US20170001415A1 - Steel Armor Wire Coatings - Google Patents
Steel Armor Wire Coatings Download PDFInfo
- Publication number
- US20170001415A1 US20170001415A1 US15/264,859 US201615264859A US2017001415A1 US 20170001415 A1 US20170001415 A1 US 20170001415A1 US 201615264859 A US201615264859 A US 201615264859A US 2017001415 A1 US2017001415 A1 US 2017001415A1
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- Prior art keywords
- wire
- layer
- metal
- ferrous
- zinc
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B15/00—Layered products comprising a layer of metal
- B32B15/01—Layered products comprising a layer of metal all layers being exclusively metallic
- B32B15/013—Layered products comprising a layer of metal all layers being exclusively metallic one layer being formed of an iron alloy or steel, another layer being formed of a metal other than iron or aluminium
- B32B15/015—Layered products comprising a layer of metal all layers being exclusively metallic one layer being formed of an iron alloy or steel, another layer being formed of a metal other than iron or aluminium the said other metal being copper or nickel or an alloy thereof
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B15/00—Layered products comprising a layer of metal
- B32B15/01—Layered products comprising a layer of metal all layers being exclusively metallic
- B32B15/013—Layered products comprising a layer of metal all layers being exclusively metallic one layer being formed of an iron alloy or steel, another layer being formed of a metal other than iron or aluminium
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C18/00—Alloys based on zinc
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C27/00—Alloys based on rhenium or a refractory metal not mentioned in groups C22C14/00 or C22C16/00
- C22C27/04—Alloys based on tungsten or molybdenum
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C30/00—Alloys containing less than 50% by weight of each constituent
- C22C30/06—Alloys containing less than 50% by weight of each constituent containing zinc
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C16/00—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes
- C23C16/06—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the deposition of metallic material
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C2/00—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor
- C23C2/02—Pretreatment of the material to be coated, e.g. for coating on selected surface areas
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C2/00—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor
- C23C2/04—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor characterised by the coating material
- C23C2/06—Zinc or cadmium or alloys based thereon
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C2/00—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor
- C23C2/26—After-treatment
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C2/00—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor
- C23C2/34—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor characterised by the shape of the material to be treated
- C23C2/36—Elongated material
- C23C2/38—Wires; Tubes
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
- C23C28/02—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings only including layers of metallic material
- C23C28/021—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings only including layers of metallic material including at least one metal alloy layer
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
- C23C28/02—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings only including layers of metallic material
- C23C28/023—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings only including layers of metallic material only coatings of metal elements only
- C23C28/025—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings only including layers of metallic material only coatings of metal elements only with at least one zinc-based layer
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/02—Pretreatment of the material to be coated, e.g. for coating on selected surface areas
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
- C23C4/06—Metallic material
- C23C4/08—Metallic material containing only metal elements
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
- C23C4/134—Plasma spraying
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/18—After-treatment
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23F—NON-MECHANICAL REMOVAL OF METALLIC MATERIAL FROM SURFACE; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL; MULTI-STEP PROCESSES FOR SURFACE TREATMENT OF METALLIC MATERIAL INVOLVING AT LEAST ONE PROCESS PROVIDED FOR IN CLASS C23 AND AT LEAST ONE PROCESS COVERED BY SUBCLASS C21D OR C22F OR CLASS C25
- C23F15/00—Other methods of preventing corrosion or incrustation
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- C—CHEMISTRY; METALLURGY
- C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
- C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
- C25D3/00—Electroplating: Baths therefor
- C25D3/02—Electroplating: Baths therefor from solutions
- C25D3/12—Electroplating: Baths therefor from solutions of nickel or cobalt
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- C—CHEMISTRY; METALLURGY
- C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
- C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
- C25D3/00—Electroplating: Baths therefor
- C25D3/02—Electroplating: Baths therefor from solutions
- C25D3/22—Electroplating: Baths therefor from solutions of zinc
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- C—CHEMISTRY; METALLURGY
- C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
- C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
- C25D3/00—Electroplating: Baths therefor
- C25D3/02—Electroplating: Baths therefor from solutions
- C25D3/54—Electroplating: Baths therefor from solutions of metals not provided for in groups C25D3/04 - C25D3/50
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- C—CHEMISTRY; METALLURGY
- C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
- C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
- C25D3/00—Electroplating: Baths therefor
- C25D3/02—Electroplating: Baths therefor from solutions
- C25D3/56—Electroplating: Baths therefor from solutions of alloys
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- C—CHEMISTRY; METALLURGY
- C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
- C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
- C25D5/00—Electroplating characterised by the process; Pretreatment or after-treatment of workpieces
- C25D5/10—Electroplating with more than one layer of the same or of different metals
- C25D5/12—Electroplating with more than one layer of the same or of different metals at least one layer being of nickel or chromium
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- C—CHEMISTRY; METALLURGY
- C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
- C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
- C25D7/00—Electroplating characterised by the article coated
- C25D7/06—Wires; Strips; Foils
- C25D7/0607—Wires
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- B32B2311/00—Metals, their alloys or their compounds
- B32B2311/20—Zinc
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- B32B2311/00—Metals, their alloys or their compounds
- B32B2311/30—Iron, e.g. steel
Definitions
- the present disclosure relates to steel armor wire strength member coating compositions, structures, and processes.
- Armor wire strength members used in wireline cables for oilfield applications are often composed of galvanized improved plow steel (GIPS).
- GIPS galvanized improved plow steel
- the steel substrate is coated with zinc via a hot dip galvanization process.
- the hot dip galvanization process involves immersion of the steel substrate in molten zinc at a temperature of around 860° F. (460° C.).
- the strength and hardness of unalloyed zinc are greater than those of tin or lead, but less than those of aluminum or copper. Except when very pure, zinc is brittle at ambient temperatures, but zinc becomes ductile at around 100° C. Pure zinc rapidly recrystallizes after deformation at ambient temperature because of the high mobility of the atoms within the lattice. Thus, zinc typically cannot be work-hardened at ambient temperature.
- Hot dip zinc coatings provide corrosion protection in a range of atmospheric and low temperature aqueous environments such as humid atmospheric conditions, natural weathering conditions, soil environments, salt-spray testing conditions and under low temperature aqueous/brine immersion conditions. This corrosion protection may be relevant when GIPS armor wire components of wireline cables are stored between wireline logging operations.
- Zinc-based coatings may fall into several categories: pure zinc, zinc-iron, zinc-aluminum, zinc-nickel and zinc composites.
- zinc coatings are produced by hot-dipping, electroplating, mechanical bonding, sherardizing and thermal spraying.
- the hot-dip methods are further divided into two processes: (1) the continuous process in which long strands of sheet, wire or tubing are continuously fed through a bath of molten zinc; and (2) the batch process in which fabricated parts such as fasteners, poles or beams are dipped into molten zinc, either individually or in discrete batches.
- zinc electroplating can be performed in a continuous or batch mode.
- the present disclosure provides a wire and a process of forming a wire.
- Embodiments of the wire can include a ferrous wire core, an interface layer circumferentially surrounding the ferrous wire core, and an outer layer circumferentially surrounding the interface layer.
- the interface layer can include nickel, molybdenum or a nickel alloy, for example.
- the outer layer can include zinc or a zinc alloy, for example.
- Embodiments of the wire can include a ferrous wire core, an inner zinc layer circumferentially surrounding the ferrous wire core, an Fe layer circumferentially surrounding the inner zinc layer, and an interface layer circumferentially surrounding the Fe layer.
- the interface layer can include nickel or molybdenum, for example.
- Embodiments of the wire can include a ferrous wire core and a layer circumferentially surrounding the ferrous wire core.
- the layer circumferentially surrounding the ferrous wire core can include nickel, molybdenum or a nickel alloy.
- the layer circumferentially surrounding the ferrous wire core can be present without an overlying zinc or zinc alloy layer.
- the layer including nickel, molybdenum or a nickel alloy can act as a protective layer in oil and gas downhole conditions and in surface storage conditions.
- Embodiments of the process of forming a wire can include placing a metal strip alongside a ferrous wire core.
- the metal strip can include Zn, Ni, Mo, or Fe, for example.
- the process can include bending the metal strip circumferentially around the ferrous wire core.
- the process can include seam welding the metal strip to form a metal tube around the ferrous wire core.
- Embodiments of the process of forming a wire can include applying a metal layer to a ferrous metal rod to form a plated rod.
- the metal layer can include Zn, Ni, or Mo, for example.
- the process can include placing a metal strip alongside the plated rod.
- the metal strip can include Zn, Ni, Mo, or Fe, for example.
- the process can include bending the metal strip circumferentially around the plated rod.
- the process can include seam welding the metal strip to form a metal tube around the plated rod.
- the process of forming a wire can include coating a ferrous wire core with a layer of nickel, molybdenum or a nickel alloy.
- the layer can circumferentially surround the ferrous wire core.
- the layer circumferentially surrounding the ferrous wire core can be present without an overlying zinc or zinc alloy layer.
- FIG. 1 is a first cross sectional view of steel armor wire consistent with at least one embodiment of the present disclosure.
- FIG. 2 is a second cross sectional view of steel armor wire consistent with at least one embodiment of the present disclosure.
- FIG. 3 is a third cross sectional view of steel armor wire consistent with at least one embodiment of the present disclosure.
- FIG. 4 is a fourth a cross sectional view of steel armor wire consistent with at least one embodiment of the present disclosure.
- FIG. 5 depicts a gas plasma coating system consistent with at least one embodiment of the present disclosure.
- FIG. 6 depicts an electrolytic plasma coating system consistent with at least one embodiment of the present disclosure.
- FIG. 7 depicts an electroplating system consistent with at least one embodiment of the present disclosure.
- FIGS. 8 a -8 d depict a method of forming a wire consistent with at least one embodiment of the present disclosure.
- FIGS. 9 a -9 e depict a method of forming a wire consistent with at least one embodiment of the present disclosure.
- FIG. 10 depicts a hot dip galvanizing process consistent with at least one embodiment of the present disclosure.
- Wireline is a single-strand or multi-strand wire or cable for intervention in oil or gas wells.
- a wireline is commonly used in association with electric logging and cables incorporating electrical conductors.
- Such augmented wireline is termed “armor wire.”
- FIG. 1 depicts wire 100 consistent with at least one embodiment of the present disclosure.
- Wire 100 includes ferrous wire core 110 .
- a ferrous wire core is a steel wire.
- Interface metal layer 120 circumferentially surrounds ferrous wire core 110 .
- Interface metal layer 120 may be composed of, for instance, nickel, molybdenum, or nickel-rich alloy. In certain embodiments, interface metal layer 120 may have a thickness of between 2 and 60 microns.
- Outer layer 130 circumferentially surrounds interface metal layer 120 . Outer layer 130 may be composed of zinc or a zinc alloy.
- the zinc alloy may include, but is not limited to, a binary Zn—Ni or Zn—Co alloy or a ternary Zn—Ni—Co, Zn—Ni—Mo or Zn—Co—Mo alloy.
- outer layer 130 may have a thickness of from about 1 to about 50 microns. Without being bound by theory, it is believed that the interposition of the interface metal layer 120 between ferrous wire core 110 and outer layer 130 acts as a barrier protection for the ferrous wire core 110 when wire 100 is exposed to harsh temperature and other environmental conditions, such as those that exist downhole in oil and gas fields. Further, without being bound by theory, it is believed that the zinc or zinc alloy in outer layer 130 provides sacrificial protection of the underlying layers during storage, such as wireline cable storage conditions between successive wireline logging jobs.
- FIG. 2 depicts wire 200 consistent with at least one embodiment of the present disclosure.
- Wire 200 includes ferrous wire core 110 .
- a ferrous wire core 110 is a steel wire.
- Interface metal layer 120 circumferentially surrounds ferrous wire core 110 .
- Interface metal layer 120 may be composed of nickel or molybdenum.
- interface metal layer 120 may have a thickness of from about 2 to about 50 microns. Without being bound by theory, interface metal layer 120 may serve as a stop layer for corrosion if the outer layer 130 (described below) is compromised.
- Fe layer 140 circumferentially surrounds interface metal layer 120 . In certain embodiments, Fe layer 140 may have a thickness of from about 2 to about 20 microns.
- Outer layer 130 circumferentially surrounds Fe layer 140 .
- Outer layer 130 may be composed of zinc or a zinc alloy.
- the zinc alloy can include, but is not limited to, a binary Zn—Ni or Zn—Co alloy, or a ternary Zn—Ni—Co, Zn—Ni—Mo or Zn—Co—Mo alloy.
- outer layer 130 may have a thickness of between 1 and 50 microns.
- FIG. 3 depicts wire 300 consistent with at least one embodiment of the present disclosure.
- Wire 300 includes ferrous wire core 110 .
- ferrous wire core 110 is a steel wire.
- Inner zinc layer 150 circumferentially surrounds ferrous wire core 110 .
- inner zinc layer 150 is between 2 and 50 microns in thickness.
- Fe layer 140 circumferentially surrounds inner zinc layer 150 .
- Fe layer 140 may have a thickness of between 2 and 20 microns.
- Interface metal layer 120 circumferentially surrounds Fe layer 140 and may be composed of nickel or molybdenum. In certain embodiments, interface metal layer 120 may have a thickness of from about 2 to about 50 microns.
- FIG. 4 depicts a cross sectional view of wire 1000 .
- Wire 1000 includes ferrous wire core 110 .
- Wire 1000 includes a layer 1120 , such as a Ni, Mo, or Ni alloy coating, circumferentially surrounding the ferrous wire core 110 .
- the layer 1120 circumferentially surrounding the ferrous wire core 110 can be present without an overlying zinc or zinc alloy layer.
- the layer 1120 can act as a protective layer in oil and gas downhole conditions and in surface storage conditions.
- the successive metal layers depicted in FIGS. 1-4 may be deposited by any number of methods, including but not limited to gas plasma, electrolytic plasma, electroplating, electrodeposition, cladding, or a combination of such methods.
- gas plasma coating system 500 includes infrared heat source 410 .
- wire or other metal object 220 such as a metallic tool, is passed through infrared heat source 410 to increase the temperature of wire or other metal object 220 to enhance bonding.
- Gas plasma coating system 500 applies positive and negative energy to two metal wires 240 as the metal wires 240 are fed through gun head 230 . As the positive and negative metal wires 240 arc, the metal in the two metal wires 240 becomes molten and is then sprayed using dry compressed air 250 onto wire or other metal object 220 . Molten droplets from the two metal wires 240 may interlock and bond to each other and the treated wire or other metal object 220 , roughening the surface of the wire or other metal object 220 .
- the metal to be deposited is plated onto the surface of the wire or other metal object 220 via electrolytic plasma coating.
- electrolytic plasma coating system 600 includes infrared heat source 510 .
- wire or other metal object 220 Prior to processing, wire or other metal object 220 is passed through infrared heat source 510 to increase the temperature of wire or other metal object 220 to enhance bonding.
- An electrical charge is applied to wire or other metal object 220 as it passes through liquid bath 310 containing metals with an opposite electrical charge.
- the opposite electrical charges of the metal create plasma layer 320 that deposits metals from liquid bath 310 to create a bonded roughened surface on wire or other metal object 220 .
- FIG. 6 depicts the charge imparted on wire or other metal object 220 as positive and the metals in liquid bath 310 as negative, the charges could be reversed.
- the metal to be deposited is plated onto the surface of the wire or other metal object 220 via electroplating.
- electroplating system 400 an electrical charge is applied to wire or other metal object 220 as it passes through liquid bath 610 .
- Liquid bath 610 is an aqueous solution of an oppositely charged electrolyte containing the metal to be electroplated. The metal in the solution bonds electro-statically to wire or other metal object 220 , and forms a solid coating over wire or other metal object 220 .
- FIG. 7 depicts the charge imparted on wire or other metal object 220 as positive and the metals in liquid bath 610 as negative, the charges could be reversed.
- FIGS. 8 a -8 d depict a method of forming a wire consistent with at least one embodiment of the present disclosure.
- ferrous wire core 110 is provided, as depicted in FIG. 8 a .
- Metal strip 710 is placed alongside ferrous wire core 110 , as depicted in FIG. 8 b .
- Metal strip 710 may be composed of, for instance, Zn, Ni, Mo or Fe.
- Metal strip 710 is bent around ferrous wire core 110 and seam-welded to form a tube which is drawn down to fit tightly over ferrous wire core 110 as shown in FIG. 8 c to form metal-covered rod 720 .
- the metal-covered rod 720 diameter may then be reduced, such as for example, by drawing or passing the metal-covered rod 720 through a series of sizing rollers 730 as shown in FIG. 8 d , to the desired final diameter.
- the orientation of sizing rollers 730 may alternate.
- Metal-covered rods 720 a - 720 d depict the reduction in diameter of metal-covered rod 720 as it passes through sizing rollers 730 .
- FIGS. 9 a -9 e depict a method of forming a wire consistent with at least one embodiment of the present disclosure.
- steel wire cladding process 800 a thin layer of Zn, Ni, or Mo is applied using gas plasma coating, electrolytic plasma, or electroplating as described above to form plated rod 810 , as shown in FIG. 9 a .
- the thin layer can be from 2 to 10 microns in thickness, for example.
- Metal strip 820 is placed alongside plated rod 810 , as shown in FIG. 9 b .
- Metal strip 820 may be formed from Zn, Ni, Mo, or Fe, for instance.
- Metal strip 820 is bent around plated rod 810 and seam-welded to form a tube, as shown in FIG. 9 c .
- the tube is drawn down to fit tightly over plated rod 810 as shown in FIG. 9 d to form metal-covered rod 830 .
- the metal-covered rod 830 diameter may then be reduced, such as for example, by drawing or passing the metal-covered rod 830 through a series of sizing rollers 840 , as shown in FIG. 9 e , to the desired final diameter.
- the orientation of sizing rollers 840 may alternate.
- Metal-covered rods 830 a - 830 d depict the reduction in diameter of metal-covered rod 830 as it passes through sizing rollers 840 .
- the outer layer 130 of zinc in wires 100 and 200 , and the inner zinc layer 150 of wire 300 may be deposited by hot-dipping, electroplating, mechanical bonding, sherardizing or thermal spraying.
- Hot-dip methods include a continuous process in which long strands of sheet, wire or tubing are continuously fed through a bath of molten zinc. Hot-dip methods also include batch processes in which fabricated parts, including such parts as fasteners, poles or beams, are dipped into molten zinc either individually or in discrete batches. Similarly, zinc electroplating can be performed in a continuous or batch mode.
- wire 100 , wire 200 , wire 300 , wire 1000 , metal-covered rod 720 , and metal-covered rod 830 may be galvanized, such as through hot dip galvanizing process 900 as shown in FIG. 10 .
- Wire 910 (which may include, for example, wire 100 , wire 200 , wire 300 , wire 1000 , metal-covered rod 720 , or metal-covered rod 830 ) may be passed through molten Zn bath 920 to form galvanized-coated wire 930 .
- Galvanized-coated wire 930 is wire 910 with an additional layer of hot-dip Zn galvanization.
Abstract
A wire includes a ferrous core. The ferrous core can be coated. The coatings can include nickel, molybdenum, zinc and Fe. A process of forming a wire can include placing a metal strip alongside a ferrous wire core, bending the strip around the core, and seam welding the strip to form a metal tube around the core. The process of forming a wire can include applying a metal layer to a ferrous metal rod to form a plated rod, placing a metal strip alongside the rod, bending the strip around the rod, and seam welding the strip to form a metal tube around the rod. The process of forming a wire can include coating a ferrous wire core with a layer of nickel, molybdenum or a nickel alloy that circumferentially surrounds the ferrous wire core.
Description
- The present disclosure relates to steel armor wire strength member coating compositions, structures, and processes.
- Armor wire strength members used in wireline cables for oilfield applications are often composed of galvanized improved plow steel (GIPS). In GIPS armor wire strength members, the steel substrate is coated with zinc via a hot dip galvanization process. The hot dip galvanization process involves immersion of the steel substrate in molten zinc at a temperature of around 860° F. (460° C.).
- The strength and hardness of unalloyed zinc are greater than those of tin or lead, but less than those of aluminum or copper. Except when very pure, zinc is brittle at ambient temperatures, but zinc becomes ductile at around 100° C. Pure zinc rapidly recrystallizes after deformation at ambient temperature because of the high mobility of the atoms within the lattice. Thus, zinc typically cannot be work-hardened at ambient temperature.
- Hot dip zinc coatings provide corrosion protection in a range of atmospheric and low temperature aqueous environments such as humid atmospheric conditions, natural weathering conditions, soil environments, salt-spray testing conditions and under low temperature aqueous/brine immersion conditions. This corrosion protection may be relevant when GIPS armor wire components of wireline cables are stored between wireline logging operations.
- Zinc-based coatings may fall into several categories: pure zinc, zinc-iron, zinc-aluminum, zinc-nickel and zinc composites. In terms of manufacturing methods, zinc coatings are produced by hot-dipping, electroplating, mechanical bonding, sherardizing and thermal spraying. The hot-dip methods are further divided into two processes: (1) the continuous process in which long strands of sheet, wire or tubing are continuously fed through a bath of molten zinc; and (2) the batch process in which fabricated parts such as fasteners, poles or beams are dipped into molten zinc, either individually or in discrete batches. Similarly, zinc electroplating can be performed in a continuous or batch mode.
- The present disclosure provides a wire and a process of forming a wire.
- Embodiments of the wire can include a ferrous wire core, an interface layer circumferentially surrounding the ferrous wire core, and an outer layer circumferentially surrounding the interface layer. The interface layer can include nickel, molybdenum or a nickel alloy, for example. The outer layer can include zinc or a zinc alloy, for example.
- Embodiments of the wire can include a ferrous wire core, an inner zinc layer circumferentially surrounding the ferrous wire core, an Fe layer circumferentially surrounding the inner zinc layer, and an interface layer circumferentially surrounding the Fe layer. The interface layer can include nickel or molybdenum, for example.
- Embodiments of the wire can include a ferrous wire core and a layer circumferentially surrounding the ferrous wire core. The layer circumferentially surrounding the ferrous wire core can include nickel, molybdenum or a nickel alloy. The layer circumferentially surrounding the ferrous wire core can be present without an overlying zinc or zinc alloy layer. The layer including nickel, molybdenum or a nickel alloy can act as a protective layer in oil and gas downhole conditions and in surface storage conditions.
- Embodiments of the process of forming a wire can include placing a metal strip alongside a ferrous wire core. The metal strip can include Zn, Ni, Mo, or Fe, for example. The process can include bending the metal strip circumferentially around the ferrous wire core. The process can include seam welding the metal strip to form a metal tube around the ferrous wire core.
- Embodiments of the process of forming a wire can include applying a metal layer to a ferrous metal rod to form a plated rod. The metal layer can include Zn, Ni, or Mo, for example. The process can include placing a metal strip alongside the plated rod. The metal strip can include Zn, Ni, Mo, or Fe, for example. The process can include bending the metal strip circumferentially around the plated rod. The process can include seam welding the metal strip to form a metal tube around the plated rod.
- The process of forming a wire can include coating a ferrous wire core with a layer of nickel, molybdenum or a nickel alloy. The layer can circumferentially surround the ferrous wire core. The layer circumferentially surrounding the ferrous wire core can be present without an overlying zinc or zinc alloy layer.
- The present disclosure can be understood from the following detailed description when read with the accompanying figures. It is emphasized that, in accordance with the standard practice in the industry, various features are not drawn to scale. In fact, the dimensions of the various features may be arbitrarily increased or reduced for clarity of discussion.
-
FIG. 1 is a first cross sectional view of steel armor wire consistent with at least one embodiment of the present disclosure. -
FIG. 2 is a second cross sectional view of steel armor wire consistent with at least one embodiment of the present disclosure. -
FIG. 3 is a third cross sectional view of steel armor wire consistent with at least one embodiment of the present disclosure. -
FIG. 4 is a fourth a cross sectional view of steel armor wire consistent with at least one embodiment of the present disclosure. -
FIG. 5 depicts a gas plasma coating system consistent with at least one embodiment of the present disclosure. -
FIG. 6 depicts an electrolytic plasma coating system consistent with at least one embodiment of the present disclosure. -
FIG. 7 depicts an electroplating system consistent with at least one embodiment of the present disclosure. -
FIGS. 8a-8d depict a method of forming a wire consistent with at least one embodiment of the present disclosure. -
FIGS. 9a-9e depict a method of forming a wire consistent with at least one embodiment of the present disclosure. -
FIG. 10 depicts a hot dip galvanizing process consistent with at least one embodiment of the present disclosure. - It is to be understood that the following disclosure provides many different embodiments, or examples, for implementing different features of various embodiments. Specific examples of components and arrangements are described below to simplify the present disclosure. These are, of course, merely examples and are not intended to be limiting. In addition, the present disclosure may repeat reference numerals and/or letters in the various examples. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various embodiments and/or configurations discussed.
- Wireline is a single-strand or multi-strand wire or cable for intervention in oil or gas wells. A wireline is commonly used in association with electric logging and cables incorporating electrical conductors. In certain circumstances, it may be desirable to augment the wire or cable to provide it with additional strength or resistance to adverse temperature or other environmental conditions. Such augmented wireline is termed “armor wire.”
-
FIG. 1 depictswire 100 consistent with at least one embodiment of the present disclosure.Wire 100 includesferrous wire core 110. One non-limiting example of a ferrous wire core is a steel wire.Interface metal layer 120 circumferentially surroundsferrous wire core 110.Interface metal layer 120 may be composed of, for instance, nickel, molybdenum, or nickel-rich alloy. In certain embodiments,interface metal layer 120 may have a thickness of between 2 and 60 microns.Outer layer 130 circumferentially surroundsinterface metal layer 120.Outer layer 130 may be composed of zinc or a zinc alloy. The zinc alloy may include, but is not limited to, a binary Zn—Ni or Zn—Co alloy or a ternary Zn—Ni—Co, Zn—Ni—Mo or Zn—Co—Mo alloy. In certain embodiments,outer layer 130 may have a thickness of from about 1 to about 50 microns. Without being bound by theory, it is believed that the interposition of theinterface metal layer 120 betweenferrous wire core 110 andouter layer 130 acts as a barrier protection for theferrous wire core 110 whenwire 100 is exposed to harsh temperature and other environmental conditions, such as those that exist downhole in oil and gas fields. Further, without being bound by theory, it is believed that the zinc or zinc alloy inouter layer 130 provides sacrificial protection of the underlying layers during storage, such as wireline cable storage conditions between successive wireline logging jobs. -
FIG. 2 depictswire 200 consistent with at least one embodiment of the present disclosure.Wire 200 includesferrous wire core 110. One non-limiting example of aferrous wire core 110 is a steel wire.Interface metal layer 120 circumferentially surroundsferrous wire core 110.Interface metal layer 120 may be composed of nickel or molybdenum. In certain embodiments,interface metal layer 120 may have a thickness of from about 2 to about 50 microns. Without being bound by theory,interface metal layer 120 may serve as a stop layer for corrosion if the outer layer 130 (described below) is compromised. In the embodiment depicted inFIG. 2 ,Fe layer 140 circumferentially surroundsinterface metal layer 120. In certain embodiments,Fe layer 140 may have a thickness of from about 2 to about 20 microns. Without being bound by theory, it is believed that nickel contact with the environment may increase brittleness, andFe layer 140 may reduce such contact and increase the longevity ofwire 200.Outer layer 130 circumferentially surroundsFe layer 140.Outer layer 130 may be composed of zinc or a zinc alloy. The zinc alloy can include, but is not limited to, a binary Zn—Ni or Zn—Co alloy, or a ternary Zn—Ni—Co, Zn—Ni—Mo or Zn—Co—Mo alloy. In certain embodiments,outer layer 130 may have a thickness of between 1 and 50 microns. -
FIG. 3 depictswire 300 consistent with at least one embodiment of the present disclosure.Wire 300 includesferrous wire core 110. One non-limiting example offerrous wire core 110 is a steel wire.Inner zinc layer 150 circumferentially surroundsferrous wire core 110. In certain embodiments of the present disclosure,inner zinc layer 150 is between 2 and 50 microns in thickness. In the embodiment depicted inFIG. 3 ,Fe layer 140 circumferentially surroundsinner zinc layer 150. In certain embodiments,Fe layer 140 may have a thickness of between 2 and 20 microns.Interface metal layer 120 circumferentially surroundsFe layer 140 and may be composed of nickel or molybdenum. In certain embodiments,interface metal layer 120 may have a thickness of from about 2 to about 50 microns. -
FIG. 4 depicts a cross sectional view ofwire 1000.Wire 1000 includesferrous wire core 110.Wire 1000 includes alayer 1120, such as a Ni, Mo, or Ni alloy coating, circumferentially surrounding theferrous wire core 110. Thelayer 1120 circumferentially surrounding theferrous wire core 110 can be present without an overlying zinc or zinc alloy layer. Thelayer 1120 can act as a protective layer in oil and gas downhole conditions and in surface storage conditions. - The successive metal layers depicted in
FIGS. 1-4 may be deposited by any number of methods, including but not limited to gas plasma, electrolytic plasma, electroplating, electrodeposition, cladding, or a combination of such methods. - In certain embodiments, the metal to be deposited is plated onto the surface of the wire or other metal object via gas plasma coating. As depicted in
FIG. 5 , gasplasma coating system 500 includesinfrared heat source 410. Prior to processing, wire orother metal object 220, such as a metallic tool, is passed throughinfrared heat source 410 to increase the temperature of wire orother metal object 220 to enhance bonding. Gasplasma coating system 500 applies positive and negative energy to twometal wires 240 as themetal wires 240 are fed throughgun head 230. As the positive andnegative metal wires 240 arc, the metal in the twometal wires 240 becomes molten and is then sprayed using drycompressed air 250 onto wire orother metal object 220. Molten droplets from the twometal wires 240 may interlock and bond to each other and the treated wire orother metal object 220, roughening the surface of the wire orother metal object 220. - In certain other embodiments, the metal to be deposited is plated onto the surface of the wire or
other metal object 220 via electrolytic plasma coating. As depicted inFIG. 6 , electrolyticplasma coating system 600 includesinfrared heat source 510. Prior to processing, wire orother metal object 220 is passed throughinfrared heat source 510 to increase the temperature of wire orother metal object 220 to enhance bonding. An electrical charge is applied to wire orother metal object 220 as it passes throughliquid bath 310 containing metals with an opposite electrical charge. At the surface of the wire orother metal object 220, the opposite electrical charges of the metal createplasma layer 320 that deposits metals fromliquid bath 310 to create a bonded roughened surface on wire orother metal object 220. As one of ordinary skill in the art will appreciate, althoughFIG. 6 depicts the charge imparted on wire orother metal object 220 as positive and the metals inliquid bath 310 as negative, the charges could be reversed. - In yet other embodiments, the metal to be deposited is plated onto the surface of the wire or
other metal object 220 via electroplating. As depicted inFIG. 7 , inelectroplating system 400, an electrical charge is applied to wire orother metal object 220 as it passes throughliquid bath 610.Liquid bath 610 is an aqueous solution of an oppositely charged electrolyte containing the metal to be electroplated. The metal in the solution bonds electro-statically to wire orother metal object 220, and forms a solid coating over wire orother metal object 220. As one of ordinary skill in the art will appreciate, althoughFIG. 7 depicts the charge imparted on wire orother metal object 220 as positive and the metals inliquid bath 610 as negative, the charges could be reversed. -
FIGS. 8a-8d depict a method of forming a wire consistent with at least one embodiment of the present disclosure. In steelwire cladding process 700,ferrous wire core 110 is provided, as depicted inFIG. 8a .Metal strip 710 is placed alongsideferrous wire core 110, as depicted inFIG. 8b .Metal strip 710 may be composed of, for instance, Zn, Ni, Mo or Fe.Metal strip 710 is bent aroundferrous wire core 110 and seam-welded to form a tube which is drawn down to fit tightly overferrous wire core 110 as shown inFIG. 8c to form metal-coveredrod 720. The metal-coveredrod 720 diameter may then be reduced, such as for example, by drawing or passing the metal-coveredrod 720 through a series of sizingrollers 730 as shown inFIG. 8d , to the desired final diameter. In certain embodiments, as shown inFIG. 8d , the orientation of sizingrollers 730 may alternate. Metal-coveredrods 720 a-720 d depict the reduction in diameter of metal-coveredrod 720 as it passes through sizingrollers 730. -
FIGS. 9a-9e depict a method of forming a wire consistent with at least one embodiment of the present disclosure. In steelwire cladding process 800, a thin layer of Zn, Ni, or Mo is applied using gas plasma coating, electrolytic plasma, or electroplating as described above to form platedrod 810, as shown inFIG. 9a . The thin layer can be from 2 to 10 microns in thickness, for example.Metal strip 820 is placed alongside platedrod 810, as shown inFIG. 9b .Metal strip 820 may be formed from Zn, Ni, Mo, or Fe, for instance.Metal strip 820 is bent around platedrod 810 and seam-welded to form a tube, as shown inFIG. 9c . The tube is drawn down to fit tightly over platedrod 810 as shown inFIG. 9d to form metal-coveredrod 830. The metal-coveredrod 830 diameter may then be reduced, such as for example, by drawing or passing the metal-coveredrod 830 through a series of sizingrollers 840, as shown inFIG. 9e , to the desired final diameter. In certain embodiments, as shown inFIG. 9e , the orientation of sizingrollers 840 may alternate. - Metal-covered
rods 830 a-830 d depict the reduction in diameter of metal-coveredrod 830 as it passes through sizingrollers 840. - In certain embodiments, the
outer layer 130 of zinc inwires inner zinc layer 150 ofwire 300 may be deposited by hot-dipping, electroplating, mechanical bonding, sherardizing or thermal spraying. Hot-dip methods include a continuous process in which long strands of sheet, wire or tubing are continuously fed through a bath of molten zinc. Hot-dip methods also include batch processes in which fabricated parts, including such parts as fasteners, poles or beams, are dipped into molten zinc either individually or in discrete batches. Similarly, zinc electroplating can be performed in a continuous or batch mode. - In certain embodiments of the present disclosure,
wire 100,wire 200,wire 300,wire 1000, metal-coveredrod 720, and metal-coveredrod 830 may be galvanized, such as through hotdip galvanizing process 900 as shown inFIG. 10 . Wire 910 (which may include, for example,wire 100,wire 200,wire 300,wire 1000, metal-coveredrod 720, or metal-covered rod 830) may be passed throughmolten Zn bath 920 to form galvanized-coatedwire 930. Galvanized-coatedwire 930 iswire 910 with an additional layer of hot-dip Zn galvanization. - The foregoing outlines features of several embodiments so that a person of ordinary skill in the art may better understand the aspects of the present disclosure. Such features may be replaced by any one of numerous equivalent alternatives, some of which are disclosed herein. One of ordinary skill in the art should appreciate that they may readily use the present disclosure as a basis for designing or modifying other processes and structures for carrying out the same purposes and/or achieving the same advantages of the embodiments introduced herein. One of ordinary skill in the art should also realize that such equivalent constructions do not depart from the spirit and scope of the present disclosure and that they may make various changes, substitutions, and alterations herein without departing from the spirit and scope of the present disclosure.
Claims (8)
1. A process of forming a wire comprising:
coating a ferrous wire core with an interface layer of nickel, molybdenum or a nickel alloy,
wherein the interface layer circumferentially surrounds the ferrous wire core; and
coating the interface layer with an outer layer.
2. The process of claim 1 , wherein the ferrous wire core is steel.
3. The process of claim 1 , wherein the interface layer has a thickness of between 2 and 60 microns.
4. The process of claim 1 , wherein outer layer has a thickness of between 1 and 50 microns.
5. The process of claim 1 , wherein the outer layer comprises a zinc alloy, and wherein the zinc allow comprises:
binary Zn—Ni or Zn—Co alloy; or
ternary Zn—Ni—Co, Zn—Ni—Mo or Zn—Co—Mo alloy.
6. The process of claim 1 , further comprising an Fe layer, wherein the Fe layer circumferentially surrounds the interface layer and is circumferentially surrounded by the outer layer.
7. The process of claim 6 , wherein the Fe layer has a thickness of between 2 and 20 microns.
8. The process of claim 1 , further comprising a galvanized zinc coating.
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US15/264,859 US20170001415A1 (en) | 2014-08-27 | 2016-09-14 | Steel Armor Wire Coatings |
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US14/470,708 US9446565B2 (en) | 2014-08-27 | 2014-08-27 | Steel armor wire coatings |
US15/264,859 US20170001415A1 (en) | 2014-08-27 | 2016-09-14 | Steel Armor Wire Coatings |
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WO2021118773A1 (en) * | 2019-12-13 | 2021-06-17 | Schlumberger Technology Corporation | Measurement of metal or alloy coating |
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US9905345B2 (en) * | 2015-09-21 | 2018-02-27 | Apple Inc. | Magnet electroplating |
JP7059885B2 (en) * | 2018-10-10 | 2022-04-26 | 日本製鉄株式会社 | Hot-dip plated wire and its manufacturing method |
CN110938849A (en) * | 2019-10-29 | 2020-03-31 | 湖北第二师范学院 | Zinc-molybdenum alloy coating titanium alloy and preparation method thereof |
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US5374778A (en) * | 1992-11-02 | 1994-12-20 | Sumitomo Wiring Systems, Ltd. | Wire harness |
US7300706B2 (en) * | 2004-02-04 | 2007-11-27 | Nv Bekaert Sa | High-carbon steel wire with nickel sub coating |
US20130130055A1 (en) * | 2010-03-25 | 2013-05-23 | Jfe Steel Corporation | Coated steel sheet, method for producing the same, and resin-coated steel sheet obtained using the same |
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FR2077770B1 (en) * | 1970-02-12 | 1973-03-16 | Michelin & Cie | |
JP2521387B2 (en) * | 1991-12-25 | 1996-08-07 | 神鋼鋼線工業株式会社 | Manufacturing method of colored spring steel molded product |
-
2014
- 2014-08-27 US US14/470,708 patent/US9446565B2/en active Active
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Patent Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
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US5374778A (en) * | 1992-11-02 | 1994-12-20 | Sumitomo Wiring Systems, Ltd. | Wire harness |
US7300706B2 (en) * | 2004-02-04 | 2007-11-27 | Nv Bekaert Sa | High-carbon steel wire with nickel sub coating |
US20130130055A1 (en) * | 2010-03-25 | 2013-05-23 | Jfe Steel Corporation | Coated steel sheet, method for producing the same, and resin-coated steel sheet obtained using the same |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
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WO2021118773A1 (en) * | 2019-12-13 | 2021-06-17 | Schlumberger Technology Corporation | Measurement of metal or alloy coating |
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US20160059519A1 (en) | 2016-03-03 |
US9446565B2 (en) | 2016-09-20 |
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