Technovations International Inc
Thermal Spray Coating for Steel Processing
Ram K. Iyengar, Technovations International Inc, Littleton, MA USA978-952-2955, firstname.lastname@example.org
Thermal spray coatingThermal spray coatings on the rolls in annealing, galvanizing, and othersteelmaking and processing sections can ensure an economically viable life at aSteel Plant.
Thermal spray coating provides an additional tool to materials engineer to overcome the problems of wear, oxidation and corrosion. There are several operations in steel processing that can benefit from the surface engineering solutions because of the followingcharacteristics of thermal pray coating:
Thermal spray coatings of a wide range of materials from pure metals to cermetshave satisfactory adherence between the substrate and the coating.
High erosion resistance against molten metal is the most important property for the use of thermal spray coating in galvanizing and aluminizing lines.
Thermal spray coating with hard cermets such as tungsten carbide has shown anexcellent load bearing capacity with an absence of wear under high load.
Thermal spray coatings have strong adhesion to the substrate and do not requiregrinding to finish.
The hardness of thermal sprayed tungsten carbide-cobalt chromium coating issimilar to hard chrome plating. The coatings are 100 times more abrasive wear resistant than hard chrome. In comparison with 316 stainless steel, thermal spraycoating offer relatively good corrosion protection.
Thermal spray coating can be functionally graded to provide thermal shock resistance when there is a large difference in the coefficient of thermal expansion between the topcoat and the substrate.
Powder particles are heated to targeted temperature and accelerated to velocityapproaching that of the gaseous jet. The powder particles are plastically flattened on thesurface and form a coating. This process provides coating with low porosity and highadhesion. Additionally, when the particles are not melted the process practically does notoxidize spray powders. This creates perfect conditions for coating sintering during serviceunder elevated temperature in zinc bath.
Thermal spray coating processes are based on heating powdered materials to appropriatetemperature and propelling them at supersonic velocity against the roll surfaces to produce coatings with desired properties. These processes include: high velocity oxygenfuel, activated combustion high velocity air, plasma, arc etc. These processes operate atdifferent temperatures with particle velocities reaching up to Mach 3. The particle