Image Credit: Craig Holbrook

Coating Processes

Project C1.1 Intermetallic Formation and Development in Metal Coating Pot

The extent to which intermetallic compounds (IMCs) affect both the metal coating product and process is governed by their relative rate of generation, growth, and removal from the coating bath. This research will provide in-depth understanding of how operational factors control the generation and growth of IMC particles in the coating bath and how the coating process may be optimised. This knowledge will be used to deliver improvements in the manufacture and quality of next generation metallic coated steel products.

Team: Ma Qian, Daniel Parker, Syed Islam, David St John, Jason Hodges, Abdul Khaliq, Rex Chen, Nega Setargew

Project C2.1 Liquid Metal Properties, Processing and Coating Quality

The production of thin, stable metallic coatings on steel substrates is challenging but is thought to be related to the physical properties of the liquid coating leading up to and including its solidification. Current knowledge of the formation of these coatings suggests that the physical properties of the liquid, the interface between the liquid and atmosphere, and the interface between the liquid and the substrate all play a crucial role in coating formation. In the case of Al-Zn and Al-Zn-Mg alloys, the melt surface oxide and the alloy layer between the coating overlay and the steel strip form the basis of these interfaces. This project aims to generate new fundamental knowledge of liquid alloy properties, such as surface tension, viscosity and density, and understand how these vary with processing conditions, alloy composition and atmospheric exposure.

Team: Kazuhiro Nogita, Wayne Renshaw, Dongdong Qu, Matt Gear, Stuart McDonald, Nega Setargew, David StJohn, Jason Hodges

Project C2.3: Fluid Dynamic Phenomena Affecting the Liquid Coating Quality in the Jet Stripping Line

In the continuous galvanizing process, the thickness, quality and stability of the thin, metal coating film on steel strip depends partially on the operational performance of air-knives used to wipe the excess coating – a process known as jet stripping. This project aims to understand the mechanisms that lead to complex fluid dynamic and interfacial phenomena associated with the stability of the liquid coating surface in the jet stripping line. The knowledge will be used to identify methods to optimise process line parameters and control surface quality. Various sophisticated computational and experimental techniques will be employed to elucidate and validate these mechanisms.

Team: Buyung Kosasih, Wayne Renshaw, Andrew Dixon, Andrew Johnstone, Le Quang Phan, Owen Milner, Rubel Ahmed,Jason Hodges, Paul Zulli