Enamel coating for protection of the 316 stainless steel against tribo-corrosion in molten zinc alloy at 460 °C

doi:10.1016/j.jmst.2020.04.079

Abstract

Abstract:

Hot-dip galvanizing provides excellent corrosion and wear resistance for steels. However, the equipment itself, such as the steel roller, immerged in corrosive molten zinc suffers serious material loss during steel’s production. Its protection has become the main technique problem in modern galvanizing line. In this study, an enamel coating was designed and prepared. Its tribo-corrosion in molten zinc alloy (Zn-0.2 wt% Al) at 460 °C was investigated in comparison with the traditional WC-12Co composite coating and the 316 stainless steel. Results indicate that the steel suffers serious material damage. Various corrosion products of Fe₂Al₅Zn_x form at the worn surface and the wear scar has reached 200 μm deep after merely 5 h tribo-corrosion. Though the two coatings provide an improved tribo-corrosion resistance, for the WC-12Co coating, its chemical reaction with the molten zinc increases brittleness and promotes cracking. The synergistic wear and corrosion cause its degradation. The enamel coating performs better during tribo-corrosion. It is chemically stable in molten zinc thus able to provide high corrosion resistance. In addition, the amorphous [SiO₄] network and the self-lubricating CaF₂ crystallite help it to build up an intact amorphous glaze layer readily at surface on sliding, leading to a reduced wear loss. During the whole tribo-corrosion process, the enamel coating is completely free of cracking, and the Zn penetration is inhibited.

Key words: Enamel coating, High temperature corrosion, Liquid alloy, Corrosive wear

Zhongdi Yu, Minghui Chen, Jinlong Wang, Fengjie Li, Shenglong Zhu, Fuhui Wang. Enamel coating for protection of the 316 stainless steel against tribo-corrosion in molten zinc alloy at 460 °C[J]. J. Mater. Sci. Technol., 2021, 65: 126-136.

Figures/Tables 14

Fig. 1. Schematic diagram of the pin-on-disk high temperature tribometer.

Table 1 HVOF parameters of spraying the WC-12Co composite coating.

Kerosene flow (GPH)	Oxygen flow (SCFH)	Air flow (SCFH)	Rotating speed (rpm)	Stress (MPa)	Distance (mm)
6	2000	23	5.5	83	360

Table 2 Nominal composition of the enamel coating (wt%).

SiO₂	B₂O₃	Li₂O	Al₂O₃	Na₂O	CaO	CaF₂
49.5	8	2.5	15	3	15	7

Fig. 2. Cross-sectional microstructures of the 316 stainless steel after tribo-corrosion in molten Zn-0.2Al for: (A) 6000 cycles, and (B) 30,000 cycles.

Fig. 3. XRD pattern (A) and surface morphology (B) of the as-prepared WC-12Co composite coating.

Fig. 4. Surface morphology (A, C) and cross-sectional microstructure (B, D) of the WC-12Co composite coating after wear at 460 °C in molten Zn-0.2Al alloy for: (A, B) 6000 cycles, and (C, D) 30,000 cycles.

Fig. 5. TEM microstructure at interface between the WC-12Co composite coating and the corrosion product after tribo-corrosion at 460 °C in molten Zn-0.2Al for 6000 cycles, along with corresponding SAED patters at areas “a” and “b” and element mappings at area “c”.

Fig. 6. XRD pattern (A) and surface morphology (B) of the as-prepared enamel coating.

Fig. 7. Surface morphology (A, C) and cross-sectional microstructure (B, D) of the enamel coating after wear at 460 °C in molten Zn-0.2Al alloy for: (A, B) 6000 cycles, and (C, D) 30,000 cycles.

Fig. 8. TEM microstructure at interface between the enamel coating and the glaze layer after tribo-corrosion at 460 °C in molten Zn-0.2Al for 6000 cycles, along with corresponding SAED patters at areas “a”, “b”, “c”, and “d”, and element mappings at area “e”.

Fig. 9. Friction coefficient of the 316 stainless steel, the WC-12Co composite coating and the enamel coating in molten Zn-0.2 Al at 460 °C.

Fig. 10. Load-unload curves of the 316 stainless steel, the WC-12Co composite coating and the enamel coating under nano-indentation.

Table 3 Young’s modulus and hardness of the 316 stainless steel and the two coatings.

	316 stainless steel	WC-12Co	Enamel
Young’s modulus	252.7	561.7	233.7
Hardness (GPa)	3.3	23.7	4.3

Fig. 11. Schematic diagram illustrating tribo-corrosion process in molten Zn-0.2Al at 460 °C of: (A) the WC-12Co composite coating, and (B) the enamel coating.

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