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Optimisation of Next Generation Galvanising Pot Hardware / GIOVANNI ALPARONE

Swansea University Author: GIOVANNI ALPARONE

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DOI (Published version): 10.23889/SUThesis.69771

Abstract

The aim of this research is to study the corrosion behaviour and tribological properties of ceramics for use as roll bearing materials in the zinc bath of continuous galvanising lines.Bulk ceramic materials were investigated, including hexagonal BN, BN Grade M26,Macor®, AlN-BN, Y2O3-ZrO2, Si3N4 and...

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Published: Swansea University, Wales, UK 2025
Institution: Swansea University
Degree level: Doctoral
Degree name: Ph.D
Supervisor: Penney, D., Sullivan, J., Mills, C., and Edy, J.
URI: https://cronfa.swan.ac.uk/Record/cronfa69771
first_indexed 2025-06-19T12:05:41Z
last_indexed 2025-06-20T04:59:20Z
id cronfa69771
recordtype RisThesis
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spelling 2025-06-19T13:15:47.7649640 v2 69771 2025-06-19 Optimisation of Next Generation Galvanising Pot Hardware a91bebac023ef8a1d649573ca608237d GIOVANNI ALPARONE GIOVANNI ALPARONE true false 2025-06-19 The aim of this research is to study the corrosion behaviour and tribological properties of ceramics for use as roll bearing materials in the zinc bath of continuous galvanising lines.Bulk ceramic materials were investigated, including hexagonal BN, BN Grade M26,Macor®, AlN-BN, Y2O3-ZrO2, Si3N4 and Al2O3, and their performance was compared to stainless steel 316L and WC-Co coatings. Microscopic examination after static testing in Zn-Al and Zn-Al-Mg found that Zn and Al diffusion occurred in stainless steel, and the thickness of WC-Co coatings was reduced from 150 to around 90 µm. Bulk ceramics, however, were observed to not react with the molten bath. Pin-on-disc testing was conducted on the ceramics and hexagonal BN displayed the lowest coefficient of friction (< 0.1).SiAlON, hexagonal and cubic BN ceramic composites were produced with Field Assisted Sintering Technology by varying the content of BN. Additions of hexagonal BN lubricant did not drastically improve the tribological properties, although static corrosion tests confirmed the corrosion resistance of the ceramic composites to molten Zn-Al and Zn-Al-Mg. Static testing was also conducted on Al2O3 coatings; however, the coatings were prone to damage caused by the large thermal expansion mismatch of 13 × 10−6 K−1 with steel and interactions with the Zn-Al-Mg bath occurred.A bespoke rig enabled dynamic testing of two potential bearing system upgrades. The first upgrade involved replacing Wallex6TM with Wallex4TM and the second upgrade replaced WC-Co with Al2O3 coatings. All the WallexTM grades were similarly corroded, although the diffusion of Zn into the WallexTM alloys was reduced by approximately 60% in the Zn-Al-Mg bath compared to Zn-Al. The wear coefficient k determined that minimal wear damage in both Zn-Al (k = 9.7 × 10−6 K−1 mm3N-1m-1) and Zn-Al-Mg (k =3.6 × 10−6 mm3N-1m-1) was obtained when coupling Al2O3 coatings with Wallex6TM. E-Thesis Swansea University, Wales, UK Continuous Galvanising, Steel, Ceramics 17 2 2025 2025-02-17 10.23889/SUThesis.69771 A selection of content is redacted or is partially redacted from this thesis to protect sensitive and personal information. COLLEGE NANME COLLEGE CODE Swansea University Penney, D., Sullivan, J., Mills, C., and Edy, J. Doctoral Ph.D EPSRC, Tata Steel EPSRC, Tata Steel 2025-06-19T13:15:47.7649640 2025-06-19T12:48:38.8285704 Faculty of Science and Engineering School of Engineering and Applied Sciences - Materials Science and Engineering GIOVANNI ALPARONE 1 69771__34522__f40fe16bd2204839ac0d5c053aa5b1d8.pdf 2024_Alparone_G.final.69771.pdf 2025-06-19T13:04:38.6626924 Output 18102998 application/pdf E-Thesis – open access true Copyright: The author, Giovanni Paolo Alparone, 2024 Distributed under the terms of a Creative Commons Attribution 4.0 License (CC BY 4.0). true eng https://creativecommons.org/licenses/by/4.0/
title Optimisation of Next Generation Galvanising Pot Hardware
spellingShingle Optimisation of Next Generation Galvanising Pot Hardware
GIOVANNI ALPARONE
title_short Optimisation of Next Generation Galvanising Pot Hardware
title_full Optimisation of Next Generation Galvanising Pot Hardware
title_fullStr Optimisation of Next Generation Galvanising Pot Hardware
title_full_unstemmed Optimisation of Next Generation Galvanising Pot Hardware
title_sort Optimisation of Next Generation Galvanising Pot Hardware
author_id_str_mv a91bebac023ef8a1d649573ca608237d
author_id_fullname_str_mv a91bebac023ef8a1d649573ca608237d_***_GIOVANNI ALPARONE
author GIOVANNI ALPARONE
author2 GIOVANNI ALPARONE
format E-Thesis
publishDate 2025
institution Swansea University
doi_str_mv 10.23889/SUThesis.69771
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
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description The aim of this research is to study the corrosion behaviour and tribological properties of ceramics for use as roll bearing materials in the zinc bath of continuous galvanising lines.Bulk ceramic materials were investigated, including hexagonal BN, BN Grade M26,Macor®, AlN-BN, Y2O3-ZrO2, Si3N4 and Al2O3, and their performance was compared to stainless steel 316L and WC-Co coatings. Microscopic examination after static testing in Zn-Al and Zn-Al-Mg found that Zn and Al diffusion occurred in stainless steel, and the thickness of WC-Co coatings was reduced from 150 to around 90 µm. Bulk ceramics, however, were observed to not react with the molten bath. Pin-on-disc testing was conducted on the ceramics and hexagonal BN displayed the lowest coefficient of friction (< 0.1).SiAlON, hexagonal and cubic BN ceramic composites were produced with Field Assisted Sintering Technology by varying the content of BN. Additions of hexagonal BN lubricant did not drastically improve the tribological properties, although static corrosion tests confirmed the corrosion resistance of the ceramic composites to molten Zn-Al and Zn-Al-Mg. Static testing was also conducted on Al2O3 coatings; however, the coatings were prone to damage caused by the large thermal expansion mismatch of 13 × 10−6 K−1 with steel and interactions with the Zn-Al-Mg bath occurred.A bespoke rig enabled dynamic testing of two potential bearing system upgrades. The first upgrade involved replacing Wallex6TM with Wallex4TM and the second upgrade replaced WC-Co with Al2O3 coatings. All the WallexTM grades were similarly corroded, although the diffusion of Zn into the WallexTM alloys was reduced by approximately 60% in the Zn-Al-Mg bath compared to Zn-Al. The wear coefficient k determined that minimal wear damage in both Zn-Al (k = 9.7 × 10−6 K−1 mm3N-1m-1) and Zn-Al-Mg (k =3.6 × 10−6 mm3N-1m-1) was obtained when coupling Al2O3 coatings with Wallex6TM.
published_date 2025-02-17T17:59:35Z
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score 11.08899

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