High temperature normalisation: the impact of scale growth on surface cosmetics and performance of carbon steel conveyance tubes
Lead Research Organisation:
Swansea University
Department Name: College of Engineering
Abstract
Background/Overview
Tata Steel's low carbon steel conveyance tubes undergo a 900 degree C normalisation to remove an undesirable heat affected zone caused by high frequency induction welding. This reheating however, generates significant surface conditioning issues and instigates severe processing inefficiencies due to insufficient protection from high temperature oxidation.
Scale growth on the surface of the tube from normalisation, causes unwanted spallation of subsequent added value coatings compromising Install 235 tube as a high performance, hot formed product. This project aims to improve surface quality and prevent spallation and through delivering a uniform coating, reduce yield loss and failures whilst providing a marketability benefit for conveyance products.
This project will combine high temperature furnace replication experiments with advanced imaging techniques to discover the factors influencing scale growth and the effects of novel preventative coatings on surface quality. Techniques include SEM, EDS, XRD, Profilometry, White-Light Interferometry, Advanced Microscopy and Raman Spectroscopy.
Project Aims
This project will combine high temperature furnace replication experiments with advanced imaging techniques to discover the factors influencing scale growth and the effects of novel preventative coatings on surface quality. Techniques include SEM, EDS, XRD, Profilometry, White-Light Interferometry, Advanced Microscopy and Raman Spectroscopy.
The research engineer will work jointly with TATA Steel (Port Talbot) to investigate how methodologies so developed may be applied to steel slab, used as feedstock for tube production.
Aims:
- To investigate how the mill processing conditions impact surface quality after normalisation due to scale growth.
- To determine suitable methods in which surface quality may be improved, due to alterations in the thermal cycle or through coating solutions prior to reheating.
- Develop new techniques and technologies to assess product quality and facilitate methods of improving adhered oxide remnant after descaling.
- To analyse scale reduction due to new coating solutions before optimising subsequent preventative solutions for the improvement of surface finish of the Tata conveyance products.
- A comprehensive analysis of the causes of surface delamination and the impact of furnace conditions on cosmetic issues due to scale.
- Optimisation of current and novel coating solutions to improve the surface quality of the conveyance tubes.
- Development of a new and improved application technique to enhance coating performance and provide a high-quality surface finish to the steel tubes.
Tata Steel's low carbon steel conveyance tubes undergo a 900 degree C normalisation to remove an undesirable heat affected zone caused by high frequency induction welding. This reheating however, generates significant surface conditioning issues and instigates severe processing inefficiencies due to insufficient protection from high temperature oxidation.
Scale growth on the surface of the tube from normalisation, causes unwanted spallation of subsequent added value coatings compromising Install 235 tube as a high performance, hot formed product. This project aims to improve surface quality and prevent spallation and through delivering a uniform coating, reduce yield loss and failures whilst providing a marketability benefit for conveyance products.
This project will combine high temperature furnace replication experiments with advanced imaging techniques to discover the factors influencing scale growth and the effects of novel preventative coatings on surface quality. Techniques include SEM, EDS, XRD, Profilometry, White-Light Interferometry, Advanced Microscopy and Raman Spectroscopy.
Project Aims
This project will combine high temperature furnace replication experiments with advanced imaging techniques to discover the factors influencing scale growth and the effects of novel preventative coatings on surface quality. Techniques include SEM, EDS, XRD, Profilometry, White-Light Interferometry, Advanced Microscopy and Raman Spectroscopy.
The research engineer will work jointly with TATA Steel (Port Talbot) to investigate how methodologies so developed may be applied to steel slab, used as feedstock for tube production.
Aims:
- To investigate how the mill processing conditions impact surface quality after normalisation due to scale growth.
- To determine suitable methods in which surface quality may be improved, due to alterations in the thermal cycle or through coating solutions prior to reheating.
- Develop new techniques and technologies to assess product quality and facilitate methods of improving adhered oxide remnant after descaling.
- To analyse scale reduction due to new coating solutions before optimising subsequent preventative solutions for the improvement of surface finish of the Tata conveyance products.
- A comprehensive analysis of the causes of surface delamination and the impact of furnace conditions on cosmetic issues due to scale.
- Optimisation of current and novel coating solutions to improve the surface quality of the conveyance tubes.
- Development of a new and improved application technique to enhance coating performance and provide a high-quality surface finish to the steel tubes.
Planned Impact
The CDT will produce 50 graduates with doctoral level knowledge and research skills focussed on the development and manufacture of functional industrial coatings. Key impact areas are:
Knowledge
- The development of new products and processes to address real scientific challenges existing in industry and to transfer this knowledge into partnering companies. The CDT will enable rapid knowledge transfer between academia and industry due to the co-created projects and co-supervision.
- The creation of knowledge sharing network for partner companies created by the environment of the CDT.
- On average 2-3 publications per RE. Publications in high impact factor journals. The scientific scope of the CDT comprises a mixture of interdisciplinary areas and as such a breadth of knowledge can be generated through the CDT. Examples would include Photovoltaic coatings - Journal of Materials Chemistry A (IF 8.867) and Anti-corrosion Coatings - Corrosion Science (IF 5.245), Progress in Organic Coatings (IF 2.903)
- REs will disseminate knowledge at leading conferences e.g. Materials Research Society (MRS), Meetings of the Electrochemical Society, and through trade associations and Institutes representing the coatings sector.
- A bespoke training package on the formulation, function, use, degradation and end of life that will embed the latest research and will be available to industry partners for employees to attend as CPD and for other PGRs demonstrating added value from the CDT environment.
Wealth Creation
- Value added products and processes created through the CDT will generate benefits for Industrial partners and supply chains helping to build a productive nation.
- Employment of graduates into industry will transfer their knowledge and skills into businesses enabling innovation within these companies.
- Swansea University will support potential spin out companies where appropriate through its dedicated EU funded commercialisation project, Agor IP.
Environment and society
- Functionalised surfaces can potentially improve human health through anti-microbial surfaces for health care infrastructure and treatment of water using photocatalytic coatings.
- Functionalised energy generation coatings will contribute towards national strategies regarding clean and secure energy.
- Responsible research and innovation is an overarching theme of the CDT with materials sustainability, ethics, energy and end of life considered throughout the development of new coatings and processes. Thus, REs will be trained to approach all future problems with this mind set.
- Outreach is a critical element of the training programme (for example, a module delivered by the Ri on public engagement) and our REs will have skills that enable the dissemination of their knowledge to wide audiences thus generating interest in science and engineering and the benefits that investments can bring.
People
- Highly employable doctoral gradates with a holistic knowledge of functional coatings manufacture who can make an immediate impact in industry or academia.
- The REs will have transferable skills that are pertinent across multiple sectors.
- The CDT will develop ethically aware engineers with sustainability embed throughout their training
- The promotion of equality, diversity and inclusivity within our cohorts through CDT and University wide initiatives.
- The development of alumni networks to grow new opportunities for our CDT and provide REs with mentors.
Knowledge
- The development of new products and processes to address real scientific challenges existing in industry and to transfer this knowledge into partnering companies. The CDT will enable rapid knowledge transfer between academia and industry due to the co-created projects and co-supervision.
- The creation of knowledge sharing network for partner companies created by the environment of the CDT.
- On average 2-3 publications per RE. Publications in high impact factor journals. The scientific scope of the CDT comprises a mixture of interdisciplinary areas and as such a breadth of knowledge can be generated through the CDT. Examples would include Photovoltaic coatings - Journal of Materials Chemistry A (IF 8.867) and Anti-corrosion Coatings - Corrosion Science (IF 5.245), Progress in Organic Coatings (IF 2.903)
- REs will disseminate knowledge at leading conferences e.g. Materials Research Society (MRS), Meetings of the Electrochemical Society, and through trade associations and Institutes representing the coatings sector.
- A bespoke training package on the formulation, function, use, degradation and end of life that will embed the latest research and will be available to industry partners for employees to attend as CPD and for other PGRs demonstrating added value from the CDT environment.
Wealth Creation
- Value added products and processes created through the CDT will generate benefits for Industrial partners and supply chains helping to build a productive nation.
- Employment of graduates into industry will transfer their knowledge and skills into businesses enabling innovation within these companies.
- Swansea University will support potential spin out companies where appropriate through its dedicated EU funded commercialisation project, Agor IP.
Environment and society
- Functionalised surfaces can potentially improve human health through anti-microbial surfaces for health care infrastructure and treatment of water using photocatalytic coatings.
- Functionalised energy generation coatings will contribute towards national strategies regarding clean and secure energy.
- Responsible research and innovation is an overarching theme of the CDT with materials sustainability, ethics, energy and end of life considered throughout the development of new coatings and processes. Thus, REs will be trained to approach all future problems with this mind set.
- Outreach is a critical element of the training programme (for example, a module delivered by the Ri on public engagement) and our REs will have skills that enable the dissemination of their knowledge to wide audiences thus generating interest in science and engineering and the benefits that investments can bring.
People
- Highly employable doctoral gradates with a holistic knowledge of functional coatings manufacture who can make an immediate impact in industry or academia.
- The REs will have transferable skills that are pertinent across multiple sectors.
- The CDT will develop ethically aware engineers with sustainability embed throughout their training
- The promotion of equality, diversity and inclusivity within our cohorts through CDT and University wide initiatives.
- The development of alumni networks to grow new opportunities for our CDT and provide REs with mentors.
People |
ORCID iD |
| Amitabha Das (Primary Supervisor) | |
| Megan Kendall (Student) |
Studentship Projects
| Project Reference | Relationship | Related To | Start | End | Student Name |
|---|---|---|---|---|---|
| EP/S02252X/1 | 01/10/2019 | 31/03/2028 | |||
| 2597133 | Studentship | EP/S02252X/1 | 01/10/2021 | 30/09/2025 | Megan Kendall |