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The Development of Novel Coating Solutions for the Improvement of Pre/Post Heat Treatment Performance Properties of Carbon Steel Conveyance Tubes / JAMES GRANT

Swansea University Author: JAMES GRANT

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DOI (Published version): 10.23889/SUthesis.66151

Abstract

Due to the normalisation process at the SR2 Mill in TATA Steel Corby, low carbon steel conveyance tubes generate an unwanted surface oxidation called scale. This is both detrimental to the yield loss and surface cosmetic appearance of the conveyance product. To inhibit this, a coating was designed t...

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Published: Swansea, Wales, UK 2024
Institution: Swansea University
Degree level: Doctoral
Degree name: EngD
Supervisor: Das, A., and Owen, C.
URI: https://cronfa.swan.ac.uk/Record/cronfa66151
first_indexed 2024-04-24T14:26:07Z
last_indexed 2026-02-14T05:17:45Z
id cronfa66151
recordtype RisThesis
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spelling 2026-02-13T14:19:31.2287425 v2 66151 2024-04-24 The Development of Novel Coating Solutions for the Improvement of Pre/Post Heat Treatment Performance Properties of Carbon Steel Conveyance Tubes 36d8fc06a96caa053bac694cacb9803d JAMES GRANT JAMES GRANT true false 2024-04-24 Due to the normalisation process at the SR2 Mill in TATA Steel Corby, low carbon steel conveyance tubes generate an unwanted surface oxidation called scale. This is both detrimental to the yield loss and surface cosmetic appearance of the conveyance product. To inhibit this, a coating was designed to be applied prior to the normalisation stage to protect the steel surface. The construction and use of a purpose-built controlled atmosphere furnace allowed coating trials to experience the 9% O2 in the SR2 mill. Samples were heat treated using a pre-set thermal cycle and metallurgically prepared for optical microscope and SEM analysis. After a wide scope of coatings trials, two solutions were determined to be effective in scale prevention and were optimised by observing the oxidation kinetics, thermomechanical and phase properties. The first coating, utilised Na5P3O10 in combination with an acrylic addition to produce an impermeable phosphate coating through sol-gel application. This solution reduced oxidation by 82.1% and surface roughness improved by 41.1%. Using Laser Flash Analysis and Differential Scanning Calorimetry, it was determined that the thermal conductivity of this coating was between 0.6-1.0W/mK which may affect thermal transfer. The second coating was a silicate-based solution which was a mullite material reinforced with ZrO2 for improved porosity traits. This solution reduced oxidation by 94.9% but increased surface roughness by 14.7%. An initial investigation of the untreated steel found that there was a clear point at 650°C where wüstite domination was prominent and that furnace atmospheres with <6% O2 caused the wüstite – magnetite ratio to reduce from 94% to 88%. E-Thesis Swansea, Wales, UK Tube Production, Scale, Oxide-Inhibition Coatings, Silicates, Phosphates, Normalisation 21 2 2024 2024-02-21 10.23889/SUthesis.66151 A selection of third party content is redacted or is partially redacted from this thesis due to copyright restrictions. COLLEGE NANME COLLEGE CODE Swansea University Das, A., and Owen, C. Doctoral EngD EPSRC , WEFO , M2A EPSRC , WEFO , M2A 2026-02-13T14:19:31.2287425 2024-04-24T15:18:22.9505293 Faculty of Science and Engineering School of Engineering and Applied Sciences - Materials Science and Engineering JAMES GRANT 1 66151__36229__9ad20661f359445b8c5df4566b2b13f1.pdf Grant_James_PhD_Thesis_Redacted_Final_Cronfa.pdf 2026-02-13T13:37:36.3255853 Output 11124671 application/pdf Redacted version - open access true Copyright: The author, James D. Grant, 2022. true eng
title The Development of Novel Coating Solutions for the Improvement of Pre/Post Heat Treatment Performance Properties of Carbon Steel Conveyance Tubes
spellingShingle The Development of Novel Coating Solutions for the Improvement of Pre/Post Heat Treatment Performance Properties of Carbon Steel Conveyance Tubes
JAMES GRANT
title_short The Development of Novel Coating Solutions for the Improvement of Pre/Post Heat Treatment Performance Properties of Carbon Steel Conveyance Tubes
title_full The Development of Novel Coating Solutions for the Improvement of Pre/Post Heat Treatment Performance Properties of Carbon Steel Conveyance Tubes
title_fullStr The Development of Novel Coating Solutions for the Improvement of Pre/Post Heat Treatment Performance Properties of Carbon Steel Conveyance Tubes
title_full_unstemmed The Development of Novel Coating Solutions for the Improvement of Pre/Post Heat Treatment Performance Properties of Carbon Steel Conveyance Tubes
title_sort The Development of Novel Coating Solutions for the Improvement of Pre/Post Heat Treatment Performance Properties of Carbon Steel Conveyance Tubes
author_id_str_mv 36d8fc06a96caa053bac694cacb9803d
author_id_fullname_str_mv 36d8fc06a96caa053bac694cacb9803d_***_JAMES GRANT
author JAMES GRANT
author2 JAMES GRANT
format E-Thesis
publishDate 2024
institution Swansea University
doi_str_mv 10.23889/SUthesis.66151
college_str Faculty of Science and Engineering
hierarchytype
hierarchy_top_id facultyofscienceandengineering
hierarchy_top_title Faculty of Science and Engineering
hierarchy_parent_id facultyofscienceandengineering
hierarchy_parent_title Faculty of Science and Engineering
department_str School of Engineering and Applied Sciences - Materials Science and Engineering{{{_:::_}}}Faculty of Science and Engineering{{{_:::_}}}School of Engineering and Applied Sciences - Materials Science and Engineering
document_store_str 1
active_str 0
description Due to the normalisation process at the SR2 Mill in TATA Steel Corby, low carbon steel conveyance tubes generate an unwanted surface oxidation called scale. This is both detrimental to the yield loss and surface cosmetic appearance of the conveyance product. To inhibit this, a coating was designed to be applied prior to the normalisation stage to protect the steel surface. The construction and use of a purpose-built controlled atmosphere furnace allowed coating trials to experience the 9% O2 in the SR2 mill. Samples were heat treated using a pre-set thermal cycle and metallurgically prepared for optical microscope and SEM analysis. After a wide scope of coatings trials, two solutions were determined to be effective in scale prevention and were optimised by observing the oxidation kinetics, thermomechanical and phase properties. The first coating, utilised Na5P3O10 in combination with an acrylic addition to produce an impermeable phosphate coating through sol-gel application. This solution reduced oxidation by 82.1% and surface roughness improved by 41.1%. Using Laser Flash Analysis and Differential Scanning Calorimetry, it was determined that the thermal conductivity of this coating was between 0.6-1.0W/mK which may affect thermal transfer. The second coating was a silicate-based solution which was a mullite material reinforced with ZrO2 for improved porosity traits. This solution reduced oxidation by 94.9% but increased surface roughness by 14.7%. An initial investigation of the untreated steel found that there was a clear point at 650°C where wüstite domination was prominent and that furnace atmospheres with <6% O2 caused the wüstite – magnetite ratio to reduce from 94% to 88%.
published_date 2024-02-21T05:16:14Z
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score 11.098272

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