Dynamic Testing of Materials for Galvanising Pot Roll Bearings with Improved Performance

Galvanising pot roll bearings are subjected to severe deterioration due to the corrosion of the bearing materials in liquid Zn, resulting in maintenance stops that can cost thousands of pounds per hour in downtime. Dynamic wear testing in molten Zn-Al and Zn-Al-Mg was conducted to assess the corrosion and wear resistance of three material pairs using a bespoke testing rig. The materials investigated in this study were Wallex6^TM coated with WC-Co, stainless steel 316L coated with Al₂O₃, and as-received Wallex6^TM and Wallex4^TM alloys. It was found that only the Al₂O₃ coating remained unreactive in Zn alloy, whereas the materials containing Co were corroded, as evidenced by the formation of intermetallic compounds containing Al-Co-Zn-Fe. The results also highlighted that the dissolution of the Co matrix and diffusion of Zn and Al from the bath occurred in Wallex6^TM and Wallex4^TM. However, the diffusion of Zn into the Wallex^TM alloys was reduced by approximately 60% in the Zn-Al-Mg bath compared to Zn-Al. The wear scars were analysed to determine the wear coefficient of the worn specimens. Out of the three material couplings investigated in this study, minimal wear damage in both Zn-Al and Zn-Al-Mg was only obtained by pairing Wallex6^TM with Al₂O₃ coatings.