Recovery Act - Nanocomposite Coatings for Life Extension in Zinc Pot Rolls
Department of Energy
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Small Business Information
24112 Rockwell Dr., Euclid, OH, 44117
Socially and Economically Disadvantaged:
AbstractCurrently, zinc pot rolls must be replaced every few days due to degradation of the roll surface and bearings causing dross pickup. This consumes a tremendous amount of energy, as the rolls must be heated up slowly over a period of days to weeks to the proper temperature, and this consumes the majority of energy in galvanizing lines. Under this SBIR MesoCoat will apply low surface energy nanocomposite coatings that are both stable in molten aluminum and zinc, and in air/combustion environments that provide 5-10X life extension for zinc pot rolls compared to current WC-Co or satellite type coatings. These self-lubricating, nanocomposite cermet coatings with low surface tension additives will be applied using thermal spray and high density IR fusion (HDIR) application techniques, and their performance in oxidation and molten zinc exposure will be evaluated leading to field trials with industrial partners. Nanoengineered cermet materials offer low friction, high wear and corrosion resistance, and high toughness combined with low cost application for preventing wear and corrosion in harsh environments. New, large area, on-line application techniques with properly engineered cladding formulations and solves many wear and corrosion problems with oil exploration, infrastructure corrosion, and for rebuilding worn components. Commercial Applications and Other Benefits: Nanocomposite cermets will provide easy machining, very good surface finish, and extreme corrosion and wear resistance, and self-lubrication potential. The ability to metallurgically bond these coatings to steel using pulsed infrared can eliminate spallation issues, and speed the heating rate allowed for these large rolls, further reducing energy consumptions in the hot dip galvanizing industry.
* information listed above is at the time of submission.