Investigation of the Properties of Metallurgical Slags and Dust of Electro Filters to Obtain Protective Anticorrosive Coatings

Corrosion-related irreparable metal failures can cause massive losses in various sectors, including agricultural engineering and construction. Steel structures are typically coated to withstand corrosion pressures during the service life specified in technical standards to avoid corrosion damage. This article presents research results on metallurgical cast iron slags and a mixture of slags with electro-filter dust to form silicate anticorrosive coatings. X-ray phase analysis, electron, and optical microscopy were used to analyze the surface nucleation of crystals in glasses using cast iron slags, a combination of steelmaking slag, and electro-filter dust with the addition of Cr₂O₃. It is shown that the main phases crystallizing from the surface of the samples are diopside . When 1.5 - 2.0 wt.% Cr₂O₃ was added, the results showed that diopside phase glasses could be made with a cast iron slag level of up to 72 wt.%. Studies have shown the important role of Fe²⁺, and Mg²⁺, especially in samples containing cast iron slag, based on the most fusible compounds obtained. The optimal model of glass formation and crystallization was established as a result of the analysis of these compositions, and the microhardness of slag glass-crystalline materials was investigated. It was found that the hardness of the obtained glass-crystal materials increases in the presence of chromium oxide. The research revealed the possibility of synthesizing glass-crystal materials from cast-iron slags and dust of electro-filters.

Glass-crystalline materials; Protective coatings; Slag; Three-layer panels

    The use of three-layer (sandwich) panels with adequate, effective insulation and protective coatings is a promising trend for the development of the construction industry, allowing for an increase in the volume of objects in industry and agriculture (Su et al., 2022). The primary material for three-layer panels is steel. Steel structures in agricultural construction are subject to severe corrosion damage due to high concentrations of animal waste, high humidity, and ammonia-phosphate fertilizers used in agriculture. To strengthen the corrosion resistance of steel and the attractiveness of the metal surface, the quality of the relevant protective coatings must be improved (Saraswati et al., 2018).
    The reduction of porosity, the structure of heterogeneity, and the composition are significant factors for enhancing protective coatings' physical and mechanical qualities. These reserves have been effectively utilized in the case of glass-ceramic coatings by using industrial waste. Compared to other coating materials, glass-crystal coatings feature chemical inertness, high-temperature resistance, and superior mechanical qualities such as scratch and impact resistance.
    Glass and glass-ceramic coatings, in general, offer good adherence to a defect-free surface as well as fire resistance in addition to imparting the essential functional qualities such as heat, abrasion, and corrosion resistance to fulfil the specific requirements of the end-use (Dorofeeva & Semin, 2014). Thus, glass and glass-ceramic coatings are not only a new generation of coatings but also versatile engineering materials that extend the life of various types of metal substrates. They have a potential and promising market, and most likely, they can significantly replace industrial painting methods (Majumdar & Jana, 2001). The use of glass-crystal materials (sitals) in coatings proved particularly effective since it was able to strengthen heat resistance and protective characteristics at high temperatures practically without deterioration of the most significant technological features (wetting ability, covering capacity, and spreading), as well as to maintain a suitably low temperature at the start of softening, i.e., protective properties at low temperatures (Solntsev, 2007). Construction opportunities are significantly great. This is due to the availability of raw materials and smelting slag while retaining the valuable technological features of ceramics. Because of their high wear and chemical resistance, slag metals may effectively be used to safeguard building structures and equipment in the chemical, mining, and other sectors (Lazareva et al., 2009).
    One of the work directions on slag disposal is their usage as the major base of mineral raw materials used to produce glasses and slag-glass. (Sycheva & Poljakova, 2016). Reuse of steelmaking slags will lead to improved quality characteristics of protective coatings, as well as to environmentally safe (Huang et al., 2012) and more efficient management of these wastes and preservation of the environment (Rincon & Romero, 1996; Rincon, 2016; Oluwasola et al., 2014; Zhao et al., 2016; Niyazbekova & Gladkikh, 2017; Maharaj et al., 2017; Sofyan et al., 2010). The use of blast furnace and metallurgical slags as the main crystal phase indicates a significant increase in the mechanical properties of composite materials. (Ponsot et al., 2014; Ashadi et al., 2015; Jexembayeva et al., 2020).
    Metallurgical slags are the valuable raw material for obtaining protective silicate coatings for structures of livestock complexes under the influence of dangerous chemical and biological factors. Therefore, the task of using inexpensive secondary raw materials - slags of local production, the dust of electro-filters for the manufacturing process in slagositals, which will solve the environmental safety concerns of inhabited regions - was allotted to work (Sarkisov, 2001; Efimov et al., 2010). This research investigates the characteristics of metallurgical iron slags and a mixture of slags and electro-filter dust used to manufacture glass-crystal materials and their appropriateness as protective coatings for building structures.
   This research also included experiments to manufacture glass-crystal materials based on metallurgical slags and electro-filter dust. The key components in producing synthesis glasses were cast iron slag, a mixture of steelmaking slag and electro filter dust, quartz sand, and tuffs. Chromium oxide was added to the glassy matrix, which can display isomorphism and increase crystallization stimulation (Yatsenko et al., 2012). Micro and nanocrystals can be formed during the heat treatment of glasses, contributing to the system's strength. 

    Cast iron slags are often used to make pyroxene glasses. All types of low-melting glasses are explained, in conclusion, by the fact that iron ions depolymerize the structure of melts and glasses, reduce the viscosity and temperature of structural changes, increase the tendency of melts to microliquation, and actively participate in the nucleation of crystals. The crystallization temperatures of glasses of optimal composition are determined. Based on the conducted research, the compositions of glass-crystal materials were developed. As a result of studying these compositions, the optimal glass formation and crystallization model of glasses was established, and the microhardness of slag glass-crystalline materials was investigated. It was found that the hardness of the obtained glass-crystal materials increases in the presence of chromium oxide. The research revealed the possibility of synthesizing glass-crystal materials from cast-iron slags and dust of electro-filters.

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