Applications and Developments of Thermal Spray Coatings for the Iron and Steel Industry

Abstract

The steel making processes involves extreme and harsh operating conditions; hence, the production hardware is exposed to degradation mechanisms under high temperature oxidation, erosion, wear, impact, and corrosive environments. These adverse factors affect the product quality and efficiency of the steel making industry, which contributes to production downtime and maintenance costs. Thermal spray technologies that circumvent surface degradation mechanisms are also attractive for their environmental safety, effectiveness and ease of use. The need of thermal spray coatings and advancement in terms of materials and spray processes are reviewed in this article. Application and development of thermal spray coatings for steel making hardware from the molten metal processing stages such as electric arc and basic oxygen furnaces, through to continuous casting, annealing, and the galvanizing line; to the final shaping process such as cold and hot rolling of the steel strips are highlighted. Specifically, thermal spray feedstock materials and processes that have potential to replace hazardous hard chrome plating are discussed. It is projected that novel coating solutions will be incorporated as awareness and acceptance of thermal spray technology grows in the steel making sectors, which will improve the productivity of the industry.

Microstructural Evolution, Hardness and Wear Resistance of WC-Co-Ni Composite Coatings Fabricated by Laser Cladding

“…WC-12Co coating powder is widely used as a material with which to coat cast rolls in casting, and to coat pinch rolls in hot rolling [29,30]. The effect of Co content is a trade-off, one in which decreasing Co content increases the wear resistance, but decreases the impact resistance; therefore, Co content should be optimized according to the required coating performance.…”

Termal Sprey Kaplamalarda Kullanılan Ni 22Cr 10Al 1Y Tozunun Özelliklerinin Araştırılması

“…Kaplama teknolojileriyle yapılan yüzey modifikasyonları sayesinde, alt tabaka malzemesi korunur ve malzemenin bozulması gecikir, değiştirme maliyetini azalır, bileşenlerin hizmet ömrünü uzatılır. Kaplama prosesi, bileşenin çalışma şartlarına göre belirlenen bileşen geometrisi ve kimyası, uygun kaplama yöntemi, bağlanma mekanizması, mekanik dayanıklılık, kaplama kalınlığı gibi parametrelere göre belirlenir [1,4,5]. Kaplamalardan yüzeyi korozyona, oksidasyona veya aşınmaya karşı koruma, biyouyumluluk, ıslatma, yapışma, dayanıklılık, katalitik aktivite ve tokluk gibi özellikler beklenir [1,[6][7][8][9].…”

“…Ayrıca bileşimi değiştirmeden özelliklerin değiştirilmesini sağlayan füzyon, katılaştırma, mekanik bağlama ve mekanik deformasyon gibi işlemler de yüzey özelliklerini geliştirmede uygulanmaktadır [1]. Termal püskürtme teknikleri parça imalatı, enerji üretimi, mekanik, tekstil, taşıma, denizcilik, havacılık, mikroelektronik, kağıt, optoelektronik, sağlık, petrokimya ve eğlence endüstrilerinde bileşenlerin korunması ve onarımı gibi geniş alanlarda tercih edilmektedir [1,[4][5][6]. Kısaca, termal sprey kaplama, teknik ve ekonomik sebeplerden dolayı üretilemeyen büyük parçaların yüzeyinde bu malzemenin performansını gerçekleştirmek için yapılır.…”

Tribological performance of thermal sprayed coatings under abrasive conditions

“…During this time, it has evolved and improved to deposit a variety of metallic, ceramic, polymeric and composite materials, and is nowadays recognised as a reliable and cost-efficient method for depositing thick coatings onto industrial components [2]. Examples of thermal sprayed coatings can be found in a variety of industrial and technological fields that range from aerospace [3], automotive [4] and biomedical [5] components, up to vital parts in manufacturing processes [6] and energy production [7]. Recently, thermal spraying is also considered a promising alternative to hard chromium coatings [8], in an effort to minimise the negative environmental impact of hard chromium electroplating processes [9].…”