Inter-metallic Inclusion Reduction in Continuous Metallic Coating

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The ZINCALUMER coating process is a core business of BlueScope Steel. Operational and quality issues are being experienced due to inter-metallic particles in the liquid metal bath. The particles cause defects in the metal coating and agglomerate, resulting in periodic shutdowns to remove the dross. Both of these factors impact significantly on the profitability of the operation. In this project a new strategy is being investigated, whereby the fluid mechanics and heat transfer mechanisms within the bath will allow inter-metallic particles to be continuously removed in the metal coating before they reach the critical size that adversely affects product quality. This will also reduce dross accumulation, thereby reducing shutdown time.