Intermetallic Compounds Formation during 316L Stainless Steel Reaction with Al-Zn-Si Coating Alloy
Steel products are coated with Aluminum (Al) and Zinc (Zn) alloys to improve their corrosion properties. Bulk steel products are coated in batches; however, steel sheets are coated by a continuous hot-dip galvanizing process. Steel sheets are guided into and out of the molten Al-Zn-Si (AZ) bath with...
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MDPI AG
2022-05-01
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| Series: | Crystals |
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| Online Access: | https://www.mdpi.com/2073-4352/12/5/735 |
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| author | Abdul Khaliq Abdulaziz S. Alghamdi Mohamed Ramadan Tayyab Subhani Wajdi Rajhi Waseem Haider Mohammad Mehedi Hasan |
| author_facet | Abdul Khaliq Abdulaziz S. Alghamdi Mohamed Ramadan Tayyab Subhani Wajdi Rajhi Waseem Haider Mohammad Mehedi Hasan |
| author_sort | Abdul Khaliq |
| collection | DOAJ |
| description | Steel products are coated with Aluminum (Al) and Zinc (Zn) alloys to improve their corrosion properties. Bulk steel products are coated in batches; however, steel sheets are coated by a continuous hot-dip galvanizing process. Steel sheets are guided into and out of the molten Al-Zn-Si (AZ) bath with the help of stainless-steel rolls, known as guiding, and sink rolls. These rolls are subjected to excessive surface corrosion with molten AZ bath and, hence, are replaced frequently. The surface deterioration of the immersed rolls has been a long-standing issue in the galvanizing industry. In this study, 316L stainless-steel (SS) rods are immersed in the AZ alloy at 600 °C. The immersion time varied from 1 day to 7 days under the static melt conditions in the iron (Fe)-saturated AZ bath. Microstructural analysis of the immersed SS samples revealed two distinct intermetallic compound (IMC) layers forming between the SS substrate and AZ alloy. The IMC layer 1 (AL-1) formed between the SS substrate and IMC layer 2 (AL-2), growing in thickness from 68 µm to 120 µm within 5 days of immersion. The AL-2, which formed between AL-1 and AZ alloy after 24 h of immersion, then grew in thickness up to 150 µm with an uneven trend. The AL-1 is composed of Fe<sub>2</sub>Al<sub>5</sub> and that of AL-2 is composed of FeAl<sub>3</sub> that were predicted by the FactSage thermodynamic analysis. Crack development between AL-1 and AL-2 layers, and disintegration of AL-2 into the AZ bath, are key findings of this study. A drastic hardness increase was observed because the IMC layers produce a hard and brittle sink roll surface. |
| first_indexed | 2024-03-10T03:05:08Z |
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| issn | 2073-4352 |
| language | English |
| last_indexed | 2024-03-10T03:05:08Z |
| publishDate | 2022-05-01 |
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| record_format | Article |
| series | Crystals |
| spelling | doaj.art-c1614e116d154629937a9b334b47f6a72023-11-23T10:36:17ZengMDPI AGCrystals2073-43522022-05-0112573510.3390/cryst12050735Intermetallic Compounds Formation during 316L Stainless Steel Reaction with Al-Zn-Si Coating AlloyAbdul Khaliq0Abdulaziz S. Alghamdi1Mohamed Ramadan2Tayyab Subhani3Wajdi Rajhi4Waseem Haider5Mohammad Mehedi Hasan6College of Engineering, University of Ha’il, P.O. Box 2440, Hail 53962, Saudi ArabiaCollege of Engineering, University of Ha’il, P.O. Box 2440, Hail 53962, Saudi ArabiaCollege of Engineering, University of Ha’il, P.O. Box 2440, Hail 53962, Saudi ArabiaCollege of Engineering, University of Ha’il, P.O. Box 2440, Hail 53962, Saudi ArabiaCollege of Engineering, University of Ha’il, P.O. Box 2440, Hail 53962, Saudi ArabiaSchool of Engineering and Technology, Central Michigan University, Mount Pleasant, MI 48859, USADepartment of Mechanical Engineering and Product Design Engineering, Swinburne University of Technology, Melbourne 3122, AustraliaSteel products are coated with Aluminum (Al) and Zinc (Zn) alloys to improve their corrosion properties. Bulk steel products are coated in batches; however, steel sheets are coated by a continuous hot-dip galvanizing process. Steel sheets are guided into and out of the molten Al-Zn-Si (AZ) bath with the help of stainless-steel rolls, known as guiding, and sink rolls. These rolls are subjected to excessive surface corrosion with molten AZ bath and, hence, are replaced frequently. The surface deterioration of the immersed rolls has been a long-standing issue in the galvanizing industry. In this study, 316L stainless-steel (SS) rods are immersed in the AZ alloy at 600 °C. The immersion time varied from 1 day to 7 days under the static melt conditions in the iron (Fe)-saturated AZ bath. Microstructural analysis of the immersed SS samples revealed two distinct intermetallic compound (IMC) layers forming between the SS substrate and AZ alloy. The IMC layer 1 (AL-1) formed between the SS substrate and IMC layer 2 (AL-2), growing in thickness from 68 µm to 120 µm within 5 days of immersion. The AL-2, which formed between AL-1 and AZ alloy after 24 h of immersion, then grew in thickness up to 150 µm with an uneven trend. The AL-1 is composed of Fe<sub>2</sub>Al<sub>5</sub> and that of AL-2 is composed of FeAl<sub>3</sub> that were predicted by the FactSage thermodynamic analysis. Crack development between AL-1 and AL-2 layers, and disintegration of AL-2 into the AZ bath, are key findings of this study. A drastic hardness increase was observed because the IMC layers produce a hard and brittle sink roll surface.https://www.mdpi.com/2073-4352/12/5/735IMCsAl-Zn-Si alloystainless steelsink rollsgalvanizingcoating |
| spellingShingle | Abdul Khaliq Abdulaziz S. Alghamdi Mohamed Ramadan Tayyab Subhani Wajdi Rajhi Waseem Haider Mohammad Mehedi Hasan Intermetallic Compounds Formation during 316L Stainless Steel Reaction with Al-Zn-Si Coating Alloy Crystals IMCs Al-Zn-Si alloy stainless steel sink rolls galvanizing coating |
| title | Intermetallic Compounds Formation during 316L Stainless Steel Reaction with Al-Zn-Si Coating Alloy |
| title_full | Intermetallic Compounds Formation during 316L Stainless Steel Reaction with Al-Zn-Si Coating Alloy |
| title_fullStr | Intermetallic Compounds Formation during 316L Stainless Steel Reaction with Al-Zn-Si Coating Alloy |
| title_full_unstemmed | Intermetallic Compounds Formation during 316L Stainless Steel Reaction with Al-Zn-Si Coating Alloy |
| title_short | Intermetallic Compounds Formation during 316L Stainless Steel Reaction with Al-Zn-Si Coating Alloy |
| title_sort | intermetallic compounds formation during 316l stainless steel reaction with al zn si coating alloy |
| topic | IMCs Al-Zn-Si alloy stainless steel sink rolls galvanizing coating |
| url | https://www.mdpi.com/2073-4352/12/5/735 |
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