Several plasma-sprayed ceramic coatings with two- and three-layers were characterized and tested for the application of cooling tube coatings at the steel making factory. Thermal cycling tests using a torch heating with compressed air cooling were carried out and characterized before and after the tests. The effects of bond coat as well as top coat were also studied. Possible failure mechanisms with low carbon steel substrate were assessed in term of microstructure, porosity, bond strength, thermal expansion coefficient, and the phase transformation. Finally, the results of field tests at the oxygen convert gas recovery system are also discussed.

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