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The Application of Thermal Spraying Technology in the Modern Iron and Steel Industry
Release time:
2020-08-30 17:31
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The Application of Thermal Spraying Technology in the Modern Iron and Steel Industry
Steel production—from raw materials to finished products—goes through a variety of processes, including raw material handling, ironmaking, steelmaking, pressure processing, and surface treatment. , The equipment used is numerous and mostly large, heavy-duty machinery. This is because the operating conditions in steel production are extremely harsh. , In production, a large number of equipment failures and damages occur due to factors such as high temperatures, wear, and corrosion. , It severely hinders the improvement of production efficiency and product optimization. As times advance, , The iron and steel industry needs to widely adopt new technologies that are essential for automation, high speed, and high quality. , Higher requirements are placed on equipment performance. Therefore, , Improving the operational performance of equipment and extending its service life have become pressing issues that the iron and steel industry must address urgently in order to enhance enterprise economic efficiency and strengthen its competitiveness in the commodity market.
Thermal spraying technology features a wide variety of sprayable materials. , It can impart multiple functions to the workpiece surface, such as wear resistance, corrosion resistance, and high-temperature resistance, while also featuring simple and flexible processes and operations. , Particularly suitable for on-site construction and localized repair of workpieces. Therefore, , Thermal spraying technology is not only an effective method for surface strengthening and pre-protection of new equipment. , Moreover, it is an effective and economical method for on-site equipment maintenance. , It has been widely used in the steel industry for various general-purpose mechanical components. , Reinforcement and repair of various shaft-type components, valves, fans, and the like. , And it has achieved remarkably significant protective effects and economic benefits. With the advancements in thermal spraying technology in recent years, , The successive introduction of high-energy, high-speed plasma equipment and high-speed flame spraying technology, among others. , As well as the continuous development of various new, high-quality spraying materials. , This has enabled overcoming the previous weaknesses of thermal spray coatings, such as low bonding strength and poor impact resistance. The application of new thermal spraying techniques has brought about a qualitative leap in coating quality. , Coating porosity can be reduced to 0.5 – 1.0%, The bonding strength between the coating and the substrate can be as high as 70 – 140 MPa Therefore, the application of thermal spray coatings in the steel industry has not only expanded in scope. , Moreover, it is expanding into higher-load applications. According to reports, the new Nippon Steel Nagoya Steel Plant... , The application of thermal spraying as a surface modification method for processing rollers is steadily increasing. , The coated area of the rollers processed by this plant. 1990 Only for the year 90 M2, And 1995 The annual figure reaches 456 M2 Growth reaches 5 Multiple times. Rollers used in the surface treatment steel plate manufacturing process, which involves high-value-added coatings. ( Such as annealing furnace rollers and molten galvanizing immersion rollers, etc. ) Its application has also achieved excellent results.
Typical applications of thermal spraying technology in the modern steel industry include:
1. Continuous casting mold copper plate
The surface of the copper plates in continuous casting molds wears down due to friction from the solidifying metal layer. , Chromium plating has long been used to enhance the wear resistance of mold surfaces. However, the hardness of chromium coatings decreases rapidly at high temperatures. ( Figure 1), Its protective performance is not entirely ideal. After adopting a self-fluxing alloy coating that does not significantly lose hardness at high temperatures and supplementing it with technical measures to enhance the bonding between the coating and the substrate, , The durability of the copper plates used in coated continuous casting molds exceeds... 1000 ch￠s (1 ch = 250 ton ), For the chrome plating layer 3 More than double.
Figure 1 High-temperature hardness of spray-coated and chrome-plated layers
2. Continuous casting roll
In continuous casting production lines, components such as support rolls, guide rolls, and clamping rolls are often affected by various factors, including different types of stress and thermal fatigue. , Large cracks develop in the circumferential direction of the roll surface, leading to roll failure and destruction. After reinforcing the roll surface with a self-melting alloy, ... , During use, this coating develops only tiny microcracks with a very low crack propagation rate along its grain boundaries. , It significantly extends the service life of continuous casting rolls and also prevents surface defects from occurring in the cast material. , Improved the quality of the castings.
3. Cold-rolled processing roll
Processing rollers in the cold rolling production line ( Such as tension rollers, guide rollers, and straightening rollers. ) Requires its surface to be wear-resistant. , The change in surface roughness during use should be minimal. , It features a constant clamping force. This roller typically has a chrome-plated surface. , But its wear resistance is insufficient. , affect the service life. However, after applying a thermal spray coating and subjecting it to special treatment, , The change in its surface roughness is very slow. , The surface clamping force is not easy to decrease. ( Figure 2.) The experiment shows that... , The wear resistance of the specially treated coating roller is equivalent to that of a chrome-plated roller. 5 – 10 Twice.
Figure 2 Variations in surface roughness of various coated surfaces
4. Continuous Annealing Furnace Roller
A continuous annealing furnace typically consists of a heating zone, a homogenizing zone, and a cooling zone. , The steel plate is positioned on the furnace rollers inside the furnace. 180° The steel sheet undergoes heat treatment via wrap-around contact. Due to the reduction of oxides on the steel sheet surface into iron under the furnace atmosphere, these oxides adhere to the roll surfaces, forming buildup lumps. , When the steel plate is conveyed through the roller surface, it leaves a pit on the plate, which affects the surface quality of the steel plate.
The automotive industry is experiencing rapid development. , Higher requirements are being placed on the surface quality of cold-rolled and galvanized steel sheets. , To improve the quality of steel plates , CAPL and CGL Furnace roller coating technology has emerged in response to demand. This coating technology... 80 The era began in Japan, 80 It had already been widely adopted and applied to nearly all [things] by the mid-20th century. CAPL and CGL Furnace roller, 80 It only began to receive attention and be applied in Europe and the United States at the end of the century.
Furnace roller coating technology involves using thermal spraying to apply a coating onto the surface of furnace rollers that has low affinity for iron. , Moreover, its coefficient of thermal expansion is matched to that of the furnace roller substrate material. , A coating that also withstands high temperatures and wear while maintaining surface roughness over the long term. This coating can reduce the formation of buildups on the surface of furnace rolls. , Therefore, high-quality automotive steel sheets with excellent surface quality can be obtained.
Corresponding to different processing temperatures , A series of coating materials has been developed. , To meet the needs of different applications, research on new furnace roller coating materials remains highly active. According to reports, countries such as Japan and the United States have successively developed coating materials containing borides and nitrides. , All possess excellent anti-scaling performance, and the furnace rollers with the longest service life can reach... 6 Year.
5. Melting Galvanizing Production Line Department
Components such as immersion rolls, stabilizing rolls, roll bearings, and bearing supports in the hot-dip galvanizing production line. , Immerse yourself in Zn at 450–480℃ In liquid , Suffering from very serious Zinc Liquid corrosion and wear , The working life is generally relatively short. Prevent. Zinc The erosion is mainly prevented. Zinc Diffusion into the coating material , Figure 3. Resistant to various materials and coatings Zinc The performance of liquid erosion. As shown in the figure, , SUS 304 Stainless steel materials are subjected to intense corrosion within a short period of time. Co The self-fluxing alloy has better resistance to molten metals than the aforementioned stainless steel. Zinc The erosion effect is good. , But the deviation is significant; WC - Co Demonstrates the finest melt resistance. Zinc the erosion performance. According to reported data, , With Co Submerged Roll with Self-Fusing Alloy Coating , Its lifespan can reach 150–180 Heaven.
Figure 3 Corrosion Resistance of Coatings and Stainless Steel Against Molten Zinc Erosion
6. Conductive
Conductive rollers for tin plating and zinc plating in electroplating production lines , Made of conductive material Fe system and With you Department of Materials and Hastelloy Corrosion-resistant alloy manufacturing , and coat its surface You or Cr Due to the effects of corrosion, wear, and the adhesion of foreign substances during the electroplating process, , Its lifespan is very short. Generally speaking, , The coating material for electroplated conductive rollers should possess the following properties:
(1) The conductivity meets the requirements of the electroplating process.
(2) Corrosion and wear are unlikely to cause changes in surface characteristics.
(3) The surface should be difficult to have foreign substances adhere to or electrodeposit on it. , Even when attached, it’s easy to remove.
There are reports on various options for coating materials used in electroplated conductive rollers. , One of the amorphous spray coatings is performing well in practical applications. 70 The surface of the celestial body remains unchanged. , And plating Cr The roller's lifespan is only 30 Heaven.
7 ．Concluding remarks
As the steel industry’s demands for surface strengthening of equipment components continue to grow, , As a practical and effective surface treatment technology, thermal spraying will undoubtedly see even wider application in the steel industry.
Guangzhou Sanxin Thermal Spraying specializes in the manufacture of various thermal spraying equipment, including plasma spraying equipment, supersonic spraying equipment, arc spraying equipment, zinc-spraying machines, aluminum-spraying machines; flame powder spraying equipment, flame wire spraying equipment, flame plastic-coating equipment, as well as a wide range of thermal spraying coating services, ceramic coating services, and tungsten carbide coating services.
Relevant Information
The complete set of plasma-sprayed equipment has been shipped to the customer’s site in Thailand.
Core spraying equipment: SX-80 plasma spray main unit, with a 15,000℃ flame suitable for multiple materials including zirconia and silicon carbide; powder feeding accuracy of ±1%, and coating thickness tolerance ≤ ±5 μm. Environmental protection support system: Customized soundproof booth + pulse dust collector—effectively addressing spray noise pollution while achieving highly efficient dust recovery, compliant with Thai environmental standards. Automated equipment: 6-axis industrial robot + intelligent spray cart, enabling precise spraying of complex workpieces and automated loading/unloading, boosting production efficiency by 40%.
On-site engineers provide hands-on training, focusing on the core operations of plasma spraying equipment such as the SX-80. Sanxin has customized a complete solution for its customers, including an automated spraying robotic arm, a soundproof booth, and a dust removal system—ensuring both high spraying efficiency and compliance with environmental standards.
Guangzhou Sanxin Thermal Spraying Turntable Shipment
Guangzhou Sanxin Company manufactures single-station and multi-station thermal spray turntables, which can be paired with plasma equipment, supersonic equipment, and arc equipment. We offer rapid, customized production tailored to customer requirements and product dimensions. A thermal spray turntable is a high-precision rotary worktable specifically designed for thermal spraying processes—including flame spraying, plasma spraying, and arc spraying. By providing controllable rotational speed and exceptional stability, it ensures uniform coating thickness on the workpiece surface, thereby enhancing spraying efficiency and quality.
SX-80 plasma equipment is being used at a customer site in Russia.
SX-80 plasma equipment is being used at a customer site in Russia.
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