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The development of surface treatments on galvanised steel products for the automotive industry utilising a chemcoater / JAMIE WILLIAMS

Swansea University Author: JAMIE WILLIAMS

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DOI (Published version): 10.23889/SUthesis.64906

Abstract

This thesis investigates the development of coatings to be applied via a two-roll roller coating system, a Chemcoater. Novel coatings were investigated to enhance a substrate’s performance and add overall value to the hot-dipped galvanised steel product, by adding fuctionalities such as improved cor...

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Published: Swansea, Wales, UK 2023
Institution: Swansea University
Degree level: Doctoral
Degree name: EngD
Supervisor: Jewell, E. and Challinor, C.
URI: https://cronfa.swan.ac.uk/Record/cronfa64906
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fullrecord <?xml version="1.0" encoding="utf-8"?><rfc1807 xmlns:xsi="http://www.w3.org/2001/XMLSchema-instance" xmlns:xsd="http://www.w3.org/2001/XMLSchema"><bib-version>v2</bib-version><id>64906</id><entry>2023-11-02</entry><title>The development of surface treatments on galvanised steel products for the automotive industry utilising a chemcoater</title><swanseaauthors><author><sid>aa3f756d7421093e83252b412c7b4205</sid><firstname>JAMIE</firstname><surname>WILLIAMS</surname><name>JAMIE WILLIAMS</name><active>true</active><ethesisStudent>false</ethesisStudent></author></swanseaauthors><date>2023-11-02</date><abstract>This thesis investigates the development of coatings to be applied via a two-roll roller coating system, a Chemcoater. Novel coatings were investigated to enhance a substrate’s performance and add overall value to the hot-dipped galvanised steel product, by adding fuctionalities such as improved corrosion resistance, enhanced surface passivation and increased surface lubricity. Historically, hexavalent chromate was a common component of coatings for hot-dipped galvanised steel to provide corrosion protection during material storage and transportation. However, REACH law within the European Union prohibited its use due to its intrinsic toxicity and detrimental environmental effects. This legislation accelerated industry and researchers’ attention toward developing alternative, more environmentally friendly processes. Initial investigations included the analysis of current coatings, PrimeCoat and PLT. Both coatings were shown to have similar rheological characteristics and similar thermal stabilities with PLT performing well as a dry film lubricant. A common laboratory polishing unit was adapted to create a novel Pin-on-Disk tribometer, providing an effective and reliable method for measuring the dynamic coefficient of friction of coated substrates. The adapted unit was designed, built, and commissioned according to ASTM G99-17, and it was able to produce repeatable results for measuring the coefficient of friction. An additional investigation showed that sulphate-based treatments could reduce the coefficient of friction of zinc-coated steel substrates. Tests indicated that a neutral ammonium sulphate solution improved lubricity by 15-10%. Ammonium and sodium sulphate treatments were deemed suitable for coil coating, improving the capacity to reduce oil volume and overall production costs. A systematic study was conducted to improve the processability of a one-step hydrophobic coating. The best-performing coating had a contact angle of 146° with a reduced processing time of ~67%, using IPA as the solvent, 2% wt. 1 M NaOH (aq), 0.2 M stearic acid and micro-SiO2 (0.2–0.3 μm). This method significantly reduced processing time and fewer health and safety risks, avoiding the use of toxic chemicals. On further analysis, the coating was shown to be relatively formable and durable, with no significant reduction in hydrophobic performance after 30% strain was induced. Several corrosion analysis techniques showed increased performance in comparison to uncoated hot-dipped galvanised steel samples. These results suggested that the coating could be a viable option for some industrial applications and showed a potentially positive alternative to banned hexavalent chromate options. The chemical constituents of the newly proposed coatings have significantly less toxicity and pose a reduced negative effect on the wider environment and its users.</abstract><type>E-Thesis</type><journal/><volume/><journalNumber/><paginationStart/><paginationEnd/><publisher/><placeOfPublication>Swansea, Wales, UK</placeOfPublication><isbnPrint/><isbnElectronic/><issnPrint/><issnElectronic/><keywords>Functional coatings, galvanised steel, corrosion resistance</keywords><publishedDay>10</publishedDay><publishedMonth>10</publishedMonth><publishedYear>2023</publishedYear><publishedDate>2023-10-10</publishedDate><doi>10.23889/SUthesis.64906</doi><url/><notes/><college>COLLEGE NANME</college><CollegeCode>COLLEGE CODE</CollegeCode><institution>Swansea University</institution><supervisor>Jewell, E. and Challinor, C.</supervisor><degreelevel>Doctoral</degreelevel><degreename>EngD</degreename><degreesponsorsfunders>Tata Steel UK, EPSRC</degreesponsorsfunders><apcterm/><funders>Tata Steel UK, EPSRC</funders><projectreference/><lastEdited>2023-11-02T14:26:48.4651845</lastEdited><Created>2023-11-02T14:18:40.4810028</Created><path><level id="1">Faculty of Science and Engineering</level><level id="2">School of Engineering and Applied Sciences - Materials Science and Engineering</level></path><authors><author><firstname>JAMIE</firstname><surname>WILLIAMS</surname><order>1</order></author></authors><documents><document><filename>64906__28921__dc277309824c4296910206fca372db8f.pdf</filename><originalFilename>2023_Williams_J.final.64906.pdf</originalFilename><uploaded>2023-11-02T14:21:13.3061241</uploaded><type>Output</type><contentLength>4666567</contentLength><contentType>application/pdf</contentType><version>E-Thesis – open access</version><cronfaStatus>true</cronfaStatus><documentNotes>Copyright: The Author, Jamie Williams, 2023.</documentNotes><copyrightCorrect>true</copyrightCorrect><language>eng</language></document></documents><OutputDurs/></rfc1807>
spelling v2 64906 2023-11-02 The development of surface treatments on galvanised steel products for the automotive industry utilising a chemcoater aa3f756d7421093e83252b412c7b4205 JAMIE WILLIAMS JAMIE WILLIAMS true false 2023-11-02 This thesis investigates the development of coatings to be applied via a two-roll roller coating system, a Chemcoater. Novel coatings were investigated to enhance a substrate’s performance and add overall value to the hot-dipped galvanised steel product, by adding fuctionalities such as improved corrosion resistance, enhanced surface passivation and increased surface lubricity. Historically, hexavalent chromate was a common component of coatings for hot-dipped galvanised steel to provide corrosion protection during material storage and transportation. However, REACH law within the European Union prohibited its use due to its intrinsic toxicity and detrimental environmental effects. This legislation accelerated industry and researchers’ attention toward developing alternative, more environmentally friendly processes. Initial investigations included the analysis of current coatings, PrimeCoat and PLT. Both coatings were shown to have similar rheological characteristics and similar thermal stabilities with PLT performing well as a dry film lubricant. A common laboratory polishing unit was adapted to create a novel Pin-on-Disk tribometer, providing an effective and reliable method for measuring the dynamic coefficient of friction of coated substrates. The adapted unit was designed, built, and commissioned according to ASTM G99-17, and it was able to produce repeatable results for measuring the coefficient of friction. An additional investigation showed that sulphate-based treatments could reduce the coefficient of friction of zinc-coated steel substrates. Tests indicated that a neutral ammonium sulphate solution improved lubricity by 15-10%. Ammonium and sodium sulphate treatments were deemed suitable for coil coating, improving the capacity to reduce oil volume and overall production costs. A systematic study was conducted to improve the processability of a one-step hydrophobic coating. The best-performing coating had a contact angle of 146° with a reduced processing time of ~67%, using IPA as the solvent, 2% wt. 1 M NaOH (aq), 0.2 M stearic acid and micro-SiO2 (0.2–0.3 μm). This method significantly reduced processing time and fewer health and safety risks, avoiding the use of toxic chemicals. On further analysis, the coating was shown to be relatively formable and durable, with no significant reduction in hydrophobic performance after 30% strain was induced. Several corrosion analysis techniques showed increased performance in comparison to uncoated hot-dipped galvanised steel samples. These results suggested that the coating could be a viable option for some industrial applications and showed a potentially positive alternative to banned hexavalent chromate options. The chemical constituents of the newly proposed coatings have significantly less toxicity and pose a reduced negative effect on the wider environment and its users. E-Thesis Swansea, Wales, UK Functional coatings, galvanised steel, corrosion resistance 10 10 2023 2023-10-10 10.23889/SUthesis.64906 COLLEGE NANME COLLEGE CODE Swansea University Jewell, E. and Challinor, C. Doctoral EngD Tata Steel UK, EPSRC Tata Steel UK, EPSRC 2023-11-02T14:26:48.4651845 2023-11-02T14:18:40.4810028 Faculty of Science and Engineering School of Engineering and Applied Sciences - Materials Science and Engineering JAMIE WILLIAMS 1 64906__28921__dc277309824c4296910206fca372db8f.pdf 2023_Williams_J.final.64906.pdf 2023-11-02T14:21:13.3061241 Output 4666567 application/pdf E-Thesis – open access true Copyright: The Author, Jamie Williams, 2023. true eng
title The development of surface treatments on galvanised steel products for the automotive industry utilising a chemcoater
spellingShingle The development of surface treatments on galvanised steel products for the automotive industry utilising a chemcoater
JAMIE WILLIAMS
title_short The development of surface treatments on galvanised steel products for the automotive industry utilising a chemcoater
title_full The development of surface treatments on galvanised steel products for the automotive industry utilising a chemcoater
title_fullStr The development of surface treatments on galvanised steel products for the automotive industry utilising a chemcoater
title_full_unstemmed The development of surface treatments on galvanised steel products for the automotive industry utilising a chemcoater
title_sort The development of surface treatments on galvanised steel products for the automotive industry utilising a chemcoater
author_id_str_mv aa3f756d7421093e83252b412c7b4205
author_id_fullname_str_mv aa3f756d7421093e83252b412c7b4205_***_JAMIE WILLIAMS
author JAMIE WILLIAMS
author2 JAMIE WILLIAMS
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publishDate 2023
institution Swansea University
doi_str_mv 10.23889/SUthesis.64906
college_str Faculty of Science and Engineering
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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
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description This thesis investigates the development of coatings to be applied via a two-roll roller coating system, a Chemcoater. Novel coatings were investigated to enhance a substrate’s performance and add overall value to the hot-dipped galvanised steel product, by adding fuctionalities such as improved corrosion resistance, enhanced surface passivation and increased surface lubricity. Historically, hexavalent chromate was a common component of coatings for hot-dipped galvanised steel to provide corrosion protection during material storage and transportation. However, REACH law within the European Union prohibited its use due to its intrinsic toxicity and detrimental environmental effects. This legislation accelerated industry and researchers’ attention toward developing alternative, more environmentally friendly processes. Initial investigations included the analysis of current coatings, PrimeCoat and PLT. Both coatings were shown to have similar rheological characteristics and similar thermal stabilities with PLT performing well as a dry film lubricant. A common laboratory polishing unit was adapted to create a novel Pin-on-Disk tribometer, providing an effective and reliable method for measuring the dynamic coefficient of friction of coated substrates. The adapted unit was designed, built, and commissioned according to ASTM G99-17, and it was able to produce repeatable results for measuring the coefficient of friction. An additional investigation showed that sulphate-based treatments could reduce the coefficient of friction of zinc-coated steel substrates. Tests indicated that a neutral ammonium sulphate solution improved lubricity by 15-10%. Ammonium and sodium sulphate treatments were deemed suitable for coil coating, improving the capacity to reduce oil volume and overall production costs. A systematic study was conducted to improve the processability of a one-step hydrophobic coating. The best-performing coating had a contact angle of 146° with a reduced processing time of ~67%, using IPA as the solvent, 2% wt. 1 M NaOH (aq), 0.2 M stearic acid and micro-SiO2 (0.2–0.3 μm). This method significantly reduced processing time and fewer health and safety risks, avoiding the use of toxic chemicals. On further analysis, the coating was shown to be relatively formable and durable, with no significant reduction in hydrophobic performance after 30% strain was induced. Several corrosion analysis techniques showed increased performance in comparison to uncoated hot-dipped galvanised steel samples. These results suggested that the coating could be a viable option for some industrial applications and showed a potentially positive alternative to banned hexavalent chromate options. The chemical constituents of the newly proposed coatings have significantly less toxicity and pose a reduced negative effect on the wider environment and its users.
published_date 2023-10-10T14:26:51Z
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score 11.013371

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