of not more than 60 minutes, in particular not more than 45 minutes, preferably not more than 30 minutes, particularly preferably not more than 8 minutes.

According to a particular embodiment of the present invention, the present invention relates to a method for hot-dip galvanizing (hot-dip galvanizing) an iron or steel component, in particular for producing a hot-dip galvanized iron or steel component with increased corrosion protection performance and/or with increased ductility, preferably in a two-stage hot-dip galvanizing process, in particular a method as described above, wherein the iron or steel component is first subjected to a first hot-dip galvanizing in a zinc melt (“Zn melt”), in particular in a galvanizing bath containing a zinc melt, and wherein the iron or steel component obtained after the first hot-dip galvanizing is subsequently subjected to a second hot-dip galvanizing in an aluminum-containing and/or aluminum-alloyed zinc melt (“Zn/Al melt”), in particular in a galvanizing bath containing an aluminum-containing and/or aluminum-alloyed zinc melt, wherein the zinc melt used in the first hot-dip galvanizing (“Zn melt”) a temperature in the range of 330 °C to 750 °C, in particular in the range of 340 °C to 650 °C, preferably in the range of 430 °C to 600 °C, particularly preferably in the range of 435 °C to 455 °C,
wherein the aluminum-alloyed and/or aluminum-containing zinc melt (“Zn/Al melt”) used in the second hot-dip galvanizing has a temperature in the range from 330 °C to 750 °C, in particular in the range from 340 °C to 600 °C, preferably in the range from 350 °C to 450 °C, particularly preferably in the range from 410 °C to 425 °C.

In the context of the method according to the invention, the temperature of the aluminum-alloyed and/or aluminum-containing zinc melt (“Zn/Al melt”) used in the second hot-dip galvanizing is typically lower than the temperature of the zinc melt (“Zn melt”) used in the first hot-dip galvanizing.

In other words, the temperature of the aluminum-alloyed and/or aluminum-containing zinc melt (“Zn/Al melt”) used in the second hot-dip galvanizing is selected in particular in such a way and/or with the proviso that it is lower than the temperature of the zinc melt (“Zn melt”) used in the first hot-dip galvanizing.

In particular, it can be provided that the temperature of the aluminum-alloyed and/or aluminum-containing zinc melt (“Zn/Al melt”) used in the second hot-dip galvanizing is at least 10 °C lower, in particular at least 25 °C lower, preferably at least 40 °C lower, than the temperature of the zinc melt used in the first hot-dip galvanizing (“Zn melt”).

If the temperature of the aluminum-alloyed and/or aluminum-containing zinc melt (“Zn/Al melt”) used in the second hot-dip galvanizing is lower than the temperature of the zinc melt (“Zn melt”) used in the first hot-dip galvanizing, the zinc layer formed in the first hot-dip galvanizing is in particular not completely melted, so that the Zn/Fe phase formed in the first hot-dip galvanizing is at least partially retained on the base material, whereby a particularly good adhesion of the entire hot-dip galvanizing layer to the iron or steel component is achieved and a particularly high level of corrosion protection is provided.

According to a further particular embodiment of the present invention, the present invention relates to a method for hot-dip galvanizing (hot-dip galvanizing) an iron or steel component, in particular for producing a hot-dip galvanized iron or steel component with increased corrosion protection performance and/or with increased ductility, preferably in a two-stage hot-dip galvanizing process, in particular a method as described above,
wherein the iron or steel component is first subjected to a first hot-dip galvanizing in a zinc melt (“Zn melt”), in particular in a galvanizing bath containing a zinc melt, and wherein the iron or steel component obtained after the first hot-dip galvanizing is subsequently subjected to a second hot-dip galvanizing in an aluminum-containing and/or aluminum-alloyed zinc melt (“Zn/Al melt”), in particular in a galvanizing bath containing an aluminum-containing and/or aluminum-alloyed zinc melt,
wherein the zinc melt used in the first hot-dip galvanizing (“Zn melt”), based on the zinc melt, contains aluminum in amounts in the range from 0 wt.% to 0.1 wt.%, in particular in the range from 0.000001 wt.% to 0.09 wt.%, preferably in the range from 0.00001 wt.% to 0.08 wt.%,
wherein the aluminium-alloyed and/or aluminium-containing zinc melt (“Zn/Al melt”) used in the second hot-dip galvanising process contains, based on the zinc melt, aluminium in quantities in the range of 1 wt. % to 25 wt. %, in particular in the range of 2 wt. % to 10 wt. %, preferably in the range of 3 wt. % to 8 wt. %, particularly preferably in the range of 4 wt. % to 6 wt. %,
wherein the temperature of the aluminum-alloyed and/or aluminum-containing zinc melt (“Zn/Al melt”) used in the second hot-dip galvanizing is lower than the temperature of the zinc melt (“Zn melt”) used in the first hot-dip galvanizing and/or wherein the temperature of the aluminum-alloyed and/or aluminum-containing zinc melt (“Zn/Al melt”) used in the second hot-dip galvanizing is selected in such a way and/or with the proviso that it is lower than the temperature of the zinc melt used in the first hot-dip galvanizing (“Zn melt”); in particular wherein the temperature of the aluminum-alloyed and/or aluminum-containing zinc melt (“Zn/Al melt”) used in the second hot-dip galvanizing is at least 10 °C lower, in particular at least 25 °C lower, preferably at least 40 °C lower, than the temperature of the zinc melt used in the first hot-dip galvanizing (“Zn melt”).

According to a particular embodiment of the present invention, it can be provided that the first hot-dip galvanizing is carried out in particular in such a way that at least one hot-dip galvanizing layer with zinc/iron phase ("Zn/Fe phase") is formed on the base material on the base material of the iron or steel component. In other words, it can be provided that the first hot-dip galvanizing is carried out with the proviso that at least one hot-dip galvanizing layer with zinc/iron phase ("Zn/Fe phase") is formed on the base material on the base material of the iron or steel component.

In this context, the base material is the material of the iron or steel component to be galvanized; ie the base material is typically iron or steel. The hot-dip galvanizing layer is formed on this base material within the framework of the process according to the invention. The specific structure of the hot-dip galvanized iron or steel component resulting from the process according to the invention is described in 1 shown.

The retention of at least one hot-dip galvanizing layer with Zn/Fe phase on the base material is particularly advantageous since there is a particularly strong adhesion between the at least one hot-dip galvanizing layer with Zn/Fe phase and the base material.

Within the scope of the method according to the invention, according to a particular embodiment, in the first hot-dip galvanizing, the layer thickness can be controlled over the duration of the galvanizing.

In particular, within the scope of the method according to the invention, the layer thickness of the hot-dip galvanizing layer resulting from the first hot-dip galvanizing can be controlled by the duration of the first hot-dip galvanizing.

The possibility of controlling the layer thickness of the hot-dip galvanizing layer resulting from the first hot-dip galvanizing over the duration of the first hot-dip galvanizing is particularly advantageous because the layer thickness of the hot-dip galvanizing layer resulting from the first hot-dip galvanizing also has a direct influence on the overall layer thickness resulting after the second hot-dip galvanizing. Consequently, the overall layer thickness of the entire hot-dip galvanizing layer can also be controlled by the duration of the first hot-dip galvanizing.

According to yet another particular embodiment of the present invention, the present invention relates to a method for hot-dip galvanizing (hot-dip galvanizing) an iron or steel component, in particular for producing a hot-dip galvanized iron or steel component with increased corrosion protection performance and/or with increased ductility, preferably in a two-stage hot-dip galvanizing process, in particular a method as described above,
wherein the iron or steel component is first subjected to a first hot-dip galvanizing in a zinc melt (“Zn melt”), in particular in a galvanizing bath containing a zinc melt, and wherein the iron or steel component obtained after the first hot-dip galvanizing is subsequently subjected to a second hot-dip galvanizing in an aluminum-containing and/or aluminum-alloyed zinc melt (“Zn/Al melt”), in particular in a galvanizing bath containing an aluminum-containing and/or aluminum-alloyed zinc melt,
wherein the zinc melt used in the first hot-dip galvanizing (“Zn melt”), based on the zinc melt, contains aluminum in amounts in the range from 0 wt.% to 0.1 wt.%, in particular in the range from 0.000001 wt.% to 0.09 wt.%, preferably in the range from 0.00001 wt.% to 0.08 wt.%,
The aluminium-alloyed and/or aluminium-containing zinc used in the second hot-dip galvanising melt (“Zn/Al melt”), based on the zinc melt, contains aluminium in amounts in the range of 1 wt.% to 25 wt.%, in particular in the range of 2 wt.% to 10 wt.%, preferably in the range of 3 wt.% to 8 wt.%, particularly preferably in the range of 4 wt.% to 6 wt.%,
wherein the zinc melt used in the first hot-dip galvanizing (“Zn melt”) has a temperature in the range from 330 °C to 750 °C, in particular in the range from 340 °C to 650 °C, preferably in the range from 430 °C to 600 °C, particularly preferably in the range from 435 °C to 455 °C,
wherein the aluminum-alloyed and/or aluminum-containing zinc melt (“Zn/Al melt”) used in the second hot-dip galvanizing has a temperature in the range from 330 °C to 750 °C, in particular in the range from 340 °C to 600 °C, preferably in the range from 350 °C to 450 °C, particularly preferably in the range from 410 °C to 425 °C
wherein the layer thickness of the hot-dip galvanizing layer resulting from the first hot-dip galvanizing is controlled by the duration of the first hot-dip galvanizing.

In particular, according to a preferred embodiment of the present invention, the second hot-dip galvanizing is carried out in such a way that a multi-layer or multi-phase (total) hot-dip galvanizing layer is formed on the base material of the iron or steel component.

According to a further preferred embodiment, the second hot-dip galvanizing is carried out in such a way that an at least partially layered hot-dip galvanizing layer with Zn/Al/Fe phases is formed, in particular as an outer hot-dip galvanizing layer and/or in particular as an outer layer. In other words, the second hot-dip galvanizing is preferably carried out with the proviso that an at least partially layered hot-dip galvanizing layer with Zn/Al/Fe phases is formed, in particular as an outer hot-dip galvanizing layer and/or in particular as an outer layer.

Without wishing to be limited to this theory, the hot-dip galvanizing layer resulting from the first hot-dip galvanizing is permeated with the aluminum-containing or aluminum-alloyed zinc melt from the second hot-dip galvanizing, in particular the aluminum contained therein. In particular, the aluminum-containing or aluminum-alloyed zinc melt, in particular the aluminum contained therein, diffuses into the hot-dip galvanizing layer resulting from the first hot-dip galvanizing, so that an at least partially layered hot-dip galvanizing layer with Zn/Al/Fe phases is formed.

According to a particular embodiment of the method according to the invention, the second hot-dip galvanizing is carried out in such a way that the aluminum-containing and/or aluminum-alloyed zinc melt (“Zn/Al melt”) at least partially diffuses into the hot-dip galvanizing layer resulting from the first hot-dip galvanizing. In other words, within the scope of the method according to the invention, it is preferred if the second hot-dip galvanizing is carried out with the proviso that the aluminum-containing and/or aluminum-alloyed zinc melt (“Zn/Al melt”) at least partially diffuses into the hot-dip galvanizing layer resulting from the first hot-dip galvanizing.

According to a further preferred embodiment, the second hot-dip galvanizing is carried out in such a way that at least one hot-dip galvanizing layer with a Zn/Fe phase, which optionally contains aluminum, is present and/or remains on the base material of the iron or steel component, in particular below (below) the outer hot-dip galvanizing layer and/or the outer layer. In other words, it is particularly preferred according to the invention if the second hot-dip galvanizing is carried out with the proviso that a hot-dip galvanizing layer with a Zn/Fe phase, which optionally contains aluminum, is present and/or remains on the base material of the iron or steel component, in particular below (below) the outer hot-dip galvanizing layer and/or the outer layer.

Carrying out the second hot-dip galvanizing in such a way that a hot-dip galvanizing layer with zinc/iron phase remains on the base material, in particular where this hot-dip galvanizing layer with zinc/iron phase was formed on the base material in the first hot-dip galvanizing, has the advantage that there is a particularly high adhesion with the base material or between the hot-dip galvanizing layer as a whole and the iron or steel component.

In this context, the retention of at least one hot-dip galvanizing layer with zinc/iron phase on the base material can be achieved in particular by - without wishing to be limited to this theory and measure - the time of the second hot-dip galvanizing is limited and furthermore by the temperature of the aluminum-containing or aluminum-alloyed zinc melt used in the second hot-dip galvanizing being lower than the zinc melt used in the first hot-dip galvanizing, as previously stated.

According to yet another preferred embodiment, the second hot-dip galvanizing is carried out with the proviso and/or in such a way that a (total) hot-dip galvanizing layer with an aluminum concentration gradient is formed.

The aluminum concentration gradient - without wishing to be limited to this theory - results in particular from the increased affinity of the aluminum to the iron of the iron or steel component. Due to this affinity, the aluminum of the aluminum-containing or aluminum-alloyed hot-dip galvanizing used in the second hot-dip galvanizing diffuses into the hot-dip galvanizing layer formed in the first hot-dip galvanizing. In a particular embodiment, however, it should be noted that the second hot-dip galvanizing must not last so long or for a period of time in which the aluminum completely diffuses through and penetrates and even replaces the entire hot-dip galvanizing layer formed in the first hot-dip galvanizing.

According to yet another particular embodiment of the present invention, the present invention relates to a method for hot-dip galvanizing (hot-dip galvanizing) an iron or steel component, in particular for producing a hot-dip galvanized iron or steel component with increased corrosion protection performance and/or with increased ductility, preferably in a two-stage hot-dip galvanizing process, in particular a method as described above,
wherein the iron or steel component is first subjected to a first hot-dip galvanizing in a zinc melt (“Zn melt”), in particular in a galvanizing bath containing a zinc melt, and wherein the iron or steel component obtained after the first hot-dip galvanizing is subsequently subjected to a second hot-dip galvanizing in an aluminum-containing and/or aluminum-alloyed zinc melt (“Zn/Al melt”), in particular in a galvanizing bath containing an aluminum-containing and/or aluminum-alloyed zinc melt,
wherein the zinc melt used in the first hot-dip galvanizing (“Zn melt”), based on the zinc melt, contains aluminum in amounts in the range from 0 wt.% to 0.1 wt.%, in particular in the range from 0.000001 wt.% to 0.09 wt.%, preferably in the range from 0.00001 wt.% to 0.08 wt.%,
wherein the aluminum-alloyed and/or aluminum-containing zinc melt (“Zn/Al melt”) used in the second hot-dip galvanizing contains, based on the zinc melt, aluminum in amounts in the range from 1 wt.% to 25 wt.%, in particular in the range from 2 wt.% to 10 wt.%, preferably in the range from 3 wt.% to 8 wt.%, particularly preferably in the range from 4 wt.% to 6 wt.%,
wherein the zinc melt used in the first hot-dip galvanizing (“Zn melt”) has a temperature in the range from 330 °C to 750 °C, in particular in the range from 340 °C to 650 °C, preferably in the range from 430 °C to 600 °C, particularly preferably in the range from 435 °C to 455 °C,
wherein the aluminum-alloyed and/or aluminum-containing zinc melt (“Zn/Al melt”) used in the second hot-dip galvanizing has a temperature in the range from 330 °C to 750 °C, in particular in the range from 340 °C to 600 °C, preferably in the range from 350 °C to 450 °C, particularly preferably in the range from 410 °C to 425 °C;
wherein the second hot-dip galvanizing is carried out in such a way and/or with the proviso that an at least partially layered hot-dip galvanizing layer with Zn/Al/Fe phases is formed, in particular as an outer hot-dip galvanizing layer and/or in particular as an outer layer, and/or
wherein the second hot-dip galvanizing is carried out in such a way and/or with the proviso that a hot-dip galvanizing layer with Zn/Fe phase, which optionally contains aluminum, is present and/or remains on the base material of the iron or steel component, in particular below (below) the outer hot-dip galvanizing layer and/or the outer layer, and/or
wherein the second hot-dip galvanizing is carried out with the proviso and/or such that a (total) hot-dip galvanizing layer with an aluminum concentration gradient is formed.

According to a particular embodiment of the present invention, the layer thickness of the hot-dip galvanizing layer resulting from the first hot-dip galvanizing can be at least 30 µm, in particular at least 35 µm, preferably at least 40 µm, particularly preferably at least 45 µm.

According to a further particular embodiment of the present invention, the layer thickness of the hot-dip galvanizing layer resulting from the first hot-dip galvanizing can be at most 650 µm, in particular at most 600 µm, preferably at most 550 µm, particularly preferably at most 500 µm.

Within the scope of the present invention, it can be provided in particular that the layer thickness of the hot-dip galvanizing layer resulting from the first hot-dip galvanizing is in the range of 30 µm to 650 µm, in particular in the range from 35 µm to 600 µm, preferably in the range from 40 µm to 550 µm, particularly preferably in the range from 45 µm to 500 µm.

These layer thicknesses of the hot-dip galvanizing layer resulting from the first hot-dip galvanizing already offer a high level of corrosion protection, which is sufficient for applications of such galvanized components in environments with moderate corrosion stress. In addition, the hot-dip galvanizing layer is thick enough to allow the aluminum-containing or aluminum-alloyed zinc melt to diffuse into the second hot-dip galvanizing layer, as described above, in particular whereby it is possible for a hot-dip galvanizing layer with a zinc/iron phase ("Zn/Fe phase") to remain on the base material (i.e. the hot-dip galvanizing layer resulting from the first hot-dip galvanizing is thick enough to allow the aluminum to diffuse through without the entire hot-dip galvanizing layer being directly penetrated by the aluminum or even replaced).

According to a particular embodiment of the method according to the invention, the (total) layer thickness of the (total) hot-dip galvanizing layer resulting from the second hot-dip galvanizing can be at least 30 µm, in particular at least 35 µm, preferably at least 40 µm, particularly preferably at least 45 µm.

According to a further particular embodiment of the method according to the invention, the (total) layer thickness of the (total) hot-dip galvanizing layer resulting from the second hot-dip galvanizing can be at most 500 µm, in particular at most 450 µm, preferably at most 400 µm, particularly preferably at most 300 µm.

Within the scope of the present invention, it can be provided in particular that the (total) layer thickness of the (total) hot-dip galvanizing layer resulting from the second hot-dip galvanizing is in the range from 30 µm to 500 µm, in particular in the range from 35 µm to 450 µm, preferably in the range from 40 µm to 400 µm, particularly preferably in the range from 45 µm to 300 µm.

According to yet another particular embodiment of the present invention, the total layer thickness of the (total) hot-dip galvanizing layer resulting after carrying out the two-stage process according to the invention can be at least 30 µm, in particular at least 35 µm, preferably at least 40 µm, particularly preferably at least 45 µm.

According to yet another particular embodiment of the present invention, the total layer thickness of the (total) hot-dip galvanizing layer resulting after carrying out the two-stage process according to the invention can be at most 500 µm, in particular at most 450 µm, preferably at most 400 µm, particularly preferably at most 300 µm.

Within the scope of the present invention, it can be provided in particular that the total layer thickness of the (total) hot-dip galvanizing layer resulting after carrying out the two-stage process according to the invention is in the range from 30 µm to 500 µm, in particular in the range from 35 µm to 450 µm, preferably in the range from 40 µm to 400 µm, particularly preferably in the range from 45 µm to 300 µm.

In the context of the present invention, it has proven particularly advantageous if the first and second hot-dip galvanizing are carried out in such a way and/or with the proviso that the total layer thickness of the hot-dip galvanizing layer resulting after carrying out the two-stage process according to the invention is in the range from 30 µm to 500 µm, in particular in the range from 35 µm to 450 µm, preferably in the range from 40 µm to 400 µm, particularly preferably in the range from 45 µm to 300 µm.

A (total) hot-dip galvanized layer resulting from the method according to the invention with the previously specified total layer thickness provides both high corrosion protection properties and is simultaneously ductile; in particular, a corresponding hot-dip galvanized iron or steel component can be reshaped, in particular bent by 90°, without the corrosion protection properties being lost or without these being significantly or significantly reduced. In particular, a hot-dip galvanized component which has been galvanized according to the two-stage hot-dip galvanizing method according to the invention also has high corrosion protection properties after reshaping or cold forming (for example 90° bending).

According to a particular embodiment of the present invention, the present invention relates to a method for hot-dip galvanizing (hot-dip galvanizing) an iron or steel component, in particular for producing a hot-dip galvanized iron or steel component with increased corrosion protection performance and/or with increased ductility, preferably in a two-stage hot-dip galvanizing process, in particular a method as described above, wherein the iron or steel component is first subjected to a first hot-dip galvanizing in a zinc melt (“Zn melt”), in particular in a galvanizing bath containing a zinc melt, and wherein the iron or steel component obtained after the first hot-dip galvanizing is subsequently subjected to a second hot-dip galvanizing in an aluminum-containing and/or aluminum-alloyed zinc melt (“Zn/Al melt”), in particular in a galvanizing bath containing an aluminum-containing and/or aluminum-alloyed zinc melt, wherein the zinc melt used in the first hot-dip galvanizing (“Zn melt”), based on the zinc melt, contains aluminium in amounts in the range from 0 wt.% to 0.1 wt.%, in particular in the range from 0.000001 wt.% to 0.09 wt.%, preferably in the range from 0.00001 wt.% to 0.08 wt.%,
wherein the aluminum-alloyed and/or aluminum-containing zinc melt (“Zn/Al melt”) used in the second hot-dip galvanizing contains, based on the zinc melt, aluminum in amounts in the range from 1 wt.% to 25 wt.%, in particular in the range from 2 wt.% to 10 wt.%, preferably in the range from 3 wt.% to 8 wt.%, particularly preferably in the range from 4 wt.% to 6 wt.%,
wherein the zinc melt used in the first hot-dip galvanizing (“Zn melt”) has a temperature in the range from 330 °C to 750 °C, in particular in the range from 340 °C to 650 °C, preferably in the range from 430 °C to 600 °C, particularly preferably in the range from 435 °C to 455 °C,
wherein the aluminum-alloyed and/or aluminum-containing zinc melt (“Zn/Al melt”) used in the second hot-dip galvanizing has a temperature in the range from 330 °C to 750 °C, in particular in the range from 340 °C to 600 °C, preferably in the range from 350 °C to 450 °C, particularly preferably in the range from 410 °C to 425 °C,
wherein the first and the second hot-dip galvanizing are carried out in such a way and/or with the proviso that the total layer thickness of the (total) hot-dip galvanizing layer resulting after carrying out the process is in the range from 30 µm to 500 µm, in particular in the range from 35 µm to 450 µm, preferably in the range from 40 µm to 400 µm, particularly preferably in the range from 45 µm to 300 µm.

In the context of the method according to the invention, it is preferred if, after the first hot-dip galvanizing and/or before the second hot-dip galvanizing, the iron or steel component obtained after the first hot-dip galvanizing is allowed to rest, in particular stored and/or transported and/or used, preferably under oxidative conditions and/or with exposure to ambient air and/or ambient atmosphere, in particular for a period of at least 10 minutes, in particular at least 60 minutes, preferably at least 24 hours.

By bringing the iron or steel component obtained after the first hot-dip galvanizing into contact with oxidative conditions, in particular with the ambient air or the ambient atmosphere, the surface of the hot-dip galvanizing layer formed in the first hot-dip galvanizing is oxidized. In the process, a natural covering layer is formed which consists in particular of zinc oxide, zinc hydroxide, zinc oxide hydroxide, zinc hydrogen carbonate, zinc carbonate and combinations thereof and has a higher melting temperature than the hot-dip galvanizing layer itself.

Furthermore, within the scope of the method according to the invention, it is also preferred if there are at least 10 minutes, in particular at least 60 minutes, preferably at least 24 hours, between the first hot-dip galvanizing and the second hot-dip galvanizing, in particular wherein the iron or steel component obtained after the first hot-dip galvanizing is exposed to oxidative conditions and/or ambient air and/or ambient atmosphere.

The applicant has found that a time of 10 minutes, in particular at least 60 minutes, preferably at least 24 hours, under oxidative conditions is usually sufficient for the previously described oxidation layer or natural covering layer to form on the hot-dip galvanizing layer. The formation of the oxidation layer further improves the corrosion protection properties, so that the iron or steel component does not corrode between the hot-dip galvanizing layers.

Within the scope of the method according to the invention, it can be provided that after the first hot-dip galvanizing and/or before the second hot-dip galvanizing, an oxidation layer is formed on the hot-dip galvanizing layer resulting from the first hot-dip galvanizing.

Furthermore, within the scope of the method according to the invention, it can also be provided that after the first hot-dip galvanizing and/or before the second hot-dip galvanizing, the iron or steel component obtained after the first hot-dip galvanizing is left to rest, in particular stored and/or transported and/or used, preferably under oxidative conditions and/or with exposure to ambient air and/or ambient atmosphere, in such a way and/or with the proviso that an oxidation layer is formed on the hot-dip galvanizing layer resulting from the first hot-dip galvanizing.

In this context, it is particularly the case that the oxidation layer comprises oxygen-containing zinc compounds, in particular selected from the group of zinc oxide, zinc hydroxide, zinc oxide hydroxide, zinc hydrogen carbonate, zinc carbonate and combinations thereof.

In connection with the process according to the invention, it is particularly preferred if the process is not carried out as a wet-on-wet process.

In a so-called wet-on-wet process or a double-dip process carried out as a wet-on-wet process, the component is dipped from one bath directly into the next bath, as previously described, without being left to rest or exposed to oxidative conditions. A reducing protective gas atmosphere, such as forming gas, is typically present. When carrying out a wet-on-wet process, the formation of the previously described oxidation layer or natural covering layer should be prevented.

As previously stated, a so-called wet-on-wet double-dip process is particularly uneconomical and energy-intensive. In addition, the layer thickness and layer structure are difficult to control and monitor.

Furthermore, according to a particular embodiment of the present invention - in contrast to a double-dip process carried out as a wet-on-wet process - in the two-stage hot-dip galvanizing process carried out according to the invention, there is in particular no complete diffusion of the aluminum in the second hot-dip galvanizing. This is - without wishing to be bound to this theory - due, among other things, to the fact that the hot-dip galvanizing layer resulting from the first hot-dip galvanizing is preferably no longer liquid in the process according to the invention or only the top layer is liquid and/or partially dissolved and/or activated when the second hot-dip galvanizing is carried out. This makes it more difficult for the aluminum to diffuse through, so that a completely different layer structure results than in the case of a conventional double-dip process carried out as a wet-on-wet process. In particular, an at least substantially aluminum-free hot-dip galvanizing layer with a Zn/Fe layer originating from the first hot-dip galvanizing remains on the base material of the iron or steel component, in particular below (below) the outer hot-dip galvanizing layer or the outer layer, whereby a particularly strong adhesion or adhesive strength of the (total) hot-dip galvanizing layer on the base material is achieved.

Furthermore, within the scope of the present invention, it can also be provided that the second hot-dip galvanizing is not carried out immediately after the first hot-dip galvanizing, in particular not without the hot-dip galvanizing layer resulting from the first hot-dip galvanizing being exposed to oxidative conditions and/or ambient air and/or ambient atmosphere.

It may also be preferred within the scope of the present invention if the second hot-dip galvanizing is not carried out immediately after the first hot-dip galvanizing, in particular not without an oxidation layer being formed on the hot-dip galvanizing layer resulting from the first hot-dip galvanizing.

Within the scope of the method according to the invention, it can be provided in particular that the second hot-dip galvanizing is carried out after the hot-dip galvanizing layer resulting from the first hot-dip galvanizing has solidified and/or cooled and/or at least partially oxidized and/or exposed to ambient air.

In the method according to the invention, it can also be provided in particular that the second hot-dip galvanizing is carried out on the hot-dip galvanizing layer resulting from the first hot-dip galvanizing and which has solidified and/or cooled and/or at least partially oxidized and/or exposed to ambient air.

In particular, it is advantageous if the hot-dip galvanizing layer resulting from the first hot-dip galvanizing has already solidified or cooled down during the second hot-dip galvanizing, since the surface tension of the hot-dip galvanizing layer formed in the first hot-dip galvanizing does not have to be overcome.

According to the invention, the process sequence should therefore be designed in such a way that sufficient time passes between the hot-dip galvanizing processes so that the hot-dip galvanizing layer resulting from the first hot-dip galvanizing solidifies or cools down. Furthermore, the iron or steel component obtained after the first hot-dip galvanizing process should be exposed to oxidative conditions in such a way that the hot-dip galvanizing layer is at least partially oxidized.

According to the invention, it can be provided that the first hot-dip galvanizing and the second hot-dip galvanizing take place spatially separated from one another.

It is possible for the corresponding hot-dip galvanizing devices or baths in which the first and second hot-dip galvanizing are carried out to be located at different locations or at the same location. However, the hot-dip galvanizing devices or baths should not be arranged or carried out immediately one after the other, and in particular not without, as previously stated, the iron or steel component being left to rest after the first hot-dip galvanizing and exposed to oxidative conditions.

Within the scope of the method according to the invention, it can be provided that a cooling treatment takes place after the first hot-dip galvanizing.

In other words, it may be provided that the iron or steel component obtained after the first hot-dip galvanizing is subjected to a cooling treatment.

The optional cooling treatment can be carried out, for example, using air and/or in the presence of air, preferably down to ambient temperature. Cooling makes handling, for example further treatment as listed below, and allowing to rest, in particular storage and/or transport and/or use, easier. In addition, the cooling treatment solidifies the hot-dip galvanizing layer formed. As previously stated, it is advantageous in the second hot-dip galvanizing if the hot-dip galvanizing layer formed in the first hot-dip galvanizing is no longer liquid or has solidified.

It can also be provided within the scope of the method according to the invention that a post-processing treatment takes place after the first hot-dip galvanizing.

In other words, it may be provided that the iron or steel component obtained after the first hot-dip galvanizing is subjected to a post-processing treatment.

Possible post-treatments include, for example, the removal of excess zinc bath residues, in particular so-called drips of zinc solidifying on the edges, as well as oxide or ash residues that adhere to the component, as well as the passivation or sealing of the surface. Post-treatment increases the quality of the hot-dip galvanized layer in particular.

According to the invention, it may be preferred if an activation treatment is carried out after the first hot-dip galvanizing. The activation treatment is carried out in particular before the second hot-dip galvanizing.

In particular, it has proven to be useful according to the invention if the iron or steel component obtained after the first hot-dip galvanizing is subjected to an activation treatment.

Through an activation treatment, the oxidation layer or natural covering layer formed under oxidative conditions can be removed again and the hot-dip galvanizing layer formed in the first hot-dip galvanizing can be made accessible and activated for the second hot-dip galvanizing. This enables a quick and reliable second hot-dip galvanizing to take place.

The activation treatment may in particular comprise at least one chemical and, if appropriate, (additionally) one mechanical treatment.

In this context, the chemical treatment may comprise at least a pickling treatment and/or flux treatment.

It may be provided that the chemical treatment is carried out using an aqueous saline solution, in particular with a pH value of less than 5.

In particular, the chemical treatment can be carried out for a period of time in the range of 1 second to 60 minutes, in particular in the range of 5 seconds to 45 minutes, preferably in the range of 10 seconds to 30 minutes.

In the event that several chemical treatments are carried out, the chemical treatment can be carried out in each case or in each bath for a period of time in the range of 1 second to 60 minutes, in particular in the range of 5 seconds to 45 minutes, preferably in the range of 10 seconds to 30 minutes.

This period of time usually leads to a detachment or dissolution of the oxidation layer and a sufficient activation of the hot-dip galvanizing layer formed in the first hot-dip galvanizing.

According to a preferred embodiment of the method according to the invention, an activation treatment is carried out after the first hot-dip galvanizing or the iron or steel component obtained after the first hot-dip galvanizing is subjected to an activation treatment, wherein the activation treatment comprises at least one chemical and optionally (additionally) one mechanical treatment.

In particular, the activation treatment takes place after the first hot-dip galvanizing and immediately before the second hot-dip galvanizing.

The additional mechanical treatment can in particular roughen the surface of the oxidation layer so that the subsequent chemical treatment, in particular flux treatment and/or pickling treatment, is particularly efficient; in particular, the corresponding flux treatment agent or pickling treatment agent has a particularly large number of attack points on the surface so that the oxidation layer can be removed quickly and completely.

Typically, the chemical treatment can be carried out by fluxing in a flux composition in a flux bath.

The flux composition of the activation treatment can be different or the same as the flux composition of the flux treatment explained below before the first hot-dip galvanizing.

Typically, the flux bath of the chemical treatment may comprise an aqueous and/or alcoholic, in particular aqueous, liquid phase, wherein the liquid phase of the flux bath contains the flux composition, in particular in dissolved or dispersed form, preferably in dissolved form.

In particular, the flux composition of the chemical treatment can comprise salts and optionally wetting agents as ingredients, in particular wherein the salts are selected from the group of chlorides, preferably from the group of zinc chloride (ZnCl ₂ ), ammonium chloride (NH ₄ Cl), alkali and/or alkaline earth chlorides, in particular potassium chloride (KCl) and/or sodium chloride (NaCl), aluminum chloride (AlCl ₃ ), silver chloride (AgCl), lead chloride (PbCl ₂ ), nickel chloride (NiCl ₂ ), tin chloride (SnCl ₂ ), manganese chloride (MnCl ₂ ), cobalt chloride (CoCl ₂ ) and combinations thereof.

In this context, it can be provided that the flux composition of the chemical treatment comprises as ingredients zinc chloride (ZnCl ₂ ) and optionally at least one alkali and/or alkaline earth chloride, in particular potassium chloride (KCl) and/or sodium chloride (NaCl), as well as optionally wetting agents and optionally at least one further salt different from the aforementioned compounds, selected from the group of chlorides, preferably from the group of ammonium chloride (NH ₄ Cl), aluminum chloride (AlCl ₃ ), silver chloride (AgCl), lead chloride (PbCl ₂ ), nickel chloride (NiCl ₂ ), tin chloride (SnCl ₂ ), manganese chloride (MnCl ₂ ), cobalt chloride (CoCl ₂ ) and combinations thereof.

Within the scope of the invention, it has proven useful if the flux composition of the chemical treatment comprises salts and optionally wetting agents as ingredients, in particular where the Flux composition comprises at least zinc chloride (ZnCl ₂ ) and at least one alkali and/or alkaline earth chloride, in particular potassium chloride (KCl) and/or sodium chloride (NaCl).

According to the invention, according to a particular embodiment, it can be provided that the flux composition of the chemical treatment is free of ammonium chloride (NH ₄ Cl). In particular, according to a particular embodiment, the flux composition of the chemical treatment can contain at least substantially no ammonium chloride (NH ₄ Cl).

In particular, the flux bath of the chemical treatment can have a salt content of at least 50 wt.%, in particular of at least 60 wt.%, preferably of at least 70 wt.%, particularly preferably of at least 80 wt.%.

In addition, the flux bath of the chemical treatment can have a salt content in the range of 100 g/l to 800 g/l, in particular in the range of 140 g/l to 720 g/l, preferably in the range of 170 g/l to 670 g/l, particularly preferably in the range of 200 g/l to 600 g/l.

Typically, the flux bath of the chemical treatment can have a salt content of at most 99 wt.%, in particular of at most 95 wt.%, preferably of at most 93 wt.%, particularly preferably of at most 90 wt.%.

Within the scope of the method according to the invention, it can be provided that the flux bath of the chemical treatment has a salt content in the range of 50 wt.% to 99 wt.%, in particular in the range of 60 wt.% to 95 wt.%, preferably in the range of 70 wt.% to 93 wt.%, particularly preferably in the range of 80 wt.% to 90 wt.%.

1. (i) Zinkchlorid (ZnCl₂), insbesondere in Mengen im Bereich von 50 bis 95 Gew.-%, insbesondere im Bereich von 55 bis 90 Gew.-%, bevorzugt im Bereich von 60 bis 85 Gew.-%, besonders bevorzugt im Bereich von 65 bis 82,5 Gew.-%, noch mehr bevorzugt im Bereich von 70 bis 82 Gew.-%,
2. (ii) Ammoniumchlorid (NH₄Cl), insbesondere in Mengen im Bereich von 5 bis 45 Gew.-%, insbesondere im Bereich von 6 bis 40 Gew.-%, bevorzugt im Bereich von 7 bis 35 Gew.-%, besonders bevorzugt im Bereich von 8 bis 25 Gew.-%, noch mehr bevorzugt im Bereich von 10 bis 20 Gew.-%,
3. (iii) Natriumchlorid (NaCl), insbesondere in Mengen im Bereich von 0,1 bis 20 Gew.-%, insbesondere im Bereich von 0,5 bis 15 Gew.-%, bevorzugt im Bereich von 1 bis 12,5 Gew.-%, besonders bevorzugt im Bereich von 2 bis 10 Gew.-%, noch mehr bevorzugt im Bereich von 4 bis 8 Gew.-%, und
4. (iv) Kaliumchlorid (KCl), insbesondere in Mengen im Bereich von 0,1 bis 15 Gew.-%, vorzugsweise im Bereich von 0,2 bis 12,5 Gew.-%, bevorzugt im Bereich von 0,4 bis 10 Gew.-%, besonders bevorzugt im Bereich von 0,5 bis 8 Gew.-%, noch mehr bevorzugt im Bereich von 0,8 bis 6 Gew.-%.

According to a particular embodiment of the invention, the flux composition of the chemical treatment can comprise the following ingredients, wherein all the quantities given below are based on the flux composition and are to be selected such that a total of 100% by weight results:

1. (i) zinc chloride (ZnCl ₂ ), in particular in amounts in the range of 50 to 95 wt.%, in particular in the range of 55 to 90 wt.%, preferably in the range of 60 to 85 wt.%, particularly preferably in the range of 65 to 82.5 wt.%, even more preferably in the range of 70 to 82 wt.%,
2. (ii) ammonium chloride (NH ₄ Cl), in particular in amounts in the range of 5 to 45 wt.%, in particular in the range of 6 to 40 wt.%, preferably in the range of 7 to 35 wt.%, particularly preferably in the range of 8 to 25 wt.%, even more preferably in the range of 10 to 20 wt.%,
3. (iii) sodium chloride (NaCl), in particular in amounts in the range of 0.1 to 20 wt.%, in particular in the range of 0.5 to 15 wt.%, preferably in the range of 1 to 12.5 wt.%, particularly preferably in the range of 2 to 10 wt.%, even more preferably in the range of 4 to 8 wt.%, and
4. (iv) Potassium chloride (KCl), in particular in amounts in the range of 0.1 to 15 wt.%, preferably in the range of 0.2 to 12.5 wt.%, more preferably in the range of 0.4 to 10 wt.%, particularly preferably in the range of 0.5 to 8 wt.%, even more preferably in the range of 0.8 to 6 wt.%.

According to a further embodiment, the chemical treatment can be carried out by means of pickling treatment.

In particular, the pickling treatment of the chemical treatment can be carried out with a hydrochloric acid-containing (HCl-containing) and/or hydrochloric acid-based (HCl-based) pickling agent, in particular wherein the pickling agent has a pH value of less than 5.

In particular, within the scope of the method according to the invention, it can be provided that the pickling treatment of the chemical treatment can be carried out with an acidic pickling agent, in particular with a pickling agent having a pH value of less than 5.

It can also be provided that the pickling treatment agent contains iron, in particular in the form of divalent and/or trivalent iron ions. In other words, for example, Fe ²⁺ and/or Fe ³⁺ ions can be included, with the trivalent iron ions (Fe ³⁺ ions) in particular enhancing the pickling effect.

Furthermore, it can be provided that the pickling treatment agent contains at least one additive, in particular at least one pickling additive, in particular selected from the group of corrosion inhibitors, pickling cleaners, pickling accelerators and pickling enhancers and combinations thereof.

In this context, the additives can be used to optimize the pickling effect. Possible pickling additives are, for example, inhibitors to prevent excessive attack and/or to protect the base material or pickling enhancers to increase the attack. Commercial products are available, for example, from STOCKMEIER Holding GmbH, with the products Lerapas® BP, Leraclen® Beizentfetter or .Leraclen® 1227

According to a further particular embodiment, the pickling treatment agent and/or the flux bath of the chemical treatment can contain at least one wetting agent and/or surfactant, in particular at least one ionic or non-ionic wetting agent and/or surfactant, preferably at least one non-ionic wetting agent and/or surfactant.

In particular, the pickling treatment agent and/or the flux bath of the chemical treatment can contain the at least one wetting agent and/or surfactant in amounts of 0.0001 to 15 wt.%, preferably in amounts of 0.001 to 10 wt.%, preferably in amounts of 0.01 to 8 wt.%, even more preferably in amounts of 0.01 to 6 wt.%, very particularly preferably in amounts of 0.05 to 3 wt.%, even more preferably in amounts of 0.1 to 2 wt.%, based on the flux bath.

According to yet another embodiment, the chemical treatment can be carried out by means of a pickling treatment and a flux treatment.

The combination of a pickling treatment and a flux treatment leads to a particularly efficient and essentially complete removal of the oxidation layer and thus to a particularly uniform second hot-dip galvanizing.

It has proven to be effective if the pickling treatment of the chemical treatment and the flux treatment of the chemical treatment are each carried out for a period of time in the range of 1 second to 60 minutes, in particular in the range of 5 seconds to 45 minutes, preferably in the range of 10 seconds to 30 minutes.

In this context, in particular, the pickling treatment can be carried out first, followed by the flux treatment, with a rinsing process taking place after the pickling treatment and before the flux treatment, in particular by immersion in a water bath.

Within the scope of the method according to the invention, it can be provided that the chemical treatment, in particular the flux treatment and/or the pickling treatment, takes place at elevated temperature.

In particular, the flux treatment and/or the pickling treatment can be carried out at a temperature in the range of 20 °C to 100 °C, in particular in the range of 25 °C to 80 °C.

As previously stated, mechanical treatment can optionally be carried out in addition to the chemical treatment as part of the activation treatment.

According to a particular embodiment, the mechanical treatment may comprise an abrasive treatment.

Possible abrasive treatments are blasting the component or carrying out the chemical treatment with a flow. As previously stated, according to the method according to the invention it is particularly provided that at least one chemical treatment takes place.

According to a particular embodiment, the iron or steel component obtained after the activation treatment can be subjected to a drying treatment.

Carrying out a drying treatment after the activation treatment and in particular immediately before the second hot-dip galvanizing has the advantage that no liquid is carried into the aluminum-containing or aluminum-alloyed zinc bath.

The drying treatment can be carried out at a temperature in the range of 30 °C to 400 °C, in particular in the range of 35 °C to 375 °C, preferably in the range of 40 °C to 350 °C, particularly preferably in the range of 50 °C to 325 °C.

In this context, it has proven to be useful if the drying treatment is carried out for a period of time in the range from 0.1 seconds to 60 minutes, in particular in the range from 1 second to 45 minutes, preferably in the range from 10 seconds to 35 minutes, particularly preferably in the range from 20 seconds to 30 minutes, even more preferably in the range from 20 seconds to 15 minutes.

The drying treatment can be carried out in the presence of and/or by means of air.

Typically, in this context, the drying treatment is carried out in at least one drying device, in particular in at least one oven.

According to a particular embodiment, it can be provided that a cooling treatment also takes place after the second hot-dip galvanizing. In other words, the iron or steel component obtained after the second hot-dip galvanizing can be subjected to a cooling treatment.

It can also be provided that a post-processing treatment takes place after the second hot-dip galvanizing. In other words, the iron or steel component obtained after the second hot-dip galvanizing can be subjected to a post-processing treatment.

In connection with the post-processing treatment after the second hot-dip galvanizing, this can also include - analogous to the post-processing treatment after the first hot-dip galvanizing - the removal of excess zinc bath residues, in particular so-called drips of zinc solidifying on the edges as well as oxide or ash residues adhering to the component, as well as the passivation or sealing of the surface. The post-processing treatment after the first hot-dip galvanizing and the post-processing treatment after the second hot-dip galvanizing are, however, independent of one another; in particular, only one post-processing treatment can be carried out and the steps or measures carried out can be the same or different. The post-processing treatment can improve the overall quality of the entire hot-dip galvanizing layer, in particular the optical and mechanical properties as well as the corrosion protection properties.

1. (a) Entfettungsbehandlung, vorzugsweise alkalische Entfettungsbehandlung, des Eisen- oder Stahlbauteils, insbesondere in mindestens einem Entfettungsbad; dann
2. (b) gegebenenfalls Spülen des in Verfahrensschritt (a) entfetteten Eisen- oder Stahlbauteils, insbesondere in mindestens einem Spülbad; dann
3. (c) Beizbehandlung, vorzugsweise saure Beizbehandlung, des in Verfahrensschritt (a) entfetteten und gegebenenfalls in Verfahrensschritt (b) gespülten Eisen- oder Stahlbauteils, insbesondere in mindestens einem Beizbad; dann
4. (d) gegebenenfalls Spülen des in Verfahrensschritt (c) gebeizten Eisen- oder Stahlbauteils, insbesondere in mindestens einem Spülbad; dann
5. (e) Flussmittelbehandlung des in Verfahrensschritt (c) gebeizten und gegebenenfalls in Verfahrensschritt (d) gespülten Eisen- oder Stahlbauteils mittels einer Flussmittelzusammensetzung in einem Flussmittelbad; dann
6. (f) gegebenenfalls Trocknungsbehandlung des in Verfahrensschritt (e) der Flussmittelbehandlung unterzogenen Eisen- oder Stahlbauteils.

According to a preferred embodiment, it can be provided that the iron or steel component is subjected to the following process steps in the order listed below before the first hot-dip galvanizing:

1. (a) degreasing treatment, preferably alkaline degreasing treatment, of the iron or steel component, in particular in at least one degreasing bath; then
2. (b) optionally rinsing the iron or steel component degreased in process step (a), in particular in at least one rinsing bath; then
3. (c) pickling treatment, preferably acidic pickling treatment, of the iron or steel component degreased in process step (a) and optionally rinsed in process step (b), in particular in at least one pickling bath; then
4. (d) optionally rinsing the iron or steel component pickled in process step (c), in particular in at least one rinsing bath; then
5. (e) fluxing the iron or steel component pickled in process step (c) and optionally rinsed in process step (d) using a flux composition in a flux bath; then
6. (f) where appropriate, drying treatment of the iron or steel component subjected to the flux treatment in process step (e).

In this context, the flux in process step (e) can comprise the following ingredients: (I) zinc chloride (ZnCl ₂ ), (II) optionally ammonium chloride (NH ₄ Cl), (III) optionally at least one alkali and/or alkaline earth salt, in particular sodium chloride and/or potassium chloride, preferably sodium chloride and potassium chloride, and (IV) optionally at least one further metal salt, in particular selected from the group of chlorides, preferably chlorides of nickel (Ni), cobalt (Co), manganese (Mn), lead (Pb), tin (Sn), bismuth

(Bi), antimony (Sb), aluminium (Al) and silver (Ag) and combinations thereof, in particular selected from the group of NiCl ₂ , CoCl ₂ , MnCl ₂ , PbCl ₂ , SnCl ₂ , BiCl ₃ , SbCl ₃ , AlCl ₃ and AgCl and combinations thereof.

The flux used in process step (e) can be the same or different from the flux used before the second hot-dip galvanizing or in the activation treatment. In particular, there are two separate flux baths. It should also be noted that different zinc baths (i.e. with different compositions) are used for the first hot-dip galvanizing and the second hot-dip galvanizing, whereby the flux composition should be adapted to the composition of the zinc bath following the flux treatment. For example, as previously stated, when using a zinc melt containing aluminum or aluminum alloy, more intensive cleaning is necessary in order to achieve an optimal galvanizing result. A pure zinc melt, as used in particular in the first hot-dip galvanizing, is less sensitive and thus high-quality, in particular continuous and error-free, galvanizing is possible even without particularly intensive fine cleaning.

1. (I) Zinkchlorid (ZnCl₂), insbesondere in Mengen im Bereich von 50 bis 95 Gew.-%,
2. (II) gegebenenfalls Ammoniumchlorid (NH₄Cl), insbesondere in Mengen im Bereich von 7 bis 50 Gew.-%,
3. (III) gegebenenfalls mindestens eine Alkali- und/oder Erdalkalisalz, insbesondere Natriumchlorid und/oder Kaliumchlorid, bevorzugt Natriumchlorid und Kaliumchlorid, insbesondere in Mengen im Bereich von 2 bis 20 Gew.-%,
4. (IV) gegebenenfalls mindestens eines Metallsalzes aus der Gruppe von NiCl₂, CoCl₂, MnCl₂, PbCl₂, SnCl₂, BiCl₃, SbCl₃, AlCl₃ und AgCl, insbesondere in Mengen im Bereich von 0,1 bis 10 Gew.-%.

According to a preferred embodiment, the flux in process step (e) can comprise the following ingredients, wherein all quantities given below are based on the flux and are to be selected such that a total of 100% by weight results:

1. (I) zinc chloride (ZnCl ₂ ), in particular in amounts ranging from 50 to 95 wt.%,
2. (II) optionally ammonium chloride (NH ₄ Cl), in particular in amounts ranging from 7 to 50% by weight,
3. (III) optionally at least one alkali and/or alkaline earth salt, in particular sodium chloride and/or potassium chloride, preferably sodium chloride and potassium chloride, in particular in amounts in the range of 2 to 20% by weight,
4. (IV) optionally at least one metal salt from the group of NiCl ₂ , CoCl ₂ , MnCl ₂ , PbCl ₂ , SnCl ₂ , BiCl ₃ , SbCl ₃ , AlCl ₃ and AgCl, in particular in amounts in the range of 0.1 to 10 wt.%.

According to a particular embodiment, it can be provided that the flux bath in process step (e) is adjusted to a defined or predetermined, in particular acidic pH value, in particular in the pH value range from 0 to 6.9, preferably in the pH value range from 0.5 to 6.5, preferably in the pH value range from 1 to 5.5, particularly preferably in the pH value range from 1.5 to 5, very particularly preferably in the pH value range from 2 to 4.5, even more preferably in the pH value range from 2 to 4.

According to a particular embodiment, it can also be provided that the flux bath in process step (e) is adjusted to a defined or predetermined, in particular acidic pH value, wherein the pH value is adjusted by means of a preferably inorganic acid in combination with a preferably inorganic basic compound, in particular ammonia (NH ₃ ).

This embodiment, ie the fine adjustment of the pH value of the flux bath in process step (e) by means of a preferably inorganic basic compound, in particular ammonia (NH ₃ ), is particularly advantageous because this counteracts undesirable hydrogen embrittlement of the component to be treated. The pH value can also be adjusted in the same way in the flux bath before the second hot-dip galvanizing (ie in the flux bath which can be used as part of the activation treatment).

Furthermore, according to a particular embodiment, it can also be provided that the flux bath in process step (e) also contains at least one wetting agent and/or surfactant, in particular at least one ionic or non-ionic wetting agent and/or surfactant, preferably at least one non-ionic wetting agent and/or surfactant.

1. (a) Entfettungsbehandlung, vorzugsweise alkalische Entfettungsbehandlung, des Eisen- oder Stahlbauteils, insbesondere in mindestens einem Entfettungsbad; dann
2. (b) gegebenenfalls Spülen des in Verfahrensschritt (a) entfetteten Eisen- oder Stahlbauteils, insbesondere in mindestens einem Spülbad; dann
3. (c) Beizbehandlung, vorzugsweise saure Beizbehandlung, des in Verfahrensschritt (a) entfetteten und gegebenenfalls in Verfahrensschritt (b) gespülten Eisen- oder Stahlbauteils, insbesondere in mindestens einem Beizbad; dann
4. (d) gegebenenfalls Spülen des in Verfahrensschritt (c) gebeizten Eisen- oder Stahlbauteils, insbesondere in mindestens einem Spülbad; dann
5. (e) Flussmittelbehandlung des in Verfahrensschritt (c) gebeizten und gegebenenfalls in Verfahrensschritt (d) gespülten Eisen- oder Stahlbauteils mittels einer Flussmittelzusammensetzung in einem Flussmittelbad; dann
6. (f) gegebenenfalls Trocknungsbehandlung des in Verfahrensschritt (e) der Flussmittelbehandlung unterzogenen Eisen- oder Stahlbauteils; dann
7. (g) erste Feuerverzinkung (Schmelztauchverzinkung) des in Verfahrensschritt (e) der Flussmittelbehandlung unterzogenen und gegebenenfalls in Verfahrensschritt (f) getrockneten Eisen- oder Stahlbauteils in einer Zinkschmelze („Zn-Schmelze“), insbesondere in einem die Zinkschmelze enthaltenden Verzinkungsbad, vorzugsweise durch Tauchen des Eisen- oder Stahlbauteils in die Zinkschmelze und/oder in das Verzinkungsbad;
8. (h) gegebenenfalls Abkühlungsbehandlung des in Verfahrensschritt (g) feuerverzinkten (schmelztauchverzinkten) Eisen- oder Stahlbauteils; dann
9. (i) gegebenenfalls Nachbearbeitung des in Verfahrensschritt (g) feuerverzinkten (schmelztauchverzinkten) und gegebenenfalls in Verfahrensschritt (h) abgekühlten Eisen- oder Stahlbauteils; dann
10. (j) Aktivierungsbehandlung des in Verfahrensschritt (g) feuerverzinkten (schmelztauchverzinkten) und gegebenenfalls in Verfahrensschritt (h) abgekühlten und gegebenenfalls in Verfahrensschritt (i) nachbearbeiteten Eisen- oder Stahlbauteils; dann
11. (k) gegebenenfalls Trocknungsbehandlung des in Verfahrensschritt (j) der Aktivierungsbehandlung unterzogenen Eisen- oder Stahlbauteils; dann
12. (l) zweite Feuerverzinkung (Schmelztauchverzinkung) des in Verfahrensschritt (j) der Aktivierungsbehandlung unterzogenen und gegebenenfalls in Verfahrensschritt (k) getrockneten Eisen- oder Stahlbauteils in einer aluminiumhaltigen und/oder aluminiumlegierten Zinkschmelze („Zn/Al-Schmelze“), insbesondere in einem die aluminiumhaltige und/oder aluminiumlegierte Zinkschmelze enthaltenden Verzinkungsbad, vorzugsweise durch Tauchen des Eisen- oder Stahlbauteils in die aluminiumhaltige und/oder aluminiumlegierte Zinkschmelze und/oder in das Verzinkungsbad; dann
13. (m) gegebenenfalls Abkühlungsbehandlung des in Verfahrensschritt (I) feuerverzinkten (schmelztauchverzinkten) Eisen- oder Stahlbauteils; dann
14. (n) gegebenenfalls Nachbearbeitung des in Verfahrensschritt (I) feuerverzinkten (schmelztauchverzinkten) und gegebenenfalls in Verfahrensschritt (m) abgekühlten Eisen- oder Stahlbauteils.

According to a particular embodiment, the method of the present invention may comprise the following method steps in the order listed below:

1. (a) degreasing treatment, preferably alkaline degreasing treatment, of the iron or steel component, in particular in at least one degreasing bath; then
2. (b) optionally rinsing the iron or steel component degreased in process step (a), in particular in at least one rinsing bath; then
3. (c) pickling treatment, preferably acidic pickling treatment, of the iron or steel component degreased in process step (a) and optionally rinsed in process step (b), in particular in at least one pickling bath; then
4. (d) optionally rinsing the iron or steel component pickled in process step (c), in particular in at least one rinsing bath; then
5. (e) fluxing the iron or steel component pickled in process step (c) and optionally rinsed in process step (d) using a flux composition in a flux bath; then
6. (f) if necessary, drying treatment of the iron or steel component subjected to flux treatment in process step (e); then
7. (g) first hot-dip galvanizing (hot-dip galvanizing) of the iron or steel component subjected to the flux treatment in process step (e) and optionally dried in process step (f) in a zinc melt (“Zn melt”), in particular in a galvanizing bath containing the zinc melt, preferably by dipping the iron or steel component into the zinc melt and/or into the galvanizing bath;
8. (h) if necessary, cooling treatment of the iron or steel component hot-dip galvanised (hot-dip galvanised) in process step (g); then
9. (i) if necessary, post-processing of the iron or steel component hot-dip galvanised (hot-dip galvanised) in process step (g) and, if necessary, cooled in process step (h); then
10. (j) activation treatment of the iron or steel component hot-dip galvanised (hot-dip galvanised) in process step (g) and optionally cooled in process step (h) and optionally post-processed in process step (i); then
11. (k) if necessary, drying treatment of the iron or steel component subjected to the activation treatment in process step (j); then
12. (l) second hot-dip galvanizing (hot-dip galvanizing) of the iron or steel component subjected to the activation treatment in process step (j) and optionally dried in process step (k) in an aluminum-containing and/or aluminum-alloyed zinc melt (“Zn/Al melt”), in particular in a galvanizing bath containing the aluminum-containing and/or aluminum-alloyed zinc melt, preferably by dipping the iron or steel component into the aluminum-containing and/or aluminum-alloyed zinc melt and/or into the galvanizing bath; then
13. (m) if necessary, cooling treatment of the iron or steel component hot-dip galvanised (hot-dip galvanised) in process step (I); then
14. (n) if necessary, post-processing of the iron or steel component hot-dip galvanised (hot-dip galvanised) in process step (I) and, if necessary, cooled in process step (m).

In the context of the method according to the invention, it is preferred if, before the activation treatment according to method step (j), the iron or steel component obtained after the first hot-dip galvanizing is left to rest, in particular stored and/or transported and/or used, preferably under oxidative conditions and/or with exposure to ambient air and/or ambient atmosphere, in particular for a period of at least 10 minutes, in particular at least 60 minutes, preferably at least 24 hours. By bringing the iron or steel component obtained after the first hot-dip galvanizing into contact with oxidative conditions, in particular with the ambient air or the ambient atmosphere, the surface of the hot-dip galvanizing layer formed in the first hot-dip galvanizing is oxidized. A natural covering layer is formed which consists in particular of zinc oxide, zinc hydroxide, zinc oxide hydroxide, zinc hydrogen carbonate, zinc carbonate and combinations thereof and has a higher melting temperature than the hot-dip galvanizing layer itself.

Within the scope of the present invention, it can be provided, if necessary, that a pretreatment takes place before the activation treatment, in which further cleaning steps, such as an alkaline and/or acidic treatment, take place.

The hot-dip galvanized iron or steel component obtainable from the process according to the invention has a more ductile zinc layer which is deformable in particular at least substantially without impairing the corrosion protection performance, e.g. in the form of a 90° bend.

In addition, the hot-dip galvanized iron or steel component obtainable from the process according to the invention, in particular with a base material thickness of at least 2 mm and a layer thickness of the (total) hot-dip galvanizing layer of at least 30 µm, does not show any red rust formation after 90° bending with a residence time of at least 1,000 h, in particular at least 1,250 h, preferably at least 1,500 h, particularly preferably at least 1,750 h, very particularly preferably at least 2,000 h, in the salt spray test, in particular according to DIN EN ISO 9227.

Furthermore, the hot-dip galvanized iron or steel component, in particular with a hot-dip galvanizing layer of at least 350 g/m ² , with a residence time of at least 1,000 h, in particular at least 2,000 h, preferably at least 5,000 h, particularly preferably at least 8,000 h, very particularly preferably at least 10,000 h, in the salt spray test, in particular according to DIN EN ISO 9227, does not show any red rust formation.

In comparison, state-of-the-art hot-dip galvanized iron or steel components can only remain in the salt spray test according to DIN EN ISO 9227 for about 800 hours without red rust formation with a hot-dip galvanizing layer of even 550 g/m ² . The hot-dip galvanized iron or steel components according to the invention can therefore remain in the salt spray test according to DIN EN ISO 9227 for a longer time without red rust formation and even with a lower layer thickness of the hot-dip galvanizing layer.

As a result, the present invention provides an efficient and economical process for producing a hot-dip galvanized iron or steel component with increased corrosion protection performance and/or with increased ductility.

• - eine erste Feuerverzinkungsvorrichtung zur Feuerverzinkung des Eisen- oder Stahlbauteils in einer Zinkschmelze („Zn-Schmelze“), insbesondere in einem eine Zinkschmelze enthaltenden Verzinkungsbad; nachgeschaltet und/oder im Verfahrensablauf stromabwärts hierzu angeordnet
• - eine zweite Feuerverzinkungsvorrichtung zur Feuerverzinkung des nach der ersten Feuerverzinkung erhaltenen Eisen- oder Stahlbauteils in einer aluminiumhaltigen und/oder aluminiumlegierten Zinkschmelze („Zn/Al-Schmelze“), insbesondere in einem eine aluminiumhaltige und/oder aluminiumlegierte Zinkschmelze enthaltenden Verzinkungsbad.

Another subject matter - according to a second aspect of the present invention - is a plant (system) for hot-dip galvanizing (hot-dip galvanizing) an iron or steel component, in particular for producing a hot-dip galvanized iron or steel component with increased corrosion protection performance and/or with increased ductility, preferably a plant (system) for carrying out a two-stage hot-dip galvanizing process, in particular a plant (system) for carrying out a previously described process, wherein the plant comprises the following devices in the order listed below:

• - a first hot-dip galvanizing device for hot-dip galvanizing the iron or steel component in a zinc melt (“Zn melt”), in particular in a galvanizing bath containing a zinc melt; arranged downstream and/or downstream of this in the process sequence
• - a second hot-dip galvanizing device for hot-dip galvanizing the iron or steel component obtained after the first hot-dip galvanizing in an aluminum-containing and/or aluminum-alloyed zinc melt ("Zn/Al melt"), in particular in a galvanizing bath containing an aluminum-containing and/or aluminum-alloyed zinc melt.

According to a particular embodiment, it can be provided that a storage and/or transfer area is arranged downstream and/or in the process sequence downstream of the first hot-dip galvanizing device and upstream and/or in the process sequence upstream of the second hot-dip galvanizing device, in particular wherein the storage and/or transfer area is designed for resting, in particular for storing and/or transporting and/or using, the iron or steel component obtained after the first hot-dip galvanizing device.

In this context, it is particularly intended that the storage and/or transfer area has oxidative conditions and/or ambient air and/or ambient atmosphere.

In other words, it is particularly intended that oxidative conditions and/or ambient air and/or ambient atmosphere are present in the storage and/or transfer area.

In the plant according to the invention, the iron or steel components are therefore not hot-dip galvanized directly one after the other in both hot-dip galvanizing devices, but are first brought to the storage and/or transfer area after the first hot-dip galvanizing and are exposed there in particular to oxidative conditions and/or the ambient air and/or the ambient atmosphere.

Within the scope of the present invention, it can be provided in particular that the second hot-dip galvanizing device is not arranged immediately downstream and/or downstream in the process sequence of the first hot-dip galvanizing device, in particular not in such a way that the hot-dip galvanizing layer resulting from the first hot-dip galvanizing is not exposed to oxidative conditions and/or ambient air and/or ambient atmosphere.

Furthermore, within the scope of the present invention, it can also be provided that the second hot-dip galvanizing device is not arranged immediately downstream and/or downstream of the first hot-dip galvanizing device in the process sequence, in particular not without an oxidation layer being formed on the hot-dip galvanizing layer resulting from the first hot-dip galvanizing.

According to a preferred embodiment, it can be provided in particular that the first hot-dip galvanizing device and the second hot-dip galvanizing device are arranged spatially separated from one another.

In this context, spatially separated means in particular that the first hot-dip galvanizing device and the second hot-dip galvanizing device are arranged in such a way that in particular the previously mentioned storage and/or transfer area is arranged between them. The first hot-dip galvanizing device and the second hot-dip galvanizing device are therefore in particular not arranged directly or immediately behind one another or adjacent to one another. In particular, the storage and/or transfer area is located between them, in which the iron or steel component obtainable after the first hot-dip galvanizing is exposed to oxidative conditions.

According to a further particular embodiment of the present invention, a first post-treatment device can be arranged downstream and/or downstream in the process sequence of the first hot-dip galvanizing device and upstream and/or upstream in the process sequence of the second hot-dip galvanizing device.

In particular, the first post-treatment device is also arranged upstream of and/or upstream in the process sequence to the previously described storage and/or transfer area; i.e. the first post-treatment device is in particular arranged immediately downstream of and/or downstream in the process sequence to the first hot-dip galvanizing device.

In particular, the first aftertreatment device can comprise at least one cooling device.

Furthermore, the first post-treatment device can comprise at least one post-processing device.

In this context, the post-treatment device can be designed in particular to remove excess zinc bath residues, in particular so-called drips of the zinc solidifying on the edges, as well as oxide or ash residues adhering to the component, as well as to passivate or seal the surface.

According to a further particular embodiment of the present invention, an intermediate treatment device can be arranged downstream and/or in the process sequence downstream of the first hot-dip galvanizing device, in particular downstream and/or in the process sequence downstream of the first hot-dip galvanizing device and downstream and/or in the process sequence downstream of the first post-treatment device.

In particular, the intermediate treatment device is also arranged downstream or after and/or downstream in the process sequence to the previously described storage and/or transfer area; i.e. the intermediate treatment device is in particular arranged immediately upstream or before and/or upstream in the process sequence to the second hot-dip galvanizing device.

According to a preferred embodiment of the present invention, the intermediate treatment device may comprise an activation device.

In particular, the activation device can be designed to carry out at least one chemical and optionally (additionally) one mechanical treatment, in particular wherein the chemical mechanical treatment comprises at least a pickling treatment and/or flux treatment and/or in particular wherein the mechanical treatment comprises an abrasive treatment.

Furthermore, it can be provided that the intermediate treatment device comprises a drying device.

In particular, the drying device may comprise at least one oven.

According to a further particular embodiment, the plant according to the invention can be designed such that a second post-treatment device is arranged downstream and/or downstream in the process sequence to the second hot-dip galvanizing device.

In particular, the second aftertreatment device can comprise at least one cooling device.

Furthermore, the second post-treatment device may comprise at least one post-processing device.

Analogous to the first post-treatment device, the second post-treatment device can also be designed in particular for removing excess zinc bath residues, in particular so-called drips of the zinc solidifying on the edges, as well as oxide or ash residues which adhere to the component, as well as for passivating or sealing the surface.

1. (a) Entfettungsbehandlung, vorzugsweise alkalische Entfettungsbehandlung, des Eisen- oder Stahlbauteils, insbesondere in mindestens einem Entfettungsbad; dann
2. (b) gegebenenfalls Spülen des in Verfahrensschritt (a) entfetteten Eisen- oder Stahlbauteils, insbesondere in mindestens einem Spülbad; dann
3. (c) Beizbehandlung, vorzugsweise saure Beizbehandlung, des in Verfahrensschritt (a) entfetteten und gegebenenfalls in Verfahrensschritt (b) gespülten Eisen- oder Stahlbauteils, insbesondere in mindestens einem Beizbad; dann
4. (d) gegebenenfalls Spülen des in Verfahrensschritt (c) gebeizten Eisen- oder Stahlbauteils, insbesondere in mindestens einem Spülbad; dann
5. (e) Flussmittelbehandlung des in Verfahrensschritt (c) gebeizten und gegebenenfalls in Verfahrensschritt (d) gespülten Eisen- oder Stahlbauteils mittels einer Flussmittelzusammensetzung in einem Flussmittelbad; dann
6. (f) gegebenenfalls Trocknungsbehandlung des in Verfahrensschritt (e) der Flussmittelbehandlung unterzogenen Eisen- oder Stahlbauteils.

According to yet another particular embodiment, the plant according to the invention can be designed such that a pretreatment device is arranged upstream and/or upstream of the first hot-dip galvanizing device in the process sequence, wherein the pretreatment device is designed to carry out the following process steps in the order listed below:

1. (a) degreasing treatment, preferably alkaline degreasing treatment, of the iron or steel component, in particular in at least one degreasing bath; then
2. (b) optionally rinsing the iron or steel component degreased in process step (a), in particular in at least one rinsing bath; then
3. (c) pickling treatment, preferably acidic pickling treatment, of the iron or steel component degreased in process step (a) and optionally rinsed in process step (b), in particular in at least one pickling bath; then
4. (d) optionally rinsing the iron or steel component pickled in process step (c), in particular in at least one rinsing bath; then
5. (e) fluxing the iron or steel component pickled in process step (c) and optionally rinsed in process step (d) using a flux composition in a flux bath; then
6. (f) where appropriate, drying treatment of the iron or steel component subjected to the flux treatment in process step (e).

• (VBH) mindestens eine Vorbehandlungseinrichtung; nachgeschaltet und/oder im Verfahrensablauf stromabwärts hierzu angeordnet
• (FZ1) mindestens eine erste Feuerverzinkungsvorrichtung; nachgeschaltet und/oder im Verfahrensablauf stromabwärts hierzu angeordnet
• (NBH1) mindestens eine erste Nachbehandlungsvorrichtung; nachgeschaltet und/oder im Verfahrensablauf stromabwärts hierzu angeordnet
• (ZBH) mindestens eine Zwischenbehandlungsvorrichtung; nachgeschaltet und/oder im Verfahrensablauf stromabwärts hierzu angeordnet
• (FZ2) mindestens eine zweite Feuerverzinkungsvorrichtung; nachgeschaltet und/oder im Verfahrensablauf stromabwärts hierzu angeordnet
• (NBH2) mindestens eine zweite Nachbehandlungsvorrichtung.

Within the scope of the present invention, it can be provided in particular that the system comprises the following devices in the order listed below:

• (VBH) at least one pre-treatment device; downstream and/or arranged downstream of this in the process sequence
• (FZ1) at least one first hot-dip galvanizing device; arranged downstream and/or downstream of this in the process sequence
• (NBH1) at least one first aftertreatment device; arranged downstream and/or downstream of it in the process sequence
• (ZBH) at least one intermediate treatment device; arranged downstream and/or in the process sequence downstream of this
• (FZ2) at least one second hot-dip galvanizing device; arranged downstream and/or downstream of this in the process sequence
• (NBH2) at least one second aftertreatment device.

1. (A) mindestens ein Entfettungsbad; nachgeschaltet und/oder im Verfahrensablauf stromabwärts hierzu angeordnet
2. (B) gegebenenfalls mindestens ein Spülbad; nachgeschaltet und/oder im Verfahrensablauf stromabwärts hierzu angeordnet
3. (C) mindestens ein Beizbad; nachgeschaltet und/oder im Verfahrensablauf stromabwärts hierzu angeordnet
4. (D) gegebenenfalls mindestens ein Spülbad; nachgeschaltet und/oder im Verfahrensablauf stromabwärts hierzu angeordnet
5. (E) mindestens ein Flussmittelbad; nachgeschaltet und/oder im Verfahrensablauf stromabwärts hierzu angeordnet
6. (F) gegebenenfalls mindestens eine Trocknungseinrichtung, insbesondere Ofen; nachgeschaltet und/oder im Verfahrensablauf stromabwärts hierzu angeordnet
7. (G) mindestens ein Verzinkungsbad; nachgeschaltet und/oder im Verfahrensablauf stromabwärts hierzu angeordnet
8. (H) gegebenenfalls Abkühlungseinrichtung; nachgeschaltet und/oder im Verfahrensablauf stromabwärts hierzu angeordnet
9. (I) gegebenenfalls Nachbearbeitungseinrichtung; nachgeschaltet und/oder im Verfahrensablauf stromabwärts hierzu angeordnet
10. (J) mindestens eine Aktivierungseinrichtung; nachgeschaltet und/oder im Verfahrensablauf stromabwärts hierzu angeordnet
11. (K) gegebenenfalls mindestens eine Trocknungseinrichtung, insbesondere Ofen; nachgeschaltet und/oder im Verfahrensablauf stromabwärts hierzu angeordnet
12. (L) Verzinkungsbad; nachgeschaltet und/oder im Verfahrensablauf stromabwärts hierzu angeordnet
13. (M) gegebenenfalls mindestens eine Abkühlungseinrichtung; nachgeschaltet und/oder im Verfahrensablauf stromabwärts hierzu angeordnet
14. (N) gegebenenfalls mindestens eine Nachbearbeitungseinrichtung.

Furthermore, within the scope of the present invention, according to a particular embodiment, it can be provided that the system comprises the following facilities and/or bathrooms in the order listed below:

1. (A) at least one degreasing bath; arranged downstream and/or in the process sequence
2. (B) optionally at least one rinsing bath; arranged downstream and/or in the process sequence downstream of this
3. (C) at least one pickling bath; arranged downstream and/or in the process sequence downstream of this
4. (D) optionally at least one rinsing bath; arranged downstream and/or in the process sequence downstream of this
5. (E) at least one flux bath; arranged downstream and/or in the process sequence downstream of this
6. (F) optionally at least one drying device, in particular an oven; arranged downstream and/or downstream of this in the process sequence
7. (G) at least one galvanizing bath; arranged downstream and/or in the process sequence downstream of this
8. (H) if necessary, cooling device; arranged downstream and/or in the process sequence downstream of this
9. (I) if necessary, post-processing equipment; arranged downstream and/or in the process sequence
10. (J) at least one activation device; arranged downstream and/or in the process sequence downstream of this
11. (K) optionally at least one drying device, in particular an oven; arranged downstream and/or downstream of this in the process sequence
12. (L) Galvanizing bath; downstream and/or downstream of it in the process sequence
13. (M) optionally at least one cooling device; arranged downstream and/or downstream of this in the process sequence
14. (N) where appropriate, at least one post-processing device.

Within the scope of the present invention, it can be provided, if necessary, that a pretreatment device is arranged upstream of the activation device, in which further cleaning steps, such as an alkaline and/or acidic treatment, are carried out.

• (VBH) mindestens eine Vorbehandlungseinrichtung, wobei die Vorbehandlungseinrichtung
  1. (A) mindestens ein Entfettungsbad; nachgeschaltet und/oder im Verfahrensablauf stromabwärts hierzu angeordnet
  2. (B) gegebenenfalls mindestens ein Spülbad; nachgeschaltet und/oder im Verfahrensablauf stromabwärts hierzu angeordnet
  3. (C) mindestens ein Beizbad; nachgeschaltet und/oder im Verfahrensablauf stromabwärts hierzu angeordnet
  4. (D) gegebenenfalls mindestens ein Spülbad; nachgeschaltet und/oder im Verfahrensablauf stromabwärts hierzu angeordnet
  5. (E) mindestens ein Flussmittelbad; nachgeschaltet und/oder im Verfahrensablauf stromabwärts hierzu angeordnet
  6. (F) gegebenenfalls mindestens eine Trocknungseinrichtung, insbesondere Ofen;
  umfasst; nachgeschaltet und/oder im Verfahrensablauf stromabwärts hierzu angeordnet
• (FZ1) mindestens eine erste Feuerverzinkungsvorrichtung, wobei die Feuerverzinkungsvorrichtung
  • (G) mindestens ein Verzinkungsbad;
  umfasst; nachgeschaltet und/oder im Verfahrensablauf stromabwärts hierzu angeordnet
• (NBH1) mindestens eine erste Nachbehandlungsvorrichtung, wobei die erste Nachbehandlungsvorrichtung
  • (H) gegebenenfalls mindestens eine Abkühlungseinrichtung; nachgeschaltet und/oder im Verfahrensablauf stromabwärts hierzu angeordnet
  • (I) gegebenenfalls mindestens eine Nachbearbeitungseinrichtung;
  umfasst; nachgeschaltet und/oder im Verfahrensablauf stromabwärts hierzu angeordnet
• (ZBH) mindestens eine Zwischenbehandlungsvorrichtung, wobei die Zwischenbehandlungsvorrichtung
  • amindestens eine Aktivierungseinrichtung; nachgeschaltet und/oder im Verfahrensablauf stromabwärts hierzu angeordnet
  • (K) gegebenenfalls mindestens eine Trocknungseinrichtung, insbesondere Ofen;
  • umfasst; nachgeschaltet und/oder im Verfahrensablauf stromabwärts hierzu angeordnet
• (FZ2) mindestens eine zweite Feuerverzinkungsvorrichtung, wobei die zweite Feuerverzinkungsvorrichtung
  • (L) mindestens ein Verzinkungsbad;
  • umfasst; nachgeschaltet und/oder im Verfahrensablauf stromabwärts hierzu angeordnet
• (NBH2) mindestens eine zweite Nachbehandlungsvorrichtung, wobei die zweite Nachbehandlungsvorrichtung
  • (M) gegebenenfalls mindestens eine Abkühlungseinrichtung; nachgeschaltet und/oder im Verfahrensablauf stromabwärts hierzu angeordnet
  • (N) gegebenenfalls mindestens eine Nachbearbeitungseinrichtung;
  umfasst.

According to yet another particular embodiment of the present invention, the installation may in particular comprise the following devices in the order listed below:

• (VBH) at least one pretreatment device, wherein the pretreatment device
  1. (A) at least one degreasing bath; arranged downstream and/or in the process sequence
  2. (B) optionally at least one rinsing bath; arranged downstream and/or in the process sequence downstream of this
  3. (C) at least one pickling bath; arranged downstream and/or in the process sequence downstream of this
  4. (D) optionally at least one rinsing bath; arranged downstream and/or in the process sequence downstream of this
  5. (E) at least one flux bath; arranged downstream and/or in the process sequence downstream of this
  6. (F) optionally at least one drying device, in particular an oven;
  comprises; arranged downstream and/or downstream in the process sequence
• (FZ1) at least one first hot-dip galvanizing device, wherein the hot-dip galvanizing device
  • (G) at least one galvanizing bath;
  comprises; arranged downstream and/or downstream in the process sequence
• (NBH1) at least one first aftertreatment device, wherein the first aftertreatment device
  • (H) optionally at least one cooling device; arranged downstream and/or downstream of this in the process sequence
  • (I) where appropriate, at least one post-processing device;
  comprises; arranged downstream and/or downstream in the process sequence
• (ZBH) at least one intermediate treatment device, wherein the intermediate treatment device
  • at least one activation device; arranged downstream and/or downstream of it in the process sequence
  • (K) optionally at least one drying device, in particular an oven;
  • comprises; arranged downstream and/or downstream in the process flow
• (FZ2) at least one second hot-dip galvanizing device, wherein the second hot-dip galvanizing device
  • (L) at least one galvanizing bath;
  • comprises; arranged downstream and/or downstream in the process flow
• (NBH2) at least one second aftertreatment device, wherein the second aftertreatment device
  • (M) optionally at least one cooling device; arranged downstream and/or downstream of this in the process sequence
  • (N) where appropriate, at least one post-processing device;
  includes.

In the context of the present invention, it can be provided, if necessary, that a pretreatment device is arranged upstream of the activation device, in which further cleaning steps, such as an alkaline and/or acidic treatment, take place.

• Insbesondere kann die erfindungsgemäße Anlage im Vergleich zu einer zur Durchführung eines als nass-in-nass-Verfahren durchgeführten Double-Dip-Verfahrens ausgebildeten Anlage, wie sie insbesondere im Zusammenhang mit einer Bandverzinkung verwendet wird, wirtschaftlicher betrieben werden.
• Insbesondere können die Feuerverzinkungsvorrichtungen getrennt betrieben werden, insbesondere auch an unterschiedlichen Standorten.

The system according to the invention is associated with a multitude of completely unexpected advantages, special features and surprising technical effects, the following description of which makes no claim to completeness, but illustrates the inventive character of the present invention:

• In particular, the plant according to the invention can be operated more economically than a plant designed to carry out a double-dip process carried out as a wet-on-wet process, as is used in particular in connection with strip galvanizing.
• In particular, the hot-dip galvanizing devices can be operated separately, especially at different locations.

In addition, the hot-dip galvanizing devices can also be operated and used independently of each other, in particular they can be used individually, which enables optimal and complete utilization of both hot-dip galvanizing devices.

For further details of the system according to the invention according to the second aspect of the invention, reference can be made to the above statements with respect to the first aspect of the invention, which also apply in a corresponding manner to the system according to the invention according to the second aspect of the invention.

Furthermore, the present invention - according to a third aspect of the present invention - relates to a hot-dip galvanized (hot-dip galvanized) iron or steel component, obtainable by a previously described method according to the invention and/or obtainable in a previously described plant according to the invention.

Likewise, the subject matter of this aspect of the invention is a hot-dip galvanized (hot-dip galvanized) iron or steel component, in particular a hot-dip galvanized iron or steel component as described above,
wherein the hot-dip galvanized iron or steel component is obtainable in that an iron or steel component has first been subjected to a first hot-dip galvanizing in a zinc melt (“Zn melt”), in particular in a galvanizing bath containing a zinc melt, and subsequently the iron or steel component obtained after the first hot-dip galvanizing has been subjected to a second hot-dip galvanizing in an aluminum-containing and/or aluminum-alloyed zinc melt (“Zn/Al melt”), in particular in a galvanizing bath containing an aluminum-containing and/or aluminum-alloyed zinc melt.

According to a particular embodiment of the present invention, the hot-dip galvanized iron or steel component can have a multi-layer or multi-phase (total) hot-dip galvanizing layer applied to the base material of the iron or steel component.

In this context, the base material is the material of the iron or steel component to be galvanized; i.e. the base material is typically iron or steel. The (total) hot-dip galvanizing layer is formed on this base material within the scope of the process according to the invention.

According to a further particular embodiment of the present invention, the hot-dip galvanized iron or steel component can have an at least partially layered hot-dip galvanizing layer with Zn/Al/Fe phases, in particular as an outer hot-dip galvanizing layer and/or in particular as an outer layer.

According to yet another particular embodiment of the present invention, the hot-dip galvanized iron or steel component can have on the base material of the iron or steel component, in particular below (below) the outer hot-dip galvanizing layer and/or the outer layer, at least one hot-dip galvanizing layer with Zn/Fe phase, which optionally contains aluminum.

In particular, the at least one hot-dip galvanizing layer with Zn/Fe phase, which may optionally contain aluminum, is formed in that a hot-dip galvanizing layer with Zn/Fe phase is formed on the base material in the first hot-dip galvanizing according to the method described above and the second hot-dip galvanizing of the method described above is carried out in such a way that the aluminum diffuses at least partially into the hot-dip galvanizing layer formed in the first hot-dip galvanizing, but does not diffuse through it completely. In particular, the hot-dip galvanizing layer formed in the first hot-dip galvanizing is not replaced or displaced as such, but only at least partially mixed with aluminum (in particular in the upper layer region of the first hot-dip galvanizing layer), so that an entirely new layer is formed, wherein the hot-dip galvanizing layer with Zn/Fe phase remains at least substantially on the base material or on the component surface and is only mixed with aluminum if necessary. If the aluminum diffuses completely through the second hot-dip galvanizing, as typically occurs in a conventional double-dip process carried out as a wet-on-wet process, there is no longer a hot-dip galvanizing layer with a Zn/Fe phase on the base material, since the second hot-dip galvanizing layer or its components diffuse completely into or through the still liquid or not yet hardened first hot-dip galvanizing layer in an uncontrolled manner, so that no controllability or monitoring of the resulting final layer structure is possible (in fundamental contrast to the inventive concept).

In particular, the hot-dip galvanized layer adheres particularly well to the iron or steel component due to the Zn/Fe phase, which may contain aluminum.

Furthermore, according to a preferred embodiment of the present invention, the hot-dip galvanized iron or steel component has a multi-layer or multi-phase (overall) hot-dip galvanizing layer applied to the base material of the iron or steel component.

Consequently, according to the invention, there is typically no uniform hot-dip galvanizing layer. In particular, several layers or phases are included or there is a non-homogeneous overall layer structure, whereby these layers/phases or the non-homogeneous overall layer structure have or have different phases (in particular with regard to an aluminum concentration gradient, as explained above). In particular, in connection with the present invention, this is to be understood as meaning that there is or is not a uniform or homogeneous composition within these layers or within the overall layer structure, but rather different areas (i.e. different phases) with different compositions, in particular different amounts of the individual components (i.e. different amounts of zinc, aluminum and iron) are included or present.

In particular, the hot-dip galvanized iron or steel component can have an at least partially layered hot-dip galvanizing layer with Zn/Al/Fe phases, in particular as an outer hot-dip galvanizing layer and/or in particular as an outer layer.

In addition, the hot-dip galvanized iron or steel component can have a hot-dip galvanized layer with Zn/Fe phase, which optionally contains aluminum, on the base material of the iron or steel component, in particular below (below) the outer hot-dip galvanized layer and/or the outer layer.

According to a particularly preferred embodiment of the present invention, the hot-dip galvanized iron or steel component can have a (total) hot-dip galvanizing layer with an aluminum concentration gradient.

According to a further particular embodiment of the present invention, the multilayer or multiphase (total) hot-dip galvanizing layer can have an aluminum concentration gradient.

In this context, the term “aluminum concentration gradient” used in the invention is to be understood in particular to mean that the concentration of aluminum in the (entire) hot-dip galvanizing layer is distributed irregularly or is not the same everywhere, in particular in such a way that a particularly high amount of aluminum is contained on the outside and, in addition, there is also an increased amount of aluminum directly or immediately on the base material. In particular, the increased amount of aluminum on the base material is due to - without wishing to be limited to this theory - the fact that there is a high affinity between the aluminum and the iron, so that part of the aluminum diffuses to the base material. In other words, the aluminum concentration is therefore relatively low, particularly in the interior or in the “middle” of the (entire) hot-dip galvanizing layer.

• Insbesondere kann das feuerverzinkte Eisen- oder Stahlbauteil eine (Gesamt-)Feuerverzinkungsschicht mit einer (Gesamt-)Schichtdicke von mindestens 30 µm, insbesondere mindestens 35 µm, bevorzugt mindestens 40 µm, besonders bevorzugt mindestens 45 µm, aufweisen.

The (total) layer thickness of the (total) hot-dip galvanizing layer of the hot-dip galvanized iron or steel component can vary in other areas:

• In particular, the hot-dip galvanized iron or steel component can have a (total) hot-dip galvanizing layer with a (total) layer thickness of at least 30 µm, in particular at least 35 µm, preferably at least 40 µm, particularly preferably at least 45 µm.

In addition, the hot-dip galvanized iron or steel component can have a (total) hot-dip galvanizing layer with a (total) layer thickness of at most 500 µm, in particular at most 450 µm, preferably at most 400 µm, particularly preferably at most 300 µm.

Furthermore, the hot-dip galvanized iron or steel component can have a (total) hot-dip galvanizing layer with a (total) layer thickness in the range from 30 µm to 500 µm, in particular in the range from 35 µm to 450 µm, preferably in the range from 40 µm to 400 µm, particularly preferably in the range from 45 µm to 300 µm.

According to a particular embodiment of the present invention, the hot-dip galvanized iron or steel component can be designed to be bendable to 90° at least substantially without impairing the corrosion protection performance.

In particular, this means that the corrosion protection performance does not decrease, or at least not significantly decreases, when the hot-dip galvanized component is bent by 90°. In particular, the hot-dip galvanized component has a very high corrosion protection performance even after a 90° bend.

According to a further particular embodiment of the present invention, the hot-dip galvanized iron or steel component, in particular with a base material thickness of the iron or steel component of at least 2 mm and a (total) thickness of the (total) hot-dip galvanizing layer of at least 30 µm, after 90° bending with a residence time of at least 1,000 h, in particular at least 1,250 h, preferably at least 1,500 h, particularly preferably at least 1,750 h, very particularly preferably at least 2,000 h, in the salt spray test, in particular according to DIN EN ISO 9227, at least substantially no red rust formation, preferably no red rust formation.

In the context of the present invention, a previously mentioned residence time in the salt spray test without red rust formation shows a high corrosion protection performance.

Red rust is primarily the corrosion products of iron and steel (iron oxides) and indicates damage to the substrate that was originally intended to be protected by the hot-dip galvanized layer. Red rust is therefore formed when there is insufficient corrosion protection.

In particular, the hot-dip galvanized iron or steel component, in particular with a (total) hot-dip galvanizing layer of at least 350 g/m ² , with a residence time of at least 1,000 h, in particular at least 2,000 h, preferably at least 5,000 h, particularly preferably at least 8,000 h, very particularly preferably at least 10,000 h, in the salt spray test, in particular according to DIN EN ISO 9227, at least substantially no red rust formation, preferably no red rust formation.

In comparison, state-of-the-art hot-dip galvanized iron or steel components can only remain in the salt spray test according to DIN EN ISO 9227 for about 800 hours without red rust formation with a hot-dip galvanizing layer of even 550 g/m ² . The hot-dip galvanized iron or steel components according to the invention can therefore remain in the salt spray test according to DIN EN ISO 9227 for a longer time without red rust formation and even with a lower layer thickness of the hot-dip galvanizing layer.

Without wishing to be limited to this theory, this improvement in corrosion protection performance is attributable to the special multi-layer or multi-phase structure of the (overall) hot-dip galvanizing layer of the hot-dip galvanized iron or steel component according to the invention, in particular to the presence of an at least partially layered hot-dip galvanizing layer with Zn/Al/Fe phases, in particular as an outer hot-dip galvanizing layer or outer layer, and a hot-dip galvanizing layer with Zn/Fe phase, which may optionally contain aluminum, on the base material of the iron or steel component, in particular below (below) the outer hot-dip galvanizing layer or outer layer.

• Denn, wie die Anmelderin nun vollkommen überraschend herausgefunden hat, weist das feuerverzinkte Eisen- oder Stahlbauteil einen höherer Korrosionsschutz bei gleicher Dicke der Feuerverzinkungsschicht im Vergleich zu einer üblichen Reinzinkschicht auf.

The hot-dip galvanized iron or steel component according to the invention is also associated with a large number of completely unexpected advantages, special features and surprising technical effects, the following description of which makes no claim to completeness, but illustrates the inventive character of the present invention:

• This is because, as the applicant has now discovered, completely unexpectedly, the hot-dip galvanised iron or steel component has a higher level of corrosion protection with the same thickness of the hot-dip galvanised layer compared to a conventional pure zinc layer.

In particular, the hot-dip galvanized iron or steel component according to the invention has an at least partially layered hot-dip galvanizing layer which consists of Zn/Al/Fe phases. The thickness of this hot-dip galvanizing layer is adjustable and, in addition, it has high corrosion protection properties and high ductility. In addition, this hot-dip galvanizing layer is very bright and therefore visually high-quality.

Furthermore, the applicant has discovered, quite surprisingly, that the layer thickness of the hot-dip galvanized iron or steel component according to the invention can be adjusted, even though an aluminum-containing or aluminum-alloyed zinc bath is used; in particular, the layer thickness of the hot-dip galvanizing layer is not limited, as is the case with conventional aluminum-containing or aluminum-alloyed hot-dip galvanizing layers.

The hot-dip galvanized iron or steel component according to the invention has a hot-dip galvanizing layer that is not obtainable in known one-stage processes and which has combinations of properties that are not achievable in one-stage processes, in particular due to the at least partially layered hot-dip galvanizing layer, which consists of Zn/Al/Fe phases.

In addition, the hot-dip galvanized iron or steel component according to the invention has, in particular on the base material of the iron or steel component, in particular below (below) the outer hot-dip galvanizing layer or outer layer, a hot-dip galvanizing layer with a Zn/Fe phase, which may optionally contain aluminum, which provides particularly good adhesion or high adhesive strength of the (entire) hot-dip galvanizing layer on the base material or on the iron or steel component. In particular, this special hot-dip galvanizing layer with a Zn/Fe phase, which may optionally contain aluminum, is only present on the base material if the aluminum has not completely diffused through the hot-dip galvanizing layer. Such a special layer structure and the presence of a hot-dip galvanizing layer with a Zn/Fe phase on the base material, which may optionally contain aluminum, cannot be provided in particular by a double-dip process carried out as a wet-on-wet process, which is customary in the prior art. In particular, the hot-dip galvanizing layer with Zn/Fe phase on the base material, which may contain aluminum, is typically not obtained in a conventional double-dip process carried out as a wet-on-wet process, especially since the aluminum is completely diffused through there.

In particular, the hot-dip galvanized layer of the hot-dip galvanized iron or steel component according to the invention is more ductile than a pure zinc layer and can therefore be formed or cold-formed, for example bent by 90°, without the corrosion protection properties being lost or significantly impaired.

In addition, the hot-dip galvanized layer of the hot-dip galvanized iron or steel component according to the invention is less brittle than a pure zinc layer and can therefore be reshaped or cold-formed, for example bent by 90°, without the corrosion protection properties being lost or significantly impaired.

Furthermore, in contrast to a classic aluminum-containing or aluminum-alloyed hot-dip galvanizing layer, the hot-dip galvanizing layer of the hot-dip galvanized iron or steel component according to the invention can be provided with at least substantially any desired layer thickness.

In particular, the layer thickness of the hot-dip galvanizing layer of the hot-dip galvanized iron or steel component according to the invention is not limited, as in the case of a classic aluminum-containing or aluminum-alloyed hot-dip galvanizing layer. Hot-dip galvanizing layers of significantly more than 25 µm can therefore also be provided.

For further details on the hot-dip galvanized iron or steel component according to the invention in accordance with the third aspect of the invention, reference can be made to the above statements with respect to the first and second aspects of the invention, which also apply in a corresponding manner to the hot-dip galvanized iron or steel component according to the invention in accordance with the third aspect of the invention.

Finally, a further object of the present invention - according to a fourth aspect of the present invention - is the use of a two-stage hot-dip galvanizing process.

In particular, the subject matter of the present invention according to this aspect is the use of a two-stage hot-dip galvanizing process for providing an aluminum-containing and/or aluminum-alloyed hot-dip galvanizing layer with increased (total) layer thickness,
wherein firstly an iron or steel component is subjected to a first hot-dip galvanizing in a zinc melt (“Zn melt”), in particular in a galvanizing bath containing a zinc melt, and wherein subsequently the iron or steel component obtained after the first hot-dip galvanizing is subjected to a second hot-dip galvanizing in an aluminum-containing and/or aluminum-alloyed zinc melt (“Zn/Al melt”), in particular in a galvanizing bath containing an aluminum-containing and/or aluminum-alloyed zinc melt.

Within the scope of the present invention, an aluminum-containing and/or aluminum-alloyed hot-dip galvanizing layer can be provided in which the total layer thickness is not limited or restricted and thus total layer thicknesses of significantly more than 25 µm can be provided. At the same time, however, a ductile hot-dip galvanizing layer is also provided which provides high corrosion protection properties.

Furthermore, according to this aspect of the present invention, the subject matter of the present invention is the use of a two-stage hot-dip galvanizing process for improving the ductility of a hot-dip galvanizing layer,
wherein firstly an iron or steel component is subjected to a first hot-dip galvanizing in a zinc melt (“Zn melt”), in particular in a galvanizing bath containing a zinc melt, and wherein subsequently the iron or steel component obtained after the first hot-dip galvanizing is subjected to a second hot-dip galvanizing in an aluminum-containing and/or aluminum-alloyed zinc melt (“Zn/Al melt”), in particular in a galvanizing bath containing an aluminum-containing and/or aluminum-alloyed zinc melt.

In this context, the improvement in ductility refers in particular to the comparison with a pure zinc layer (“Zn layer”), which in particular contains only very small amounts of aluminum, preferably at most 2% by weight, particularly preferably at most 0.1% by weight of aluminum. In particular, such pure zinc layers, which contain only very small amounts of aluminum, are not ductile and in particular cannot be formed or cold-formed, for example bent by 90°, without the corrosion protection performance decreasing significantly. In particular, this is due to the fact that such pure zinc layers, which contain only very small amounts of aluminum, are very brittle overall.

Yet another object of the present invention according to this aspect of the present invention is the use of a two-stage hot-dip galvanizing process for improving and/or controlling the formation of an aluminum-containing and/or aluminum-alloyed hot-dip galvanizing layer, in particular for improving and/or controlling the (total) layer thickness and/or layer structure of an aluminum-containing and/or aluminum-alloyed hot-dip galvanizing layer,
wherein firstly an iron or steel component is subjected to a first hot-dip galvanizing in a zinc melt (“Zn melt”), in particular in a galvanizing bath containing a zinc melt, and wherein subsequently the iron or steel component obtained after the first hot-dip galvanizing is subjected to a second hot-dip galvanizing in an aluminum-containing and/or aluminum-alloyed zinc melt (“Zn/Al melt”), in particular in a galvanizing bath containing an aluminum-containing and/or aluminum-alloyed zinc melt.

In particular, the (total) layer thickness and/or layer structure of an aluminum-containing and/or aluminum-alloyed hot-dip galvanizing layer can be controlled by the two-stage hot-dip galvanizing process. Such control is not possible in single-stage hot-dip galvanizing processes.

Furthermore, a further subject matter of the present invention according to this aspect is the use of a two-stage hot-dip galvanizing process for improving the corrosion protection performance, in particular for improving the corrosion protection performance of an aluminum-containing and/or aluminum-alloyed hot-dip galvanizing layer, wherein firstly an iron or steel component is subjected to a first hot-dip galvanizing in a zinc melt (“Zn melt”), in particular in a galvanizing bath containing a zinc melt, and wherein the iron or steel component obtained after the first hot-dip galvanizing is subsequently subjected to a second hot-dip galvanizing in an aluminum-containing and/or aluminum-alloyed zinc melt (“Zn/Al melt”), in particular in a galvanizing bath containing an aluminum-containing and/or aluminum-alloyed zinc melt.

Furthermore, the subject matter of the present invention according to this aspect is the use of a silicon content (Si content) of an iron or steel component in a two-stage hot-dip galvanizing process, in particular as in a previously described process, for controlling the (total) layer thickness of the hot-dip galvanizing.

In particular, with increasing silicon content of the iron or steel component, the (total) layer thickness of the (total) hot-dip galvanizing layer can be increased and/or the hot-dip galvanizing time can be reduced.

Without wishing to be limited to this theory, the applicant has found that an increased silicon content in the base material of the iron or steel component increases the reactivity in the hot-dip galvanizing process and thus higher layer thicknesses can be provided with a shorter reaction time.

Surprisingly, higher silicon contents in steel, such as those used in particular for the so-called calming of the steel during its production, lead to increased reactivity between the zinc melt and the base material and, as a result, to strong growth of the iron/zinc alloy layer. This leads in particular to the formation of relatively large total layer thicknesses, even in hot-dip galvanizing layers containing aluminum or aluminum alloys.

For further details on the uses according to the invention according to the fourth aspect of the invention, reference can be made to the above statements with respect to the preceding aspects of the invention, which also apply in a corresponding manner to the uses according to the invention according to the fourth aspect of the invention.

Further features, advantages and possible applications of the present invention emerge from the following description of embodiments with reference to drawings and the drawings themselves. All described and/or illustrated features, individually or in any combination, form the subject matter of the present invention, regardless of their summary in the claims and their relationships.

• 1 ein erfindungsgemäßes feuerverzinktes Eisen- oder Stahlbauteil gemäß einer besondere Ausführungsform der vorliegenden Erfindung,
• 2 eine schematische Darstellung einer erfindungsgemäßen Anlage gemäß einer besonderen Ausführungsform der vorliegenden Erfindung,
• 3 den Einfluss des Siliziumgehalts im Eisen- oder Stahlbauteil auf die Ausbildung der aus der ersten Feuerverzinkung resultierenden Feuerverzinkungsschicht, insbesondere im Hinblick auf die Schichtdicke der Feuerverzinkungsschicht.

It shows:

• 1 a hot-dip galvanized iron or steel component according to a particular embodiment of the present invention,
• 2 a schematic representation of a system according to the invention according to a particular embodiment of the present invention,
• 3 the influence of the silicon content in the iron or steel component on the formation of the hot-dip galvanizing layer resulting from the first hot-dip galvanizing, in particular with regard to the layer thickness of the hot-dip galvanizing layer.

In 1 a hot-dip galvanized iron or steel component 1 is shown according to a particular embodiment of the present invention, wherein the iron or steel component 1 has a multilayer or multiphase (total) hot-dip galvanizing layer applied to the base material of the iron or steel component 2. The multilayer or multiphase hot-dip galvanizing layer comprises an at least partially layered hot-dip galvanizing layer with Zn/Al/Fe phases, in particular as an outer hot-dip galvanizing layer and/or in particular as an outer layer, and on the base material 2 of the iron or steel component, in particular below (below) the outer hot-dip galvanizing layer or the outer layer, a hot-dip galvanizing layer 3 with Zn/Fe phase, which may optionally contain aluminum. For further details, reference can be made to the above statements.

2 shows a system according to a particular embodiment, wherein the devices are shown in the corresponding order or sequence of the process steps to be carried out (i.e. in the order or sequence of the process direction): The system for hot-dip galvanizing AZ initially comprises a pretreatment device VBH, downstream and/or arranged downstream therefrom in the process sequence, a first hot-dip galvanizing device FZ1, downstream and/or arranged downstream therefrom in the process sequence, a first post-treatment device NBH1, downstream and/or arranged downstream therefrom in the process sequence, an intermediate treatment device ZBH, downstream and/or arranged downstream therefrom in the process sequence, a second hot-dip galvanizing device FZ2 and downstream and/or arranged downstream therefrom in the process sequence, a second post-treatment device NBH2. For further details, reference can be made to the above explanations.

3 shows the influence of the silicon content in the iron or steel component on the formation of the hot-dip galvanizing layer resulting from the first hot-dip galvanizing, in particular with regard to the layer thickness of the hot-dip galvanizing layer. The x-axis (abscissa) shows the immersion time in the first hot-dip galvanizing bath in minutes and the y-axis (ordinate) shows the layer thickness of the hot-dip galvanizing layer of the first hot-dip galvanizing in micrometers. In this context, low-silicon steel sheets (sum of silicon and phosphorus in the steel below 0.03 wt.%; in 3 represented as dots) and Sandelin steel sheets (total silicon and phosphorus in the steel between 0.03 and 0.12 wt.%; in 3 shown as squares) in the first hot-dip galvanizing of a two-stage hot-dip galvanizing process according to the invention. In the case of Sandelin steel sheets, mixed structures are formed and the Sandelin structure grows through; this results in the formation of so-called pimple-shaped structures, which represent the Sandelin structure growing through the iron/zinc alloy (the formation of the pimple-shaped structures or mixed structures can be significantly reduced or essentially prevented by regulating the residence time in the zinc bath to less than 5 minutes and by setting the temperature of the zinc bath to less than 445 °C).

With the same galvanizing time, a thicker hot-dip galvanizing layer is formed on Sandelin steel sheets compared to low-silicon steel sheets (cf. 3 ). The thickness (as well as the layer structure of the hot-dip galvanized layer) can be controlled depending on the silicon content in the steel sheets. In particular, the hot-dip galvanized layer grows faster with a higher silicon content.

During the first hot-dip galvanizing within the scope of the process according to the invention, correspondingly thicker hot-dip galvanizing layers are obtained for the Sandelin steel sheets (60 to 300 µm) compared to the low-silicon steel sheets (40 to 60 µm).

With low-silicon steel, the layer structure and the layer thickness only depend on the residence time in the zinc melt. Consequently, the layer structure and the layer thickness depend on the silicon content of the iron or steel sheet and can be controlled in a targeted manner in this way. With a subsequent second hot-dip galvanizing, correspondingly higher total hot-dip galvanizing layers are achieved with the Sandelin steel sheets compared to the low-silicon steel sheets.

Further embodiments, modifications and variations of the present invention are readily apparent and feasible to the person skilled in the art upon reading the description, without departing from the scope of the present invention.

The present invention is illustrated by the following embodiments, which, however, are not intended to limit the present invention in any way, but are merely intended to explain exemplary and non-limiting implementations and embodiments.

EXAMPLES OF IMPLEMENTATION

Example 1: Two-stage hot-dip galvanizing process

Hot-dip galvanized steel sheets with the size 100 mm × 200 mm × 2 mm are produced according to the two-stage hot-dip galvanizing process according to the invention.

For this purpose, the sheets are first degreased, rinsed, pickled, rinsed, treated with a flux and dried according to the usual procedure.

The first hot-dip galvanizing then takes place in a so-called pure zinc bath in accordance with DIN EN ISO 1461 and DASt guideline 022. The residence time in this galvanizing bath is 5 minutes.

After the first hot-dip galvanizing, the steel sheets obtained are cooled and taken to a storage area where oxidative conditions exist (ambient atmosphere). The components remain there for about 24 hours after they have been removed from the hot-dip galvanizing holder (frame) used in the first hot-dip galvanizing.

After storage, the components are then subjected to an activation treatment, whereby this activation treatment comprises a pickling treatment with a hydrochloric acid pickling solution with a pH value of less than 5 (followed by a neutral rinse) and a subsequent flux treatment. The flux used in the flux treatment is water-based and has the following ingredients (weight information based on the dry weight): 80 wt.% zinc chloride, 15 wt.% ammonium chloride and 5 wt.% sodium chloride, whereby the flux bath also has a pH value of less than 5.

The sheets remain for 5 minutes each in the hydrochloric acid pickling solution and then in the aqueous flux bath.

After they have been dried, the sheets are subjected to a second hot-dip galvanizing. In the second hot-dip galvanizing, a zinc melt containing aluminum or aluminum alloy is used, which contains approximately 5% aluminum by weight. The second hot-dip galvanizing is carried out according to DIN 50997:2020-08 with a residence time of 2 min.

The basic process sequence of the two-stage hot-dip galvanizing process according to the invention is described in 2 shown.

Microscopic analyses show that there are not two different or separate layers on top of each other, but rather that the aluminum-containing or aluminum-alloyed zinc melt diffuses into the layer resulting from the first hot-dip galvanizing. Overall, there is therefore a multi-layer or multi-phase (total) hot-dip galvanizing layer on the base material of the iron or steel component, with an at least partially layered hot-dip galvanizing layer with Zn/Al/Fe phases as the outer hot-dip galvanizing layer or outer layer and a hot-dip galvanizing layer with Zn/Fe phase, which contains aluminum, on the base material of the iron or steel component below (below) the outer hot-dip galvanizing layer or outer layer. The basic layer structure is in 1 shown schematically.

Example 2: Corrosion protection performance

To compare the corrosion protection performance of hot-dip galvanizing layers based on a zinc melt (Zn melt), hot-dip galvanizing layers based on an aluminum-containing or aluminum-alloyed zinc melt (Zn/Al melt) with 5 wt.% aluminum and hot-dip galvanizing layers based on the two-stage hot-dip galvanizing according to the invention, in addition to the steel sheets previously hot-dip galvanized according to the invention, steel sheets measuring 100 mm × 200 mm × 2 mm are also hot-dip galvanized in the corresponding galvanizing baths (i.e. hot-dip galvanizing only in the previously described first hot-dip galvanizing bath according to DIN EN ISO 1461 and DASt guideline 022 [comparison], hot-dip galvanizing only in the previously described second hot-dip galvanizing bath according to DIN 50997:2020-08 [also comparison] and two-stage hot-dip galvanizing according to the invention).

All zinc sheets are then treated with a ZINQ ^® duropass passivation (passivation with chromium (III)).

To check the corrosion protection performance, the steel sheets are tested in straight or unprocessed form on the one hand and after bending by 90° (ie after cold forming) on the other hand in the salt spray test according to DIN EN ISO 9227 for 1008 hours. The amount of white rust and red rust formed on the surface is then determined, with the proportion of the surface showing white rust or red rust being specified. Table 1: Results of the straight sheets Proceedings two-stage hot-dip galvanizing (according to the invention) Zn melt Zn/Al melt (5 wt.% Al) layer thickness 76.5 µm 68.6 µm 6.9 µm white rust 40 - 50% 90 - 95% 5 - 10% red rust 0% 0.5 - 1% ≤ 0.5% Table 2: Results of the 90° bent sheets Proceedings two-stage hot-dip galvanizing (according to the invention) Zn melt Zn/Al melt (5 wt.% Al) layer thickness 46.2 µm 68.2 µm 6.8 µm white rust 20% 90 - 95% 5 - 10% red rust 0% 1 - 2.5% 5%

The white rust that forms is the corrosion products of the zinc (zinc oxide, zinc hydroxide, zinc carbonate and the like), which only affects the visual impression; it is therefore not material damage, as the base material remains intact or uncorroded. The red rust that forms, on the other hand, is the corrosion products of the iron or steel-based base material or component (namely iron oxides), which indicates material damage; red rust is therefore only formed when there is insufficient corrosion protection.

As can be seen from the results in Tables 1 and 2, neither the straight nor the formed components hot-dip galvanized using the two-stage hot-dip galvanizing process according to the invention show red rust after 1,008 hours in the salt spray test. In contrast, red rust forms on the surface of both the straight and the formed components hot-dip galvanized in the Zn melt and the Zn/Al melt.

Example 3: Comparison of different fluxes in the activation treatment

In addition, different fluxes are compared in the activation treatment of the two-stage hot-dip galvanizing according to the present invention.

• • Flussmittel Nr. 1 („FM1“): 80 Gew.-% ZnCl₂, 15 Gew.-% NH₄Cl, 5 Gew.-% NaCl
• • Flussmittel Nr. 2 („FM2“): 60 Gew.-% ZnCl₂, 40 Gew.-% NH₄Cl Flussmittel Nr. 3 („FM3“): wie FM1, jedoch mit KCl anstelle NaCl

For this purpose, the previously described two-stage hot-dip galvanizing process according to the invention is repeated according to Example 1, whereby different fluxes are used for the activation treatment carried out after the pickling treatment (weight information based on the dry weight of the flux):

• • Flux No. 1 (“FM1”): 80 wt.% ZnCl ₂ , 15 wt.% NH ₄ Cl, 5 wt.% NaCl
• • Flux No. 2 (“FM2”): 60 wt.% ZnCl ₂ , 40 wt.% NH ₄ Cl Flux No. 3 (“FM3”): as FM1, but with KCl instead of NaCl

The corrosion protection performance of the corresponding steel sheets bent by 90° or formed (ie after cold forming) is then tested in the salt spray test according to DIN EN ISO 9227 for 1008 hours. The amount of white rust and red rust formed on the surface is then determined, with the proportion of the surface showing white rust or red rust being indicated. Table 3: Results of the sheets bent by 90° with different fluxes flux FM1 FM2 FM3 white rust 20% 25% 20% red rust 0% 1-5% 1%

As can be seen from Table 3, the steel sheets each show a very small amount of red rust after 1008 hours in the salt spray test. The use of the flux FM1 results in a hot-dip galvanized layer with particularly high corrosion protection properties.

Example 4: Influence of silicon content in iron or steel components

In order to determine the influence of the silicon content in the iron or steel component on the formation of the hot-dip galvanizing layer resulting from the first hot-dip galvanizing and in particular the thickness of the hot-dip galvanizing layer, low-silicon steel sheets (sum of silicon and phosphorus in the steel less than 0.03 wt. %) and Sandelin steel sheets (sum of silicon and phosphorus in the steel between 0.03 and 0.12 wt. %) are galvanized in the first hot-dip galvanizing of the two-stage hot-dip galvanizing process according to the invention (see previous detailed description).

Mixed structures are formed in Sandelin steel sheets and the Sandelin structure grows through. This results in the formation of so-called pimple-shaped structures, which represent the Sandelin structure growing through the iron/zinc alloy. The formation of pimple-shaped structures or mixed structures can be significantly reduced or essentially prevented by regulating the residence time in the zinc bath to less than 5 minutes and by setting the temperature of the zinc bath to less than 445 °C.

In addition, further tests show that, with the same galvanizing time, a thicker hot-dip galvanizing layer is formed on Sandelin steel sheets compared to low-silicon steel sheets. The thickness (as well as the layer structure of the hot-dip galvanizing layer) can be specifically controlled depending on the silicon content in the steel sheets (cf. 3 ). In particular, with higher silicon content, the hot-dip galvanizing layer grows faster (cf. 3 ).

In the case of low-silicon steel, the layer structure and the layer thickness depend only on the residence time in the zinc melt.

Consequently, the layer structure and the layer thickness depend on the silicon content of the iron or steel sheet and can thus be specifically controlled.

During the first hot-dip galvanizing within the framework of the process according to the invention, correspondingly thicker hot-dip galvanizing layers are obtained for the Sandelin steel sheets (60 to 300 µm) in comparison to the low-silicon steel sheets (40 to 60 µm) (cf. 3 ).

In a subsequent second hot-dip galvanizing process, correspondingly higher total hot-dip galvanizing layers are obtained for the Sandelin steel sheets compared to the low-silicon steel sheets.

QUOTES INCLUDED IN THE DESCRIPTION

This list of documents listed by the applicant was generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions.

Cited patent literature

• WO 2002/042512 A1 [0022]
• EP 1 352 100 B1 [0022]
• DE 601 24 767 T2 [0022]
• US 2003/0219543 A1 [0022]

Cited non-patent literature

• DIN 50997:2020-08 [0340]

Claims (81)

Method for hot-dip galvanizing (hot-dip galvanizing) an iron or steel component, in particular for producing a hot-dip galvanized iron or steel component with increased corrosion protection performance and/or with increased ductility, preferably in a two-stage hot-dip galvanizing process, wherein firstly the iron or steel component is subjected to a first hot-dip galvanizing in a zinc melt (“Zn melt”), in particular in a galvanizing bath containing a zinc melt, and wherein the iron or steel component obtained after the first hot-dip galvanizing is subsequently subjected to a second hot-dip galvanizing in an aluminum-containing and/or aluminum-alloyed zinc melt (“Zn/Al melt”), in particular in a galvanizing bath containing an aluminum-containing and/or aluminum-alloyed zinc melt. procedure according to claim 1 , wherein the zinc melt used in the first hot-dip galvanizing (“Zn melt”) contains at least substantially no aluminum and/or is at least substantially free of aluminum; and/or wherein the zinc melt used in the first hot-dip galvanizing (“Zn melt”) contains, based on the zinc melt, at most 1,000 ppm, in particular at most 900 ppm, preferably at most 800 ppm, of aluminum; and/or wherein the zinc melt used in the first hot-dip galvanizing (“Zn melt”) contains, based on the zinc melt, at most 0.1 wt. %, in particular at most 0.09 wt. %, preferably at most 0.08 wt. %, of aluminum; and/or wherein the zinc melt used in the first hot-dip galvanizing (“Zn melt”), based on the zinc melt, contains aluminum in amounts in the range from 0 wt.% to 0.1 wt.%, in particular in the range from 0.000001 wt.% to 0.09 wt.%, preferably in the range from 0.00001 wt.% to 0.08 wt.%. procedure according to claim 1 or claim 2 , wherein the aluminum-alloyed and/or aluminum-containing zinc melt (“Zn/Al melt”) used in the second hot-dip galvanizing contains, based on the zinc melt, at least 2 wt. %, in particular at least 3 wt. %, preferably at least 4 wt. %, aluminum; and/or wherein the aluminum-alloyed and/or aluminum-containing zinc melt (“Zn/Al melt”) used in the second hot-dip galvanizing contains, based on the zinc melt, at most 10 wt. %, in particular at most 8 wt. %, preferably at most 6 wt. %, aluminum; and/or wherein the aluminum-alloyed and/or aluminum-containing zinc melt (“Zn/Al melt”) used in the second hot-dip galvanizing contains, based on the zinc melt, aluminum in amounts in the range from 1 wt.% to 25 wt.%, in particular in the range from 2 wt.% to 10 wt.%, preferably in the range from 3 wt.% to 8 wt.%, particularly preferably in the range from 4 wt.% to 6 wt.%. Method according to one of the preceding claims, wherein the zinc melt used in the first hot-dip galvanizing (“Zn melt”), based on the zinc melt, contains aluminum in amounts in the range from 0 wt.% to 0.1 wt.% and the aluminum-alloyed and/or aluminum-containing zinc melt used in the second hot-dip galvanizing (“Zn/Al melt”), based on the zinc melt, contains aluminum in amounts in the range from 2 wt.% to 10 wt.%; and/or wherein the zinc melt used in the first hot-dip galvanizing (“Zn melt”), based on the zinc melt, contains aluminum in amounts in the range from 0 wt.% to 0.09 wt.% and the aluminum-alloyed and/or aluminum-containing zinc melt used in the second hot-dip galvanizing (“Zn/Al melt”), based on the zinc melt, contains aluminum in amounts in the range from 3 wt.% to 8 wt.%; and/or wherein the zinc melt used in the first hot-dip galvanizing (“Zn melt”) contains, based on the zinc melt, aluminum in amounts ranging from 0 wt.% to 0.08 wt.% and the aluminum-alloyed and/or aluminum-containing zinc melt used in the second hot-dip galvanizing (“Zn/Al melt”) contains, based on the zinc melt, aluminum in amounts ranging from 4 wt.% to 6 wt.%. Method for hot-dip galvanizing (hot-dip galvanizing) an iron or steel component, in particular for producing a hot-dip galvanized iron or steel component with increased corrosion protection performance and/or with increased ductility, preferably in a two-stage hot-dip galvanizing process, in particular method according to one of the preceding claims, wherein firstly the iron or steel component is subjected to a first hot-dip galvanizing in a zinc melt (“Zn melt”), in particular in a galvanizing bath containing a zinc melt, and wherein subsequently the iron or steel component obtained after the first hot-dip galvanizing is galvanized in an aluminum-containing and/or aluminum-alloyed zinc melt (“Zn/Al melt”), in particular in an aluminum galvanizing bath containing aluminum and/or aluminum-alloyed zinc melt, is subjected to a second hot-dip galvanizing, wherein the zinc melt (“Zn melt”) used in the first hot-dip galvanizing contains, based on the zinc melt, aluminum in amounts in the range from 0 wt. % to 0.1 wt. %, in particular in the range from 0.000001 wt. % to 0.09 wt. %, preferably in the range from 0.00001 wt. % to 0.08 wt. %, wherein the aluminum-alloyed and/or aluminum-containing zinc melt (“Zn/Al melt”) used in the second hot-dip galvanizing contains, based on the zinc melt, aluminum in amounts in the range from 1 wt. % to 25 wt. %, in particular in the range from 2 wt. % to 10 wt. %, preferably in the range from 3 wt. % to 8 wt. %, particularly preferably in the range from 4 wt. % to 6 wt. %. Method according to one of the preceding claims, wherein the aluminum-alloyed and/or aluminum-containing zinc melt (“Zn/Al melt”) used in the second hot-dip galvanizing contains, based on the zinc melt, at most 10 wt.%, in particular at most 3 wt.%, preferably at most 2 wt.%, magnesium; and/or wherein the aluminum-alloyed and/or aluminum-containing zinc melt (“Zn/Al melt”) used in the second hot-dip galvanizing contains, based on the zinc melt, magnesium in amounts in the range from 0.1 wt.% to 10 wt.%, in particular in the range from 0.1 wt.% to 3 wt.%, preferably in the range from 0.1 wt.% to 2 wt.%. Method according to one of the preceding claims, wherein the aluminum-alloyed and/or aluminum-containing zinc melt (“Zn/Al melt”) used in the second hot-dip galvanizing contains, based on the zinc melt, 5 wt.% aluminum and 2 wt.% magnesium, in particular 5 wt.% aluminum and 3 wt.% magnesium. Method according to one of the preceding claims, wherein the zinc melt used in the first hot-dip galvanizing ("Zn melt"), based on the zinc melt, contains aluminum in amounts in the range from 0 wt. % to 0.1 wt. %, in particular in the range from 0.000001 wt. % to 0.09 wt. %, preferably in the range from 0.00001 wt. % to 0.08 wt. %, and optionally at least one further metal, in particular in amounts of up to 10 wt. % and/or in particular selected from the group of bismuth (Bi), lead (Pb), tin (Sn), nickel (Ni), silicon (Si), magnesium (Mg) and combinations thereof, and the remaining portion of the aluminum-alloyed and/or aluminum-containing zinc melt is formed by zinc, wherein all of the above-mentioned quantities are to be selected such that a total of 100 wt. % results. Method according to one of the preceding claims, wherein the zinc melt (“Zn melt”) used in the first hot-dip galvanizing has the following composition, wherein all the quantities given below are based on the zinc melt (“Zn melt”) and are to be selected such that a total of 100 wt.% results: (i) zinc (Zn), in particular in amounts in the range from 92 to 100 wt.%, in particular in the range from 80 to 99.999 wt.%, preferably in the range from 85 to 99.995 wt.%, particularly preferably in the range from 90 to 99.99 wt.%, (ii) optionally aluminum (Al), in particular in amounts in the range from 0 wt.% to 0.1 wt.%, in particular in the range from 0.000001 wt.% to 0.09 wt.%, preferably in the range from 0.00001 wt.% to 0.08 wt.%, (iii) optionally at least one further metal, in particular in (total) amounts of up to 10 wt.% and/or in particular selected from the group of bismuth (Bi), lead (Pb), tin (Sn), nickel (Ni), silicon (Si), magnesium (Mg) and combinations thereof. Method according to one of the preceding claims, wherein the aluminum-alloyed and/or aluminum-containing zinc melt (“Zn/Al melt”) used in the second hot-dip galvanizing, based on the zinc melt, contains aluminum in amounts in the range from 1 wt.% to 25 wt.%, in particular in the range from 2 wt.% to 10 wt.%, preferably in the range from 3 wt.% to 8 wt.%, particularly preferably in the range from 4 wt.% to 6 wt.%, optionally magnesium, in particular in amounts in the range from 0.1 wt.% to 10 wt.%, in particular in the range from 0.1 wt.% to 3 wt.%, preferably in the range from 0.1 wt.% to 2 wt.%, and optionally at least one further metal, in particular in amounts of up to 10 wt.% and/or in particular selected from the group of bismuth (Bi), lead (Pb), tin (Sn), nickel (Ni), silicon (Si) and combinations thereof, and the remaining portion of the aluminum-alloyed and/or aluminum-containing zinc melt is replaced by zinc. is formed, whereby all the above-mentioned amounts are selected such that a total of 100 wt.% results. Method according to one of the preceding claims, wherein the aluminum-alloyed and/or aluminum-containing zinc melt (“Zn/Al melt”) used in the second hot-dip galvanizing has the following composition, wherein all the quantities given below are based on the aluminum-alloyed and/or aluminum-containing zinc melt (“Zn/Al melt”) and are to be selected such that a total of 100 wt.% results: (i) zinc (Zn), in particular in amounts in the range from 75 to 99 wt.%, in particular in the range from 80 to 98 wt.%, preferably in the range from 85 to 97 wt.%, particularly preferably in the range from 90 to 96 wt.%, (ii) optionally aluminum (Al), in particular in amounts in the range from 1 wt.% to 25 wt.%, in particular in the range from 2 wt.% to 10 wt.%, preferably in the range from 3 wt.% to 8 wt.%, particularly preferably in the range from 4 wt.% to 6 wt.%, (iii) optionally magnesium (Mg), in particular in amounts in the range from 0.1 wt.% to 10 wt.%, in particular in the range from 0.1 wt.% to 3 wt.%, preferably in the range from 0.1 wt.% to 2 wt.%; (iii) optionally at least one further metal, in particular in (total) amounts of up to 10 wt.% and/or in particular selected from the group of bismuth (Bi), lead (Pb), tin (Sn), nickel (Ni), silicon (Si) and combinations thereof. Method according to one of the preceding claims, wherein the zinc melt (“Zn melt”) used in the first hot-dip galvanizing has a temperature in the range from 330 °C to 750 °C, in particular in the range from 340 °C to 650 °C, preferably in the range from 430 °C to 600 °C, particularly preferably in the range from 435 °C to 455 °C. Method according to one of the preceding claims, wherein the iron or steel component is dipped into the zinc melt (“Zn melt”) used in the first hot-dip galvanizing, in particular dipped therein and moved, in particular for a period of time which is sufficient to ensure effective hot-dip galvanizing (hot-dip galvanizing), in particular for a period of time in the range of 0.1 to 90 minutes, in particular in the range of 0.75 to 60 minutes, preferably in the range of 1 to 45 minutes, particularly preferably in the range of 1.25 to 30 minutes; and/or wherein the iron or steel component is dipped into the zinc melt (“Zn melt”) used in the first hot-dip galvanizing process, in particular dipped therein and moved, in particular for a period of time which is sufficient to ensure effective hot-dip galvanizing (hot-dip galvanizing), in particular for a period of time of at least 0.1 minutes, in particular at least 0.75 minutes, preferably at least 1 minute, particularly preferably at least 1.25 minutes; and/or wherein the iron or steel component is dipped into the zinc melt (“Zn melt”) used in the first hot-dip galvanizing process, in particular dipped therein and moved, in particular for a period of time which is sufficient to ensure effective hot-dip galvanizing (hot-dip galvanizing), in particular for a period of time of at most 90 minutes, in particular at most 60 minutes, preferably at most 45 minutes, particularly preferably at most 30 minutes. Method according to one of the preceding claims, wherein the aluminum-alloyed and/or aluminum-containing zinc melt ("Zn/Al melt") used in the second hot-dip galvanizing has a temperature in the range from 330 °C to 750 °C, in particular in the range from 340 °C to 600 °C, preferably in the range from 350 °C to 450 °C, particularly preferably in the range from 410 °C to 425 °C. Method for hot-dip galvanizing (hot-dip galvanizing) an iron or steel component, in particular for producing a hot-dip galvanized iron or steel component with increased corrosion protection performance and/or with increased ductility, preferably in a two-stage hot-dip galvanizing process, in particular method according to one of the preceding claims, wherein firstly the iron or steel component is subjected to a first hot-dip galvanizing in a zinc melt (“Zn melt”), in particular in a galvanizing bath containing a zinc melt, and wherein subsequently the iron or steel component obtained after the first hot-dip galvanizing is subjected to a second hot-dip galvanizing in an aluminum-containing and/or aluminum-alloyed zinc melt (“Zn/Al melt”), in particular in a galvanizing bath containing an aluminum-containing and/or aluminum-alloyed zinc melt, wherein the zinc melt (“Zn melt”) used in the first hot-dip galvanizing has a temperature in the range of 330 °C to 750 °C, in particular in the range from 340 °C to 650 °C, preferably in the range from 430 °C to 600 °C, particularly preferably in the range from 435 °C to 455 °C, wherein the aluminum-alloyed and/or aluminum-containing zinc melt (“Zn/Al melt”) used in the second hot-dip galvanizing has a temperature in the range from 330 °C to 750 °C, in particular in the range from 340 °C to 600 °C, preferably in the range from 350 °C to 450 °C, particularly preferably in the range from 410 °C to 425 °C. Method according to one of the preceding claims, wherein the iron or steel component is dipped into the aluminum-alloyed and/or aluminum-containing zinc melt (“Zn/Al melt”) used in the second hot-dip galvanizing, in particular dipped therein and moved, in particular for a period of time which is sufficient to ensure effective further hot-dip galvanizing (hot-dip galvanizing), in particular for a period of time in the range from 0.0001 to 60 minutes, in particular in the range from 0.001 to 45 minutes, preferably in the range from 0.5 to 30 minutes, particularly preferably in the range from 4 to 8 minutes; and/or wherein the iron or steel component is dipped into the aluminum-alloyed and/or aluminum-containing zinc melt (“Zn/Al melt”) used in the second hot-dip galvanizing, in particular dipped therein and moved, in particular for a period of time which is sufficient to achieve effective further hot-dip galvanizing (hot-dip galvanizing), in particular for a period of time of at least 0.0001 minutes, in particular at least 0.001 minutes, preferably at least 0.5 minutes, particularly preferably at least 4 minutes; and/or wherein the iron or steel component is dipped into the aluminum-alloyed and/or aluminum-containing zinc melt (“Zn/Al melt”) used in the second hot-dip galvanizing, in particular dipped therein and moved, in particular for a period of time which is sufficient to achieve effective further hot-dip galvanizing (hot-dip galvanizing), in particular for a period of time of at most 60 minutes, in particular at most 45 minutes, preferably at most 30 minutes, particularly preferably at most 8 minutes. Method for hot-dip galvanizing (hot-dip galvanizing) an iron or steel component, in particular for producing a hot-dip galvanized iron or steel component with increased corrosion protection performance and/or with increased ductility, preferably in a two-stage hot-dip galvanizing process, in particular method according to one of the preceding claims, wherein firstly the iron or steel component is subjected to a first hot-dip galvanizing in a zinc melt (“Zn melt”), in particular in a galvanizing bath containing a zinc melt, and wherein subsequently the iron or steel component obtained after the first hot-dip galvanizing is subjected to a second hot-dip galvanizing in an aluminum-containing and/or aluminum-alloyed zinc melt (“Zn/Al melt”), in particular in a galvanizing bath containing an aluminum-containing and/or aluminum-alloyed zinc melt, wherein the zinc melt used in the first hot-dip galvanizing (“Zn melt”), based on the Zinc melt, contains aluminum in amounts in the range from 0 wt.% to 0.1 wt.%, in particular in the range from 0.000001 wt.% to 0.09 wt.%, preferably in the range from 0.00001 wt.% to 0.08 wt.%, wherein the aluminum-alloyed and/or aluminum-containing zinc melt used in the second hot-dip galvanizing (“Zn/Al melt”), based on the zinc melt, contains aluminum in amounts in the range from 1 wt.% to 25 wt.%, in particular in the range from 2 wt.% to 10 wt.%, preferably in the range from 3 wt.% to 8 wt.%, particularly preferably in the range from 4 wt.% to 6 wt.%, wherein the zinc melt used in the first hot-dip galvanizing (“Zn melt”) has a temperature in the range from 330 °C to 750 °C, in particular in the range from 340 °C to 650 °C, preferably in the range from 430 °C to 600 °C, particularly preferably in the range from 435 °C to 455 °C, wherein the aluminum-alloyed and/or aluminum-containing zinc melt (“Zn/Al melt”) used in the second hot-dip galvanizing has a temperature in the range from 330 °C to 750 °C, in particular in the range from 340 °C to 600 °C, preferably in the range from 350 °C to 450 °C, particularly preferably in the range from 410 °C to 425 °C. Method according to one of the preceding claims, wherein the temperature of the aluminum-alloyed and/or aluminum-containing zinc melt used in the second hot-dip galvanizing process ("Zn/Al melt") is lower than the temperature of the zinc melt used in the first hot-dip galvanizing process ("Zn melt"); and/or wherein the temperature of the aluminum-alloyed and/or aluminum-containing zinc melt used in the second hot-dip galvanizing process ("Zn/Al melt") is selected in such a way and/or with the proviso that it is lower than the temperature of the zinc melt used in the first hot-dip galvanizing process ("Zn melt"); in particular wherein the temperature of the aluminum-alloyed and/or aluminum-containing zinc melt (“Zn/Al melt”) used in the second hot-dip galvanizing is at least 10 °C lower, in particular at least 25 °C lower, preferably at least 40 °C lower, than the temperature of the zinc melt used in the first hot-dip galvanizing (“Zn melt”). Method for hot-dip galvanizing (hot-dip galvanizing) an iron or steel component, in particular for producing a hot-dip galvanized iron or steel component with increased corrosion protection performance and/or with increased ductility, preferably in a two-stage hot-dip galvanizing process, in particular method according to one of the preceding claims, wherein firstly the iron or steel component is subjected to a first hot-dip galvanizing in a zinc melt (“Zn melt”), in particular in a galvanizing bath containing a zinc melt, and wherein subsequently the iron or steel component obtained after the first hot-dip galvanizing is subjected to a second hot-dip galvanizing in an aluminum-containing and/or aluminum-alloyed zinc melt (“Zn/Al melt”), in particular in a galvanizing bath containing an aluminum-containing and/or aluminum-alloyed zinc melt, wherein the zinc melt used in the first hot-dip galvanizing (“Zn melt”), based on the zinc melt, contains aluminum in Amounts in the range from 0 wt.% to 0.1 wt.%, in particular in the range from 0.000001 wt.% to 0.09 wt.%, preferably in the range from 0.00001 wt.% to 0.08 wt.%, wherein the aluminum-alloyed and/or aluminum-containing zinc melt (“Zn/Al melt”) used in the second hot-dip galvanizing, based on the zinc melt, contains aluminum in amounts in the range from 1 wt.% to 25 wt.%, in particular in the range from 2 wt.% to 10 wt.%, preferably in the range from 3 wt.% to 8 wt.%, particularly preferably in the range from 4 wt.% to 6 wt.%, wherein the temperature of the aluminum-alloyed and/or aluminum-containing zinc melt (“Zn/Al melt”) used in the second hot-dip galvanizing is lower than the temperature of the zinc melt (“Zn melt”) used in the first hot-dip galvanizing and/or wherein the temperature of the zinc melt used in the second hot-dip galvanizing, wherein the temperature of the aluminum-alloyed and/or aluminum-containing zinc melt (“Zn/Al melt”) used in the first hot-dip galvanizing is selected such that and/or with the proviso that it is lower than the temperature of the zinc melt used in the first hot-dip galvanizing (“Zn melt”); in particular wherein the temperature of the aluminum-alloyed and/or aluminum-containing zinc melt (“Zn/Al melt”) used in the second hot-dip galvanizing is at least 10 °C lower, in particular at least 25 °C lower, preferably at least 40 °C lower, than the temperature of the zinc melt used in the first hot-dip galvanizing (“Zn melt”). Method according to one of the preceding claims, wherein the first hot-dip galvanizing is carried out such that a hot-dip galvanizing layer with zinc/iron phase (“Zn/Fe phase”) is formed on the base material of the iron or steel component; and/or wherein the first hot-dip galvanizing is carried out with the proviso that a hot-dip galvanizing layer with zinc/iron phase (“Zn/Fe phase”) is formed on the base material of the iron or steel component. Method according to one of the preceding claims, wherein in the first hot-dip galvanizing the layer thickness is controlled by the duration of the galvanizing; and/or wherein the layer thickness of the hot-dip galvanizing layer resulting from the first hot-dip galvanizing is controlled by the duration of the first hot-dip galvanizing. Method for hot-dip galvanizing (hot-dip galvanizing) an iron or steel component, in particular for producing a hot-dip galvanized iron or steel component with increased corrosion protection performance and/or with increased ductility, preferably in a two-stage hot-dip galvanizing process, in particular method according to one of the preceding claims, wherein firstly the iron or steel component is subjected to a first hot-dip galvanizing in a zinc melt (“Zn melt”), in particular in a galvanizing bath containing a zinc melt, and wherein subsequently the iron or steel component obtained after the first hot-dip galvanizing is subjected to a second hot-dip galvanizing in an aluminum-containing and/or aluminum-alloyed zinc melt (“Zn/Al melt”), in particular in a galvanizing bath containing an aluminum-containing and/or aluminum-alloyed zinc melt, wherein the zinc melt used in the first hot-dip galvanizing (“Zn melt”), based on the zinc melt, contains aluminum in Amounts in the range from 0 wt.% to 0.1 wt.%, in particular in the range from 0.000001 wt.% to 0.09 wt.%, preferably in the range from 0.00001 wt.% to 0.08 wt.%, wherein the aluminum-alloyed and/or aluminum-containing zinc melt (“Zn/Al melt”) used in the second hot-dip galvanizing, based on the zinc melt, contains aluminum in amounts in the range from 1 wt.% to 25 wt.%, in particular in the range from 2 wt.% to 10 wt.%, preferably in the range from 3 wt.% to 8 wt.%, particularly preferably in the range from 4 wt.% to 6 wt.%, wherein the zinc melt used in the first hot-dip galvanizing (“Zn melt”) has a temperature in the range from 330 °C to 750 °C, in particular in the range from 340 °C to 650 °C, preferably in the range from 430 °C to 600 °C, particularly preferably in the range of 435 °C to 455 °C, wherein the aluminum-alloyed and/or aluminum-containing zinc melt (“Zn/Al melt”) used in the second hot-dip galvanizing has a temperature in the range from 330 °C to 750 °C, in particular in the range from 340 °C to 600 °C, preferably in the range from 350 °C to 450 °C, particularly preferably in the range from 410 °C to 425 °C, wherein the layer thickness of the hot-dip galvanizing layer resulting from the first hot-dip galvanizing is controlled by the duration of the first hot-dip galvanizing. Method according to one of the preceding claims, wherein the second hot-dip galvanizing is carried out in such a way that a multi-layer or multi-phase (total) hot-dip galvanizing layer is formed on the base material of the iron or steel component; and/or wherein the second hot-dip galvanizing is carried out in such a way that an at least partially layered hot-dip galvanizing layer with Zn/Al/Fe phases is formed, in particular as an outer hot-dip galvanizing layer and/or in particular as an outer layer; and/or wherein the second hot-dip galvanizing is carried out with the proviso that an at least partially layered hot-dip galvanizing layer with Zn/Al/Fe phases is formed, in particular as an outer hot-dip galvanizing layer and/or in particular as an outer layer; and/or wherein the second hot-dip galvanizing is carried out in such a way that the aluminum-containing and/or aluminum-alloyed zinc melt (“Zn/Al melt”) at least partially diffuses into the hot-dip galvanizing layer resulting from the first hot-dip galvanizing; and/or wherein the second hot-dip galvanizing is carried out with the proviso that the aluminum-containing and/or aluminum-alloyed zinc melt (“Zn/Al melt”) at least partially diffuses into the hot-dip galvanizing layer resulting from the first hot-dip galvanizing; and/or wherein the second hot-dip galvanizing is carried out in such a way that a hot-dip galvanizing layer with a Zn/Fe phase, which optionally contains aluminum, is present and/or remains on the base material of the iron or steel component, in particular below (below) the outer hot-dip galvanizing layer and/or the outer layer; and/or wherein the second hot-dip galvanizing is carried out with the proviso that a hot-dip galvanizing layer with a Zn/Fe phase, which optionally contains aluminum, is present and/or remains on the base material of the iron or steel component, in particular below (below) the outer hot-dip galvanizing layer and/or the outer layer; and/or wherein the second hot-dip galvanizing is carried out with the proviso and/or in such a way that a (total) hot-dip galvanizing layer with an aluminum concentration gradient is formed. Method for hot-dip galvanizing (hot-dip galvanizing) an iron or steel component, in particular for producing a hot-dip galvanized iron or steel component with increased corrosion protection performance and/or with increased ductility, preferably in a two-stage hot-dip galvanizing process, in particular method according to one of the preceding claims, wherein firstly the iron or steel component is subjected to a first hot-dip galvanizing in a zinc melt (“Zn melt”), in particular in a galvanizing bath containing a zinc melt, and wherein subsequently the iron or steel component obtained after the first hot-dip galvanizing is subjected to a second hot-dip galvanizing in an aluminum-containing and/or aluminum-alloyed zinc melt (“Zn/Al melt”), in particular in a galvanizing bath containing an aluminum-containing and/or aluminum-alloyed zinc melt, wherein the zinc melt used in the first hot-dip galvanizing (“Zn melt”), based on the zinc melt, contains aluminum in Amounts in the range from 0 wt.% to 0.1 wt.%, in particular in the range from 0.000001 wt.% to 0.09 wt.%, preferably in the range from 0.00001 wt.% to 0.08 wt.%, wherein the aluminum-alloyed and/or aluminum-containing zinc melt (“Zn/Al melt”) used in the second hot-dip galvanizing, based on the zinc melt, contains aluminum in amounts in the range from 1 wt.% to 25 wt.%, in particular in the range from 2 wt.% to 10 wt.%, preferably in the range from 3 wt.% to 8 wt.%, particularly preferably in the range from 4 wt.% to 6 wt.%, wherein the zinc melt used in the first hot-dip galvanizing (“Zn melt”) has a temperature in the range from 330 °C to 750 °C, in particular in the range from 340 °C to 650 °C, preferably in the range from 430 °C to 600 °C, particularly preferably in the range from 435 °C to 455 °C, wherein the aluminum-alloyed and/or aluminum-containing zinc melt (“Zn/Al melt”) used in the second hot-dip galvanizing has a temperature in the range from 330 °C to 750 °C, in particular in the range from 340 °C to 600 °C, preferably in the range from 350 °C to 450 °C, particularly preferably in the range from 410 °C to 425 °C; wherein the second hot-dip galvanizing is carried out in such a way and/or with the proviso that an at least partially layered hot-dip galvanizing layer with Zn/Al/Fe phases, in particular as outer hot-dip galvanizing galvanizing layer and/or in particular as an outer layer, and/or wherein the second hot-dip galvanizing is carried out in such a way and/or with the proviso that a hot-dip galvanizing layer with a Zn/Fe phase, which optionally contains aluminum, is present and/or remains on the base material of the iron or steel component, in particular below (below) the outer hot-dip galvanizing layer and/or the outer layer, and/or wherein the second hot-dip galvanizing is carried out with the proviso and/or in such a way that a (total) hot-dip galvanizing layer with an aluminum concentration gradient is formed. Method according to one of the preceding claims, wherein the layer thickness of the hot-dip galvanizing layer resulting from the first hot-dip galvanizing is at least 30 µm, in particular at least 35 µm, preferably at least 40 µm, particularly preferably at least 45 µm; and/or wherein the layer thickness of the hot-dip galvanizing layer resulting from the first hot-dip galvanizing is at most 650 µm, in particular at most 600 µm, preferably at most 550 µm, particularly preferably at most 500 µm; and/or wherein the layer thickness of the hot-dip galvanizing layer resulting from the first hot-dip galvanizing is in the range from 30 µm to 650 µm, in particular in the range from 35 µm to 600 µm, preferably in the range from 40 µm to 550 µm, particularly preferably in the range from 45 µm to 500 µm. Method according to one of the preceding claims, wherein the (total) layer thickness of the (total) hot-dip galvanizing layer resulting from the second hot-dip galvanizing is at least 30 µm, in particular at least 35 µm, preferably at least 40 µm, particularly preferably at least 45 µm; and/or wherein the (total) layer thickness of the (total) hot-dip galvanizing layer resulting from the second hot-dip galvanizing is at most 500 µm, in particular at most 450 µm, preferably at most 400 µm, particularly preferably at most 300 µm; and/or wherein the (total) layer thickness of the (total) hot-dip galvanizing layer resulting from the second hot-dip galvanizing is in the range from 30 µm to 500 µm, in particular in the range from 35 µm to 450 µm, preferably in the range from 40 µm to 400 µm, particularly preferably in the range from 45 µm to 300 µm. Method according to one of the preceding claims, wherein the total layer thickness of the (total) hot-dip galvanizing layer resulting after carrying out the method is at least 30 µm, in particular at least 35 µm, preferably at least 40 µm, particularly preferably at least 45 µm; and/or wherein the total layer thickness of the (total) hot-dip galvanizing layer resulting after carrying out the method is at most 500 µm, in particular at most 450 µm, preferably at most 400 µm, particularly preferably at most 300 µm; and/or wherein the total layer thickness of the (total) hot-dip galvanizing layer resulting after carrying out the process is in the range from 30 µm to 500 µm, in particular in the range from 35 µm to 450 µm, preferably in the range from 40 µm to 400 µm, particularly preferably in the range from 45 µm to 300 µm; and/or wherein the first and the second hot-dip galvanizing are carried out in such a way and/or with the proviso that the total layer thickness of the (total) hot-dip galvanizing layer resulting after carrying out the process is in the range from 30 µm to 500 µm, in particular in the range from 35 µm to 450 µm, preferably in the range from 40 µm to 400 µm, particularly preferably in the range from 45 µm to 300 µm. Method for hot-dip galvanizing (hot-dip galvanizing) an iron or steel component, in particular for producing a hot-dip galvanized iron or steel component with increased corrosion protection performance and/or with increased ductility, preferably in a two-stage hot-dip galvanizing process, in particular method according to one of the preceding claims, wherein firstly the iron or steel component is subjected to a first hot-dip galvanizing in a zinc melt (“Zn melt”), in particular in a galvanizing bath containing a zinc melt, and wherein subsequently the iron or steel component obtained after the first hot-dip galvanizing is subjected to a second hot-dip galvanizing in an aluminum-containing and/or aluminum-alloyed zinc melt (“Zn/Al melt”), in particular in a galvanizing bath containing an aluminum-containing and/or aluminum-alloyed zinc melt, wherein the zinc melt used in the first hot-dip galvanizing (“Zn melt”), based on the zinc melt, contains aluminum in Amounts in the range of 0 wt.% to 0.1 wt.%, in particular in the range of 0.000001 wt.% to 0.09 wt.%, preferably in the range of 0.00001 wt.% to 0.08 wt.%, wherein the aluminum-alloyed and/or aluminum-containing zinc used in the second hot-dip galvanizing melt (“Zn/Al melt”), based on the zinc melt, contains aluminum in amounts in the range from 1 wt.% to 25 wt.%, in particular in the range from 2 wt.% to 10 wt.%, preferably in the range from 3 wt.% to 8 wt.%, particularly preferably in the range from 4 wt.% to 6 wt.%, wherein the zinc melt (“Zn melt”) used in the first hot-dip galvanizing has a temperature in the range from 330 °C to 750 °C, in particular in the range from 340 °C to 650 °C, preferably in the range from 430 °C to 600 °C, particularly preferably in the range from 435 °C to 455 °C, wherein the aluminum-alloyed and/or aluminum-containing zinc melt (“Zn/Al melt”) used in the second hot-dip galvanizing has a temperature in the range from 330 °C to 750 °C, in particular in the range from 340 °C to 600 °C, preferably in the range from 350 °C to 450 °C, particularly preferably in the range from 410 °C to 425 °C, wherein the first and the second hot-dip galvanizing are carried out in such a way and/or with the proviso that the total layer thickness of the (total) hot-dip galvanizing layer resulting after carrying out the process is in the range from 30 µm to 500 µm, in particular in the range from 35 µm to 450 µm, preferably in the range from 40 µm to 400 µm, particularly preferably in the range from 45 µm to 300 µm. Method according to one of the preceding claims, wherein after the first hot-dip galvanizing and/or before the second hot-dip galvanizing, the iron or steel component obtained after the first hot-dip galvanizing is left to rest, in particular stored and/or transported and/or used, preferably under oxidative conditions and/or with exposure to ambient air and/or ambient atmosphere, in particular for a period of at least 10 minutes, in particular at least 60 minutes, preferably at least 24 hours; and/or where there is at least 10 minutes, in particular at least 60 minutes, preferably at least 24 hours, between the first hot-dip galvanizing and the second hot-dip galvanizing, in particular where the iron or steel component obtained after the first hot-dip galvanizing is exposed to oxidative conditions and/or ambient air and/or ambient atmosphere. Method according to one of the preceding claims, wherein after the first hot-dip galvanizing and/or before the second hot-dip galvanizing, an oxidation layer is formed on the hot-dip galvanizing layer resulting from the first hot-dip galvanizing; and/or wherein after the first hot-dip galvanizing and/or before the second hot-dip galvanizing, the iron or steel component obtained after the first hot-dip galvanizing is left to rest, in particular stored and/or transported and/or used, preferably under oxidative conditions and/or with exposure to ambient air and/or ambient atmosphere, in such a way and/or with the proviso that an oxidation layer is formed on the hot-dip galvanizing layer resulting from the first hot-dip galvanizing; in particular wherein the oxidation layer comprises oxygen-containing zinc compounds, in particular selected from the group of zinc oxide, zinc hydroxide, zinc oxide hydroxide, zinc hydrogen carbonate, zinc carbonate and combinations thereof. Method according to one of the preceding claims, wherein the method is not carried out as a wet-on-wet method; and/or wherein the second hot-dip galvanizing is not carried out immediately after the first hot-dip galvanizing, in particular not without the hot-dip galvanizing layer resulting from the first hot-dip galvanizing being exposed to oxidative conditions and/or ambient air and/or ambient atmosphere; and/or wherein the second hot-dip galvanizing is not carried out immediately after the first hot-dip galvanizing, in particular not without an oxidation layer being formed on the hot-dip galvanizing layer resulting from the first hot-dip galvanizing. Method according to one of the preceding claims, wherein the second hot-dip galvanizing is carried out after the hot-dip galvanizing layer resulting from the first hot-dip galvanizing has solidified and/or cooled and/or at least partially oxidized and/or exposed to ambient air; and/or wherein the second hot-dip galvanizing is carried out on the hot-dip galvanizing layer resulting from the first hot-dip galvanizing and solidified and/or cooled and/or at least partially oxidized and/or exposed to ambient air. Method according to one of the preceding claims, wherein the first hot-dip galvanizing and the second hot-dip galvanizing are carried out spatially separated from one another. Method according to one of the preceding claims, wherein a cooling treatment is carried out after the first hot-dip galvanizing; and/or wherein the iron or steel component obtained after the first hot-dip galvanizing is subjected to a cooling treatment; and/or wherein a post-processing treatment is carried out after the first hot-dip galvanizing; and/or wherein the iron or steel component obtained after the first hot-dip galvanizing is subjected to a post-processing treatment. Method according to one of the preceding claims, wherein an activation treatment is carried out after the first hot-dip galvanizing; and/or wherein the iron or steel component obtained after the first hot-dip galvanizing is subjected to an activation treatment. Procedure according to a claim 35 , wherein the activation treatment comprises at least one chemical and optionally (additionally) one mechanical treatment. procedure according to claim 36 , wherein the chemical treatment comprises at least one pickling treatment and/or flux treatment; and/or wherein the chemical treatment is carried out by an aqueous saline solution, in particular with a pH of less than 5; and/or wherein the chemical treatment is carried out for a period of time in the range from 1 second to 60 minutes, in particular in the range from 5 seconds to 45 minutes, preferably in the range from 10 seconds to 30 minutes. Method according to one of the preceding claims, wherein an activation treatment is carried out after the first hot-dip galvanizing; and/or wherein the iron or steel component obtained after the first hot-dip galvanizing is subjected to an activation treatment, wherein the activation treatment comprises at least one chemical and optionally (additionally) one mechanical treatment; wherein the chemical treatment is carried out by means of flux treatment in a flux composition in a flux bath; in particular wherein the flux bath of the chemical treatment comprises an aqueous and/or alcoholic, in particular aqueous, liquid phase, wherein the liquid phase of the flux bath contains the flux composition, in particular in dissolved or dispersed form, preferably in dissolved form, and/or in particular wherein the flux composition of the chemical treatment comprises salts and optionally wetting agents as ingredients, in particular wherein the salts are selected from the group of chlorides, preferably from the group of zinc chloride (ZnCl ₂ ), ammonium chloride (NH ₄ Cl), alkali and/or alkaline earth chlorides, in particular potassium chloride (KCl) and/or sodium chloride (NaCl), aluminum chloride (AlCl ₃ ), silver chloride (AgCl), lead chloride (PbCl ₂ ), nickel chloride (NiCl ₂ ), tin chloride (SnCl ₂ ), manganese chloride (MnCl ₂ ), cobalt chloride (CoCl ₂ ) and combinations thereof; and/or in particular wherein the flux composition of the chemical treatment comprises as ingredients zinc chloride (ZnCl ₂ ) and optionally at least one alkali and/or alkaline earth chloride, in particular potassium chloride (KCl) and/or sodium chloride (NaCl), and optionally wetting agents and optionally at least one further salt different from the aforementioned compounds, selected from the group of chlorides, preferably from the group of ammonium chloride (NH ₄ Cl), aluminum chloride (AlCl ₃ ), silver chloride (AgCl), lead chloride (PbCl ₂ ), nickel chloride (NiCl ₂ ), tin chloride (SnCl ₂ ), manganese chloride (MnCl ₂ ), cobalt chloride (CoCl ₂ ) and combinations thereof; and/or in particular wherein the flux composition of the chemical treatment comprises as ingredients salts and optionally wetting agents, in particular wherein the flux composition comprises at least zinc chloride (ZnCl ₂ ) and at least one alkali and/or alkaline earth chloride, in particular potassium chloride (KCl) and/or sodium chloride (NaCl); and/or in particular wherein the flux composition of the chemical treatment is free of ammonium chloride (NH ₄ Cl); and/or in particular wherein the flux composition of the chemical treatment contains at least substantially no ammonium chloride (NH ₄ Cl); and/or in particular wherein the flux bath of the chemical treatment has a salt content of at least 50 wt.%, in particular of at least 60 wt.%, preferably of at least 70 wt.%, particularly preferably of at least 80 wt.%; and/or in particular wherein the flux bath of the chemical treatment has a salt content of at most 99 wt.%, in particular of at most 95 wt.%, preferably of at most 93 wt.%, particularly preferably of at most 90 wt.%; and/or in particular wherein the flux bath of the chemical treatment has a salt content in the range of 50 % by weight to 99 % by weight, in particular in the range from 60 % by weight to 95 % by weight, preferably in the range from 70 % by weight to 93 % by weight, particularly preferably in the range from 80 % by weight to 90 % by weight; and/or in particular wherein the flux bath of the chemical treatment has a salt content in the range from 100 g/l to 800 g/l, in particular in the range from 140 g/l to 720 g/l, preferably in the range from 170 g/l to 670 g/l, particularly preferably in the range from 200 g/l to 600 g/l. procedure according to claim 38 , wherein the flux composition of the chemical treatment has the following ingredients, wherein all the amounts given below are based on the flux composition and are to be selected such that a total of 100 wt.% results: (i) zinc chloride (ZnCl ₂ ), in particular in amounts in the range from 50 to 95 wt.%, in particular in the range from 55 to 90 wt.%, preferably in the range from 60 to 85 wt.%, particularly preferably in the range from 65 to 82.5 wt.%, even more preferably in the range from 70 to 82 wt.%, (ii) ammonium chloride (NH ₄ Cl), in particular in amounts in the range from 5 to 45 wt.%, in particular in the range from 6 to 40 wt.%, preferably in the range from 7 to 35 wt.%, particularly preferably in the range from 8 to 25 wt.%, even more preferably in the range from 10 to 20 wt.%, (iii) sodium chloride (NaCl), in particular in amounts in the range from 0.1 to 20 wt.%, in particular in the range of 0.5 to 15 wt.%, preferably in the range of 1 to 12.5 wt.%, particularly preferably in the range of 2 to 10 wt.%, even more preferably in the range of 4 to 8 wt.%, and (iv) potassium chloride (KCl), in particular in amounts in the range of 0.1 to 15 wt.%, preferably in the range of 0.2 to 12.5 wt.%, preferably in the range of 0.4 to 10 wt.%, particularly preferably in the range of 0.5 to 8 wt.%, even more preferably in the range of 0.8 to 6 wt.%. Method according to one of the Claims 36 until 39 , wherein the chemical treatment is carried out by means of pickling treatment; in particular wherein the pickling treatment of the chemical treatment is carried out with a hydrochloric acid-containing (HCl-containing) and/or hydrochloric acid-based (HCl-based) pickling treatment agent, in particular wherein the pickling treatment agent has a pH of less than 5; and/or in particular wherein the pickling treatment of the chemical treatment is carried out with an acidic pickling treatment agent, in particular with a pickling treatment agent with a pH of less than 5, and/or in particular wherein the pickling treatment agent contains iron, in particular in the form of divalent and/or trivalent iron ions; and/or in particular wherein the pickling treatment agent contains at least one additive, in particular at least one pickling additive, in particular selected from the group of corrosion inhibitors, pickling cleaners, pickling accelerators and pickling enhancers and combinations thereof. Method according to one of the Claims 36 until 40 , wherein the pickling treatment agent and/or the flux bath of the chemical treatment contains at least one wetting agent and/or surfactant, in particular at least one ionic or non-ionic wetting agent and/or surfactant, preferably at least one non-ionic wetting agent and/or surfactant; in particular wherein the pickling treatment agent and/or flux bath of the chemical treatment contains the at least one wetting agent and/or surfactant in amounts of 0.0001 to 15 wt. %, preferably in amounts of 0.001 to 10 wt. %, preferably in amounts of 0.01 to 8 wt. %, even more preferably in amounts of 0.01 to 6 wt. %, very particularly preferably in amounts of 0.05 to 3 wt. %, even more preferably in amounts of 0.1 to 2 wt. %, based on the flux bath. Method according to one of the Claims 36 until 41 , wherein the chemical treatment is carried out by means of a pickling treatment and a flux treatment; in particular wherein the pickling treatment of the chemical treatment and the flux treatment of the chemical treatment each take place for a period of time in the range from 1 second to 60 minutes, in particular in the range from 5 seconds to 45 minutes, preferably in the range from 10 seconds to 30 minutes; and/or in particular wherein the pickling treatment is carried out first and then the flux treatment, wherein after the pickling treatment and before the flux treatment a rinsing process takes place, in particular by immersion in a water bath. Procedure according to a Claims 36 until 42 , wherein the chemical treatment, in particular the flux treatment and/or the pickling treatment, is carried out at elevated temperature; in particular wherein the flux treatment and/or the pickling treatment is carried out at a temperature in the range of 20 °C to 100 °C, in particular in the range of 25 °C to 80 °C. Procedure according to a Claims 36 until 43 , wherein the mechanical treatment comprises an abrasive treatment. Procedure according to a Claims 36 until 44 , wherein the iron or steel component obtained after the activation treatment is subjected to a drying treatment; in particular wherein the drying treatment is carried out at a temperature in the range from 30 °C to 400 °C, in particular in the range from 35 °C to 375 °C, preferably in the range from 40 °C to 350 °C, particularly preferably in the range from 50 °C to 325 °C; and/or in particular wherein the drying treatment is carried out for a period of time in the range from 0.1 seconds to 60 minutes, in particular in the range from 1 second to 45 minutes, preferably in the range from 10 seconds to 35 minutes, particularly preferably in the range from 20 seconds to 30 minutes, even more preferably in the range from 20 seconds to 15 minutes; and/or in particular wherein the drying treatment is carried out in the presence of and/or by means of air; and/or in particular wherein the drying treatment is carried out in at least one drying device, in particular in at least one oven. Method according to one of the preceding claims, wherein a cooling treatment takes place after the second hot-dip galvanizing; and/or wherein the iron or steel component obtained after the second hot-dip galvanizing is subjected to a cooling treatment; and/or wherein a post-processing treatment takes place after the second hot-dip galvanizing; and/or wherein the iron or steel component obtained after the second hot-dip galvanizing is subjected to a post-processing treatment. Method according to one of the preceding claims, wherein the iron or steel component is subjected to the following method steps in the following order before the first hot-dip galvanizing: a) degreasing treatment, preferably alkaline degreasing treatment, of the iron or steel component, in particular in at least one degreasing bath; then (b) optionally rinsing the iron or steel component degreased in method step (a), in particular in at least one rinsing bath; then (c) pickling treatment, preferably acidic pickling treatment, of the iron or steel component degreased in method step (a) and optionally rinsed in method step (b), in particular in at least one pickling bath; then (d) optionally rinsing the iron or steel component pickled in method step (c), in particular in at least one rinsing bath; then (e) flux treatment of the iron or steel component pickled in method step (c) and optionally rinsed in method step (d) using a flux composition in a flux bath; then (f) if necessary, drying treatment of the iron or steel component subjected to flux treatment in process step (e). Procedure according to a claim 47 , wherein the flux in process step (e) comprises the following ingredients: (I) zinc chloride (ZnCl ₂ ), (II) optionally ammonium chloride (NH ₄ Cl), (III) optionally at least one alkali and/or alkaline earth salt, in particular sodium chloride and/or potassium chloride, preferably sodium chloride and potassium chloride, and (IV) optionally at least one further metal salt, in particular selected from the group of chlorides, preferably chlorides of nickel (Ni), cobalt (Co), manganese (Mn), lead (Pb), tin (Sn), bismuth (Bi), antimony (Sb), aluminum (Al) and silver (Ag) and combinations thereof, in particular selected from the group of NiCl ₂ , CoCl ₂ , MnCl ₂ , PbCl ₂ , SnCl ₂ , BiCl ₃ , SbCl ₃ , AlCl ₃ and AgCl and combinations thereof. Procedure according to a claim 47 or claim 48 , wherein the flux in process step (e) has the following ingredients, wherein all the quantities given below are based on the flux and are to be selected such that a total of 100 wt.% results: (I) zinc chloride (ZnCl ₂ ), in particular in amounts in the range from 50 to 95 wt.%, (II) optionally ammonium chloride (NH ₄ Cl), in particular in amounts in the range from 7 to 50 wt.%, (III) optionally at least one alkali and/or alkaline earth salt, in particular sodium chloride and/or potassium chloride, preferably sodium chloride and potassium chloride, in particular in amounts in the range from 2 to 20 wt.%, (IV) optionally at least one metal salt from the group of NiCl ₂ , CoCl ₂ , MnCl ₂ , PbCl ₂ , SnCl ₂ , BiCl ₃ , SbCl ₃ , AlCl ₃ and AgCl, in particular in amounts in the range from 0.1 to 10 wt.%. Method according to one of the Claims 47 until 49 , wherein the flux bath in process step (e) is adjusted to a defined or predetermined, in particular acidic pH value, in particular in the pH value range from 0 to 6.9, preferably in the pH value range from 0.5 to 6.5, preferably in the pH value range from 1 to 5.5, particularly preferably in the pH value range from 1.5 to 5, very particularly preferably in the pH value range from 2 to 4.5, even more preferably in the pH value range from 2 to 4; and/or wherein the flux bath in process step (e) is adjusted to a defined or predetermined, in particular acidic pH value, wherein the pH value is adjusted by means of a preferably inorganic acid in combination with a preferably inorganic basic compound, in particular ammonia (NH ₃ ); and/or wherein the flux bath in process step (e) further contains at least one wetting agent and/or surfactant, in particular at least one ionic or non-ionic wetting agent and/or surfactant, preferably at least one non-ionic wetting agent and/or surfactant. Method according to one of the preceding claims, wherein the method comprises the following method steps in the order listed below: (a) degreasing treatment, preferably alkaline degreasing treatment, of the iron or steel component, in particular in at least one degreasing bath; then (b) optionally rinsing the iron or steel component degreased in method step (a), in particular in at least one rinsing bath; then (c) pickling treatment, preferably acidic pickling treatment, of the iron or steel component degreased in method step (a) and optionally rinsed in method step (b), in particular in at least one pickling bath; then (d) optionally rinsing the iron or steel component pickled in method step (c), in particular in at least one rinsing bath; then (e) flux treatment of the iron or steel component pickled in method step (c) and optionally rinsed in method step (d) by means of a flux composition in a flux bath; then (f) optionally drying treatment of the iron or steel component subjected to flux treatment in process step (e); then (g) first hot-dip galvanizing (hot-dip galvanizing) of the iron or steel component subjected to flux treatment in process step (e) and optionally dried in process step (f) in a zinc melt (“Zn melt”), in particular in a galvanizing bath containing the zinc melt, preferably by dipping the iron or steel component into the zinc melt and/or into the galvanizing bath; then (h) optionally cooling treatment of the iron or steel component hot-dip galvanized (hot-dip galvanized) in process step (g); then (i) optionally post-processing of the iron or steel component hot-dip galvanized (hot-dip galvanized) in process step (g) and optionally cooled in process step (h); then (j) activation treatment of the iron or steel component hot-dip galvanized (hot-dip galvanized) in process step (g) and optionally cooled in process step (h) and optionally post-processed in process step (i); then (k) optionally drying treatment of the iron or steel component subjected to the activation treatment in process step (j); then (I) second hot-dip galvanizing (hot-dip galvanizing) of the iron or steel component subjected to the activation treatment in process step (j) and optionally dried in process step (k) in an aluminum-containing and/or aluminum-alloyed zinc melt (“Zn/Al melt”), in particular in a galvanizing bath containing the aluminum-containing and/or aluminum-alloyed zinc melt, preferably by dipping the iron or steel component into the aluminum-containing and/or aluminum-alloyed zinc melt and/or into the galvanizing bath; then (m) if necessary, cooling treatment of the iron or steel component hot-dip galvanised (hot-dip galvanised) in process step (I); then (n) if necessary, post-processing of the iron or steel component hot-dip galvanised (hot-dip galvanised) in process step (I) and if necessary, cooled in process step (m). Plant (system) (AF) for hot-dip galvanizing (hot-dip galvanizing) an iron or steel component, in particular for producing a hot-dip galvanized iron or steel component with increased corrosion protection performance and/or with increased ductility, preferably plant (system) (AF) for carrying out a two-stage hot-dip galvanizing process, in particular plant (system) (AF) for carrying out a process according to one of the preceding claims, wherein the plant comprises the following devices in the order listed below: - a first hot-dip galvanizing device (FZ1) for hot-dip galvanizing the iron or steel component in a zinc melt ("Zn melt"), in particular in a galvanizing bath containing a zinc melt; downstream and/or arranged downstream therefrom in the process sequence - a second hot-dip galvanizing device (FZ2) for hot-dip galvanizing the iron or steel component obtained after the first hot-dip galvanizing in an aluminum-containing and/or aluminum-alloyed zinc melt ("Zn/Al melt"), in particular in a galvanizing bath containing an aluminum-containing and/or aluminum-alloyed zinc melt. facility according to claim 52 , wherein a storage and/or transfer area is arranged downstream and/or in the process sequence downstream of the first hot-dip galvanizing device (FZ1) and upstream and/or in the process sequence upstream of the second hot-dip galvanizing device (FZ2), in particular wherein the storage and/or transfer area is designed for resting, in particular for storing and/or transporting and/or using, the iron or steel component obtained after the first hot-dip galvanizing device (FZ1); in particular wherein the storage and/or transfer area has oxidative conditions and/or ambient air and/or ambient atmosphere; and/or in particular wherein oxidative conditions and/or ambient air and/or ambient atmosphere are present in the storage and/or transfer area. facility according to claim 52 or claim 53 , wherein the second hot-dip galvanizing device (FZ2) is not arranged immediately downstream and/or downstream in the process sequence to the first hot-dip galvanizing device (FZ1), in particular not in such a way that the hot-dip galvanizing layer resulting from the first hot-dip galvanizing is not exposed to oxidative conditions and/or ambient air and/or ambient atmosphere; and/or wherein the second hot-dip galvanizing device (FZ2) is not arranged immediately downstream and/or downstream in the process sequence to the first hot-dip galvanizing device (FZ1), in particular not without an oxidation layer being formed on the hot-dip galvanizing layer resulting from the first hot-dip galvanizing. Plant according to one of the preceding claims, wherein the first hot-dip galvanizing device (FZ1) and the second hot-dip galvanizing device (FZ2) are arranged spatially separated from one another. Plant according to one of the preceding claims, wherein a first post-treatment device (NBH1) is arranged downstream and/or in the process sequence downstream of the first hot-dip galvanizing device (FZ1) and upstream and/or in the process sequence upstream of the second hot-dip galvanizing device (FZ2); in particular, wherein the first post-treatment device (NBH1) comprises at least one cooling device; and/or in particular, wherein the first post-treatment device (NBH1) comprises at least one post-processing device. Plant according to one of the preceding claims, wherein an intermediate treatment device (ZBH) is arranged downstream and/or in the process sequence downstream of the first hot-dip galvanizing device (FZ1), in particular downstream and/or in the process sequence downstream of the first hot-dip galvanizing device (FZ1) and downstream and/or in the process sequence downstream of the first post-treatment device (NBH1). Plant after a claim 56 , wherein the intermediate treatment device (ZBH) comprises an activation device; in particular wherein the activation device is designed to carry out at least one chemical and optionally (additionally) one mechanical treatment, in particular wherein the chemical treatment comprises at least one pickling treatment and/or flux treatment and/or in particular wherein the mechanical treatment comprises an abrasive treatment. facility according to claim 57 , wherein the intermediate treatment device (ZBH) comprises a drying device; in particular wherein the drying device comprises at least one oven. Plant according to one of the preceding claims, wherein a second post-treatment device (NBH2) is arranged downstream and/or downstream in the process sequence to the second hot-dip galvanizing device (FZ2); in particular, wherein the second post-treatment device (NBH2) comprises at least one cooling device; and/or in particular, wherein the second post-treatment device (NBH2) comprises at least one post-processing device. Plant according to one of the preceding claims, wherein a pretreatment device (VBH) is arranged upstream and/or in the process sequence upstream of the first hot-dip galvanizing device (FZ1), wherein the pretreatment device (VBH) is designed to carry out the following process steps in the order listed below: (a) degreasing treatment, preferably alkaline degreasing treatment, of the iron or steel component, in particular in at least one degreasing bath; then (b) optionally rinsing the iron or steel component degreased in process step (a), in particular in at least one rinsing bath; then (c) pickling treatment, preferably acidic pickling treatment, of the iron or steel component degreased in process step (a) and optionally rinsed in process step (b), in particular in at least one pickling bath; then (d) optionally rinsing the iron or steel component pickled in process step (c), in particular in at least one rinsing bath; then (e) fluxing the iron or steel component pickled in process step (c) and optionally rinsed in process step (d) using a flux composition in a flux bath; then (f) optionally drying the iron or steel component subjected to the fluxing treatment in process step (e). Plant according to one of the preceding claims, wherein the plant comprises the following devices in the following order: (VBH) at least one pretreatment device (VBH); downstream and/or arranged downstream of this in the process sequence (FZ1) at least one first hot-dip galvanizing device (FZ1); downstream and/or arranged downstream of this in the process sequence (NBH1) at least one first post-treatment device (NBH1); downstream and/or arranged downstream of this in the process sequence (ZBH) at least one intermediate treatment device (ZBH); downstream and/or arranged downstream of this in the process sequence (FZ2) at least one second hot-dip galvanizing device (FZ2); downstream and/or arranged downstream of this in the process sequence (NBH2) at least one second post-treatment device (NBH2). Plant according to one of the preceding claims, wherein the plant comprises the following devices and/or baths in the following order: (A) at least one degreasing bath; downstream and/or downstream in the process sequence (B) optionally at least one rinsing bath; downstream and/or downstream in the process sequence (C) at least one pickling bath; downstream and/or downstream in the process sequence (D) optionally at least one rinsing bath; downstream and/or downstream in the process sequence (E) at least one flux bath; downstream and/or downstream in the process sequence (F) optionally at least one drying device, in particular oven; downstream and/or downstream in the process sequence (G) at least one galvanizing bath; downstream and/or downstream in the process sequence (H) optionally cooling device; downstream and/or downstream in the process sequence arranged for this purpose (I) if necessary, post-processing device; downstream and/or arranged downstream in the process sequence (J) at least one activation device; downstream and/or arranged downstream in the process sequence (K) if necessary, at least one drying device, in particular an oven; downstream and/or arranged downstream in the process sequence (L) galvanizing bath; downstream and/or arranged downstream in the process sequence (M) if necessary, at least one cooling device; downstream and/or arranged downstream in the process sequence (N) if necessary, at least one post-processing device. Plant according to one of the preceding claims, wherein the plant comprises the following devices in the following order: (VBH) at least one pretreatment device (VBH), wherein the pretreatment device (VBH) (A) at least one degreasing bath; downstream and/or arranged downstream of this in the process sequence (B) optionally at least one rinsing bath; downstream and/or arranged downstream of this in the process sequence (C) at least one pickling bath; downstream and/or arranged downstream of this in the process sequence (D) optionally at least one rinsing bath; downstream and/or arranged downstream of this in the process sequence (E) at least one flux bath; downstream and/or arranged downstream of this in the process sequence (F) optionally at least one drying device, in particular oven; downstream and/or downstream in the process sequence (FZ1) at least one first hot-dip galvanizing device (FZ1), the hot-dip galvanizing device (FZ1) (G) comprising at least one galvanizing bath; downstream and/or downstream in the process sequence (NBH1) at least one first post-treatment device (NBH1), the first post-treatment device (NBH1) (H) optionally comprising at least one cooling device; downstream and/or downstream in the process sequence (I) optionally comprising at least one post-processing device; downstream and/or downstream in the process sequence (ZBH) at least one intermediate treatment device (ZBH), the intermediate treatment device (ZBH) (J) at least one activation device; downstream and/or downstream in the process sequence (K) optionally comprising at least one drying device, in particular oven; downstream and/or downstream in the process sequence (FZ2) at least one second hot-dip galvanizing device (FZ2), the second hot-dip galvanizing device (FZ2) (L) comprising at least one galvanizing bath; downstream and/or downstream in the process sequence (NBH2) at least one second post-treatment device (NBH2), the second post-treatment device (NBH2) (M) optionally comprising at least one cooling device; downstream and/or downstream in the process sequence (N) optionally comprising at least one post-processing device; Installation according to one of the preceding claims, each characterized by one or more of the features of Claims 1 until 51 . Hot-dip galvanized (hot-dip galvanized) iron or steel component (1), obtainable by a process according to one of the preceding claims and/or obtainable in a plant according to one of the preceding claims. Hot-dip galvanized iron or steel component (1), in particular hot-dip galvanized iron or steel component according to claim 66 , wherein the hot-dip galvanized iron or steel component (1) is obtainable in that an iron or steel component (2) has first been subjected to a first hot-dip galvanizing in a zinc melt (“Zn melt”), in particular in a galvanizing bath containing a zinc melt, and subsequently the iron or steel component obtained after the first hot-dip galvanizing has been subjected to a second hot-dip galvanizing in an aluminum-containing and/or aluminum-alloyed zinc melt (“Zn/Al melt”), in particular in a galvanizing bath containing an aluminum-containing and/or aluminum-alloyed zinc melt. Hot-dip galvanized iron or steel component according to claim 66 or claim 67 , wherein the hot-dip galvanized iron or steel component (1) has a multi-layer and/or multi-phase (total) hot-dip galvanizing layer (5) applied to the base material of the iron or steel component (2); wherein the hot-dip galvanized iron or steel component (1) has an at least partially layered hot-dip galvanizing layer (4) with Zn/Al/Fe phases, in particular as an outer hot-dip galvanizing layer and/or in particular as an outer layer; and wherein the hot-dip galvanized iron or steel component (1) has a hot-dip galvanizing layer (3) with Zn/Fe phases, which optionally contains aluminum, on the base material (2) of the iron or steel component, in particular below (below) the outer hot-dip galvanizing layer (4) and/or the outer layer (4). Hot-dip galvanized iron or steel component, in particular hot-dip galvanized iron or steel component according to one of the Claims 66 until 68 , wherein the hot-dip galvanized iron or steel component (1) has a multi-layer and/or multi-phase (total) hot-dip galvanizing layer (5) applied to the base material of the iron or steel component (2); wherein the hot-dip galvanized iron or steel component (1) has an at least partially layered hot-dip galvanizing layer (4) with Zn/Al/Fe phases, in particular as an outer hot-dip galvanizing layer and/or in particular as an outer layer; and wherein the hot-dip galvanized iron or steel component (1) has a hot-dip galvanizing layer (3) with a Zn/Fe phase, which optionally contains aluminum, on the base material (2) of the iron or steel component, in particular below (below) the outer hot-dip galvanizing layer (4) and/or the outer layer (4). Hot-dip galvanized iron or steel component according to one of the preceding claims, wherein the hot-dip galvanized iron or steel component (1) has a (total) hot-dip galvanizing layer (5) with an aluminum concentration gradient; and/or wherein the multi-layer and/or multi-phase (total) hot-dip galvanizing layer (5) has an aluminum concentration gradient. Hot-dip galvanized iron or steel component according to one of the preceding claims, wherein the hot-dip galvanized iron or steel component (1) has a (total) hot-dip galvanizing layer with a (total) layer thickness of at least 30 µm, in particular at least 35 µm, preferably at least 40 µm, particularly preferably at least 45 µm; and/or wherein the hot-dip galvanized iron or steel component (1) has a (total) hot-dip galvanizing layer with a (total) layer thickness of at most 500 µm, in particular at most 450 µm, preferably at most 400 µm, particularly preferably at most 300 µm; and/or wherein the hot-dip galvanized iron or steel component (1) has a (total) hot-dip galvanizing layer with a (total) layer thickness in the range from 30 µm to 500 µm, in particular in the range from 35 µm to 450 µm, preferably in the range from 40 µm to 400 µm, particularly preferably in the range from 45 µm to 300 µm. Hot-dip galvanized iron or steel component according to one of the preceding claims, wherein the hot-dip galvanized iron or steel component (1) is designed to be bendable to 90° at least substantially without impairing the corrosion protection performance; and/or wherein the hot-dip galvanized iron or steel component (1), in particular with a base material thickness of the iron or steel component of at least 2 mm and a (total) thickness of the (total) hot-dip galvanizing layer of at least 30 µm, after 90° bending with a residence time of at least 1,000 h, in particular at least 1,250 h, preferably at least 1,500 h, particularly preferably at least 1,750 h, very particularly preferably at least 2,000 h, in the salt spray test, in particular according to DIN EN ISO 9227, at least substantially no red rust formation, preferably no red rust formation. Hot-dip galvanized iron or steel component according to one of the preceding claims, wherein the hot-dip galvanized iron or steel component (1), in particular with a (total) hot-dip galvanizing layer of at least 350 g/m ² , with a residence time of at least 1,000 h, in particular at least 2,000 h, preferably at least 5,000 h, particularly preferably at least 8,000 h, very particularly preferably at least 10,000 h, in the salt spray test, in particular according to DIN EN ISO 9227, at least substantially no red rust formation, preferably no red rust formation. Hot-dip galvanized iron or steel component according to one of the preceding claims, each characterized by one or more of the features of Claims 1 until 65 . Use of a two-stage hot-dip galvanizing process for providing an aluminum-containing and/or aluminum-alloyed hot-dip galvanizing layer with an increased (total) layer thickness, wherein firstly an iron or steel component is subjected to a first hot-dip galvanizing in a zinc melt ("Zn melt"), in particular in a galvanizing bath containing a zinc melt, and wherein the iron or steel component obtained after the first hot-dip galvanizing is subsequently subjected to a second hot-dip galvanizing in an aluminum-containing and/or aluminum-alloyed zinc melt ("Zn/Al melt"), in particular in a galvanizing bath containing an aluminum-containing and/or aluminum-alloyed zinc melt. Use of a two-stage hot-dip galvanizing process for improving the ductility of a hot-dip galvanizing layer, wherein firstly an iron or steel component is subjected to a first hot-dip galvanizing in a zinc melt ("Zn melt"), in particular in a galvanizing bath containing a zinc melt, and wherein subsequently the iron or steel component obtained after the first hot-dip galvanizing is subjected to a second hot-dip galvanizing in an aluminum-containing and/or aluminum-alloyed zinc melt ("Zn/Al melt"), in particular in a galvanizing bath containing an aluminum-containing and/or aluminum-alloyed zinc melt. Use of a two-stage hot-dip galvanizing process for improving and/or controlling the formation of an aluminum-containing and/or aluminum-alloyed hot-dip galvanizing layer, in particular for improving and/or controlling the (total) layer thickness and/or layer structure of an aluminum-containing and/or aluminum-alloyed hot-dip galvanizing layer, wherein firstly an iron or steel component is subjected to a first hot-dip galvanizing in a zinc melt (“Zn melt”), in particular in a galvanizing bath containing a zinc melt, and wherein subsequently the iron or steel component obtained after the first hot-dip galvanizing is subjected to a second hot-dip galvanizing in an aluminum-containing and/or aluminum-alloyed zinc melt (“Zn/Al melt”), in particular in a galvanizing bath containing an aluminum-containing and/or aluminum-alloyed zinc melt. Use of a two-stage hot-dip galvanizing process for improving the corrosion protection performance, in particular for improving the corrosion protection performance of an aluminum-containing and/or aluminum-alloyed hot-dip galvanizing layer, wherein firstly an iron or steel component is subjected to a first hot-dip galvanizing in a zinc melt ("Zn melt"), in particular in a galvanizing bath containing a zinc melt, and wherein the iron or steel component obtained after the first hot-dip galvanizing is subsequently subjected to a second hot-dip galvanizing in an aluminum-containing and/or aluminum-alloyed zinc melt ("Zn/Al melt"), in particular in a galvanizing bath containing an aluminum-containing and/or aluminum-alloyed zinc melt. Use of a silicon content (Si content) of an iron or steel component in a two-stage hot-dip galvanizing process, in particular as in one of the Claims 1 until 51 defined to control the (total) layer thickness of the hot-dip galvanizing. Use after claim 79 , whereby with increasing silicon content of the iron or steel component, the (total) layer thickness of the (total) hot-dip galvanizing layer is increased and/or the hot-dip galvanizing time is reduced. Use according to one of the Claims 75 until 80 , each characterized by one or more of the features of the Claims 1 until 74 .

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