Abstract
This two-part article series reviews the application of thermal spray coating technology in the production of steel and steel sheet products. Part 2 of this article series is dedicated to coating solutions in the continuous galvanizing line. The corrosion mechanisms of Fe- and Co-based bulk materials are briefly reviewed as a basis for the development of thermal spray coating solutions. WC-Co thermal spray coatings are commonly applied to low Al-content galvanizing hardware due to their superior corrosion resistance compared to Fe and Co alloys. The effect of phase degradation, carbon content, and WC grain size are discussed. At high Al concentrations, the properties of WC-Co coatings degrade significantly, leading to the application of oxide-based coatings and corrosion-resistant boride containing coatings. The latest results of testing are summarized, highlighting the critical coating parameters.
Similar content being viewed by others
References
H.E. Townsend, Continuous Hot Dip Coatings, ASM Handbook Volume 5: Surface Engineering, Vol 5, ASM International, 1994, p 339-348.
A.R. Marder, The Metallurgy of Zinc-Coated Steel, Prog. Mater. Sci., 2000, 45, p 191-271
GalvInfoNote 2.4—The Role of Aluminium in Continuous Hot-Dip Galvanizing (Revision 1.1 March 2009), Retrieved 9 February 2010 from GalvInfo Centre Web site: http://www.galvinfo.com/
The Science of Steel, Retrieved 3 February 2010 from the NZ Steel Web site: http://www.nzsteel.co.nz/go/about-new-zealand-steel/student-information/the-science-of-steel
M. Bright and A. Ensminger, Identification of Failure Mechanisms in Correcting Roll Bearings of a Continuous Galvanizing Line, 2004 Galvanizers Association Annual Meeting, Charleston, South Carolina, USA, 2004
K. Zhang and L. Battiston, Sliding Wear of Various Materials in Molten Zinc, Mater. Sci.Technol., 2002, 18, p 1551-1560
E. Barbero and C. Irwin, Development of Improved Materials for Continuous Steel Hot-Dipping Processes—Final Technical Report (DOE Project Award Number: DE-FC36-01ID14042), West Virginia University, USA, 2005
K. Zhang, N.Y. Tang, F.E. Goodwin, and S. Sexton, Reaction of 316L Stainless Steel With a Galvanizing Bath, J. Mater. Sci., 2007, 42, p 9736-9745
J. Morando, Material Formulation for Galvanizing Equipment Submerged in Molten Aluminium and Aluminium/Zinc Melts, United States Patent, Publication Number US6168757 B1. Alphatech Inc., 2001.
B.G. Seong, S.Y. Hwang, M.C. Kim, and K.Y. Kim, Reaction of WC-Co Coatings with Molten Zinc in a Zinc Pot of a Continuous Galvanizing Line, Surf. Coat. Technol., 2001, 138, p 101-110
X. Liu, V. Sikka, M. Bright, S. Sexton, E. Barbero, and J. Hales, Development of a New Weld Overlay for Pot Hardware in Continuous Galvanizing Lines, GALVATECH 07—7th International Conference on Zinc and Zinc Alloy Coated Steel Sheet, Osaka, Japan, 2007
H. Kim, B. Yoon, and C. Lee, Sliding Wear Performance in Molten Zn-Al Bath of Cobalt-Based Overlayers Produced by Plasma Transferred Arc Weld-Surfacing, Wear, 2003, 254, p 408-414
M. Bright, Investigating Galvanneal Reactions on Pot Hardware Materials, AISTech 2007 Conference, Indianapolis, USA, 2007
X. Liu, E. Barbero, J. Xu, M. Burris, K. Chang, and V. Sikka, Liquid Metal Corrosion of 316L, Fe3Al, and FeCrSi in Molten Zn-Al Baths, Metall. Mater. Trans. A, 2005, 36A, p 2049-2058
J. Xu, M. Bright, X. Liu, and E. Barbero, Liquid Metal Corrosion of 316L Stainless Steel, 410 Stainless Steel, and 1015 Carbon Steel in a Molten Zinc Bath, Metall. Mater. Trans. A, 2007, 38A, p 2727-2736
J. Xu, X. Liu, M. Bright, J. Hemrick, V. Sikka, and E. Barbero, Reactive Wetting of an Iron-Base Superalloy MSA2020 and 316L Stainless Steel by Molten Zinc-Aluminium Alloy, Metall. Mater. Trans. A, 2008, 39A, p 1382-1391
E. Baril and G. L’Esperance, Studies of the Morphology of the Al-Rich interfacial Layer Formed During the Hot Dip Galvanizing of Steel Sheet, Metall. Mater. Trans. A, 1999, 30A, p 681-695
M. Bright and E. Barbero, Effect of Aluminium Concentration of the Dissolution of 316L Stainless Steel in Molten Zinc, 7th International Conference on Zinc and Zinc Alloy Coated Steel Sheet, Osaka, Japan, 2007, p 94-99.
K. Zhang and N. Tang, Reactions of Co Based and Fe Based Superalloys With a Molten Zn-Al Alloy, Mater. Sci. Technol., 2004, 20, p 476-739
D. Yan, J. He, B. Tian, Y. Dong, X. Li, J. Zhang, L. Xiao, and W. Jing, The Corrosion Behaviour of Plasma Sprayed Fe2Al5 Coating in Molten Zn, Surf. Coat. Technol., 2006, 201, p 2662-2666
W.J. Wang, J.P. Lin, Y.L. Wang, and G.L. Chen, The Corrosion of Intermetallic Alloys in Liquid Zinc, J. Alloy Compd., 2007, 428(1-2), p 237-243
J. Song and H. Kim, Sliding Wear Performance of Cobalt Based Alloys in Molten Al Added Zinc Bath, Wear, 1997, 210, p 291-298
M.X. Yao, J.B.C. Wu, and R. Liu, Microstructural Characteristics and Corrosion Resistance in Molten Zn-Al Bath of Co-Mo-Cr-Si Alloys, Mater. Sci. Eng. A, 2005, 407, p 299-305
W. Xibao, Corrosion of Co-Cr-W Alloy in Liquid Zinc, Metall. Mater. Trans. A, 2003, 34B, p 881-886
M. Bright, “Dissolution and Diffusion Characteristics of 316L Stainless Steel in Molten Zinc Containing Variable Concentrations of Aluminium,” Doctoral Thesis, College of Engineering and Mineral Resources, West Virginia University, Morgantown, West Virginia, 2007
X. Ren, X. Mei, J. She, and J. Ma, Materials Resistance to Liquid Zinc Corrosion on Surface of Sink Roll, Proceedings of Sino-Swedish Structural Materials Symposium 2007, 2007, p 130-136.
H.H. Fukubayashi, Present Furnace and Pot Roll Coatings and Future Development, Proceedings of the International Thermal Spray Conference 2004, 10-12 May, 2004 (Osaka, Japan), ASM International, 2004, p 125-131.
B.G. Seong, S.Y. Hwang, M.C. Kim, K.Y. Kim, Observation on the WC-Co Coating Used in a Zinc Pot of a Continuous Galvanizing Line, Thermal Spray: Surface Engineering Via Applied Research, C.C. Berndt, Ed., 8-11 May, 2000 (Montréal, QC, Canada), ASM International, Materials Park, OH, USA, 2000, p 1159-1167
M. Sawa and J. Oohori, Application of Thermal Spraying Technology at Steelworks, Thermal Spraying: Current Status and Future Trends—Proceedings of the 14th International Thermal Spray Conference, A. Ohmori, Ed., May 22-26, 1995 (Kobe, Japan), High Temperature Society of Japan, 1995, p 37-42.
R.L. Hao, Thermal Spraying Technology and Its Applications in the Iron & Steel Industry in China, Thermal Spray 2007: Global Coating Solutions, B.R. Marple, M.M. Hyland, Y.C. Lau, C.J. Li, R.S. Lima and G. Montavon, Ed., 14-16 May, 2007 (Beijing, China), ASM International, Materials Park, OH, USA, 2007, p 291-296
B.G. Seong, S.Y. Hwang, and K.Y. Kim, Factors on the Corrosion Resistance of Thermally Sprayed WC-Co Coatings in Molten Zinc, Proceedings of the 1st International Surface Engineering Congress, 2003, p 555-562.
Y. Harada and K. Tani, Spray-Coated Roll for Continuous Galvanization, United States Patent, Publication Number US 5316859. Tocalo Co. Ltd., 1994.
L. Jacobs, Structure-Property Relations and Decarburisation in WC-Cermet Coatings Deposited by High Velocity (HV) Thermal Spray Techniques, Department of Chemical and Materials Engineering, Auckland, New Zealand, University of Auckland, 1999, p 226.
L. Jacobs, M.M. Hyland, and M.d. Bonte, Comparative Study of WC-Cermet Coatings Sprayed Via the HVOF and HVAF Processes, J. Therm. Spray Tech., 1998, 7(2), p 213-218
L. Jacobs, M.M. Hyland, and M.d. Bonte, Study of the Influence of Microstructural Properties on the Sliding-Wear Behaviour of HVOF and HVAF Sprayed WC-Cermet Coatings, J. Therm. Spray Tech., 1999, 8(1), p 125-132
T. Tomita, Y. Takatani, Y. Kobayashi, Y. Harada, and H. Nakahira, Durability of WC/Co Sprayed Coatings in Molten Pure Zinc, ISIJ Int., 1993, 33(9), p 982-988
H.P. Lv, J. Wang, C.S. Zhai, F. Li, B.D. Sun, Durability of HVOF Sprayed MoB/CoCr Coating on the 316L Stainless Substrate in Molten 55%Al-Zn-1.5%Si Bath, Thermal Spray 2007: Global Coating Solutions, B.R. Marple, M.M. Hyland, Y.C. Lau, C.J. Li, R.S. Lima, and G. Montavon, Ed., 14-16 May, 2007 (Beijing, China), ASM International, Materials Park, OH, USA, 2007, p 513-517
H. Mizuno, J. Kitamura, S. Osawa, and T. Itsukaichi, Development of Durable Spray Coatings in Molten Aluminum Alloy, Proceedings of the 2005 International Thermal Spray Conference, E. Lugscheider, Ed., 2-4 May, 2005 (Basel, Switzerland), ASM International, Materials Park, OH, USA, 2005
H. Mizuno and J. Kitamura, MoB/CoCr Cermet Coatings by HVOF Spraying Against Erosion by Molten Al-Zn Alloy, J. Therm. Spray Tech., 2007, 16(3), p 404-413
W. Jarosinski, J. Quest, D. Wang, V. Belov, and S.A. Kleyman, Thermal Spray Coated Rolls, World Patent, Publication Number WO2007047330 (A1). Praxair Technology Inc, 2007.
H. Nitta and A. Tsuyuki, Pot Roll for Continuous Hot-Dip Galvanizing, European Patent, Publication Number EP 0712939 A2. Praxair S.T. Technology Inc., 1996.
SINM Coatings Service, Retrieved 3 February 2010 from the Inframat Website: http://www.inframat.com/steel.htm
K. Tani, T. Tomita, Y. Kobayashi, Y. Takatani, and Y. Harada, Durability of Sprayed WC/Co Coatings in Al-Added Zinc Bath, ISIJ Int., 1994, 34(10), p 822-828
X.H. Tan, Z.H. Jiang, Y.G. Zhang, J.S. Sun, Investigation of the Corrosion Behaviour of HVOF-Sprayed Carbide Cermet Coatings in Molten Al-Zn-Si Alloy Bath, Thermal Spray 2007: Global Coating Solutions, B.R. Marple, M.M. Hyland, Y.C. Lau, C.J. Li, R.S. Lima, and G. Montavon, Ed., 14-16 May, 2007 (Beijing, China), ASM International, Materials Park, OH, USA, 2007, p 937-942.
H. Mizuno and J. Kitamura, Thermal Spray Coating and Thermal Spray Powder, United States Patent, Publication Number US 2007/0184253. 2007.
M. Mizunuma, T. Uchiyama, and K. Tarumi, Method of Manufacturing an Immersion Member with Pore-Sealing Layer, United States Patent, Publication Number US 5395661. Nippon Steel Hardfacing Co Ltd., 1995.
Y. Dong, D. Yan, J. He, J. Zhang, and X. Li, Degradation Behaviour of ZrO2-Ni/Al Gradient Coatings in Molten Zn, Surf. Coat. Technol., 2006, 201, p 2455-2459
T. Sato, K. Tarumi, Y. Michikata, Y. Horie, and J. Yasuoka, Member With Film Formed by Thermal Spraying of Thermal Spray Material, United States Patent, Publication Number US 6569546. Nippon Steel Hardfacing Co. Ltd., 2003.
K. Hollis, M. Peters, and B. Bartram, Plasma-Sprayed Ceramic coatings for Molten Metal Environments, Thermal Spray 2003: Advancing the Science and Applying the Technology, C. Moreau and B. Marple, Ed., 5-8 May, 2003 (Orlando, FL), ASM International, Materials Park, OH, USA, 2003, p 153-158.
N. Noda, M. Yamada, Y. Sano, S. Sugiyama, and S. Kobayashi, Thermal Stress for All-Ceramic Rolls Used in Molten Metal to Produce Stable High Quality Galvanized Steel Sheet, Eng. Fail. Anal., 2008, 15, p 261-274
S.Y. Hwang and B.G. Sung, Method for Coating Oxides on Roll Used in Hot Dip Galvanizing Pot, Korean Patent, Publication Number KR 20020051089. Posco Res. Inst. Science and Tech., 2002.
R. Betts, Refractory Metal Coated Articles for Use in Molten Metal Environments, United States Patent, Publication Number US 6534196. Cincinnati Thermal Spray, 2003.
H. Mizuno, S. Tawada, I. Aoki, and J. Kitamura, HVOF Coatings of MoB/CoCr Against Erosion by Molten Al-Zn Alloy, Thermal Spray 2007: Global Coating Solutions, B.R. Marple, M.M. Hyland, Y.C. Lau, C.J. Li, R.S. Lima, and G. Montavon, Ed., 14-16 May, 2007 (Beijing, China), ASM International, Materials Park, OH, USA, 2007, p 567-571.
Y. Harada, T. Oka, and J. Takeuchi, Member for Molten Metal and its Production, Japanese Patent, Publication Number JP 2236266. Tocalo Co. Ltd., 1990
Y. Kurisu and K. Ando, Member for Hot Dip Metal Bath and Its Production, Japanese Patent, Publication Number JP 11061369. Nippon Steel Corp., 1999
Y. Harada, K. Tani, and T. Doi, Composite Film Coated Member Excellent in Wear Resistance and Molten Metal Resistance and its Manufacture, Japanese Patent, Publication Number JP 4088159. Tocalo Co. Ltd., 1992
H.P. Lv, J. Wang, C.S. Zhai, F. Li, and B.D. Sun, Study of Microstructure, Vickers Microindentation and Microhardness Distribution of HVOF Sprayed Composite MoB/CoCr Coating, Thermal Spray 2007: Global Coating Solutions, B.R. Marple, M.M. Hyland, Y.C. Lau, C.J. Li, R.S. Lima, and G. Montavon, Ed., 14-16 May, 2007 (Beijing, China), ASM International, Materials Park, OH, USA, 2007, p 528-532
J. Wood, S. Katoh, and H. Nitta, Molten Zinc Resistant Alloy and Its Manufacturing Method, United States Patent, Publication Number US 5456950. Praxair S.T. Technology Inc., 1995
T. Itsukaichi and S. Osawa, Thermal Spraying Powder and Method of Forming a Thermal Sprayed Coating Using the Same, United States Patent, Publication Number US 6984255 B2. Fujimi Inc., 2006
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Matthews, S., James, B. Review of Thermal Spray Coating Applications in the Steel Industry: Part 2—Zinc Pot Hardware in the Continuous Galvanizing Line. J Therm Spray Tech 19, 1277–1286 (2010). https://doi.org/10.1007/s11666-010-9519-7
Received:
Revised:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s11666-010-9519-7