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Open AccessArticle

Influence of the Manufacturing Process on Defects in the Galvanized Coating of High Carbon Steel Wires

1
Department of Mechanical and Industrial Engineering, Università degli Studi di Brescia, Via Branze 38, 25123 Brescia, Italy
2
IFP SpA, Via Predalva, 25050 Pian Camuno, Italy
*
Author to whom correspondence should be addressed.
Academic Editor: Jung Ho Je
Materials 2017, 10(3), 264; https://doi.org/10.3390/ma10030264
Received: 10 January 2017 / Revised: 22 February 2017 / Accepted: 28 February 2017 / Published: 6 March 2017
This study is a detailed failure analysis of galvanized high carbon steel wires, which developed coating cracks during the torsion test performed as a quality control at the end of the manufacturing process. Careful visual inspections showed that the cracks are already present in the coating before the torsion test. In order to explain the origin of these cracks, systematic metallographic investigations were performed by means of optical and scanning electron microscope on both the wires and the rods that have been cold drawn to produce the wire. The chemical composition of the galvanized coatings was evaluated by means of energy dispersive spectroscopy. Micro bidimensional X-ray diffraction experiments were also performed to measure the residual stresses in the galvanized coating. The results showed that the failure is related to two main factors: the relatively high content of silicon in the steel and the unsuitable cooling rate of the rods at the exit from the galvanizing bath. The mechanism proposed to explain the origin of the defects was supported by Finite Elements Methods simulations and verified with in-plant tests. The proper countermeasures were then applied and the problem successfully solved. View Full-Text
Keywords: hot-dip galvanizing; high carbon steel wire; cold drawing; defects; FEM; SEM; XRD hot-dip galvanizing; high carbon steel wire; cold drawing; defects; FEM; SEM; XRD
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MDPI and ACS Style

Gelfi, M.; Solazzi, L.; Poli, S. Influence of the Manufacturing Process on Defects in the Galvanized Coating of High Carbon Steel Wires. Materials 2017, 10, 264.

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