System and method for stainless steel cladding of carbon steel pieces

1. A method of cladding a carbon steel piece with stainless steel, the method comprising:

conducting a first cleaning of the carbon steel piece using abrasive blasting;

after conducting the first cleaning of the carbon steel piece using abrasive blasting, heating the carbon steel piece using induction heating;

after heating the carbon steel piece using induction heating, coating the carbon steel piece with the stainless steel, wherein coating the carbon steel piece with the stainless steel comprises:

melting the stainless steel;

atomizing the melted stainless steel; and

spraying the atomized stainless steel so that at least a portion of the atomized stainless steel is deposited on the carbon steel piece to thereby coat the carbon steel piece with the stainless steel;

after coating the carbon steel piece with the stainless steel, conducting a first cooling of the carbon steel piece; and

after conducting the first cooling of the carbon steel piece, strengthening the carbon steel piece.

2. The method of claim 1 , further comprising:

after strengthening the carbon steel piece, conducting a second cooling of the carbon steel piece; and

after conducting the second cooling of the carbon steel piece, conducting a second cleaning of the carbon steel piece using abrasive blasting.

3. The method of claim 2 , wherein the steps of conducting the first cleaning, heating, coating, conducting the first cooling, strengthening, and conducting the second cooling, are executed within an inert atmosphere.

4. The method of claim 2 , wherein heating the carbon steel piece comprises heating the carbon steel piece to a first surface temperature of between about 1800 and about 2500 degrees Fahrenheit;

wherein conducting the first cooling of the carbon steel piece comprises cooling the carbon steel piece to a second surface temperature of between about 1100 and about 1400 degrees Fahrenheit; and

wherein conducting the second cooling of the carbon steel piece comprises cooling the carbon steel piece to a third surface temperature below about 400 degrees Fahrenheit.

5. The method of claim 2 , wherein liquid nitrogen is used to conduct each of the first and second coolings of the carbon steel piece; and

wherein strengthening the carbon steel piece comprises strengthening the carbon steel piece by impacting the carbon steel piece with shot in a cold working process.

6. The method of claim 1 , wherein conducting the first cleaning of the carbon steel piece using abrasive blasting comprises cleaning the carbon steel piece using a grit or shot blaster.

7. The method of claim 1 , wherein heating the carbon steel piece using induction heating comprises:

supplying electrical power to an induction coil; and

passing the carbon steel piece through the induction coil.

8. The method of claim 1 , wherein melting the stainless steel comprises melting two or more stainless steel wires using an electric arc; and

wherein atomizing the melted stainless steel comprises passing through an atomizing passage an inert gas so that the inert gas contacts the melted two or more stainless steel wires.

9. The method of claim 1 , wherein melting the stainless steel and atomizing the melted stainless steel are part of either an electrode induction melting gas atomization (EIGA) process or a plasma melting induction guiding gas atomization (PIGA) process.

10. The method of claim 1 , wherein the carbon steel piece is a carbon steel rebar piece; and

wherein the atomized stainless steel is deposited on the carbon steel piece in a semi-molten condition.

11. The method of claim 1 , further comprising:

collecting stainless steel overspray; and

recycling the collected stainless steel overspray.

12. A method of cladding a carbon steel piece with stainless steel, the method comprising:

conducting a first cleaning of the carbon steel piece;

heating the carbon steel piece;

coating the carbon steel piece with stainless steel, wherein coating the carbon steel piece with the stainless steel comprises:

melting the stainless steel;

atomizing the melted stainless steel; and

spraying the atomized stainless steel so that at least a portion of the atomized stainless steel is deposited on the carbon steel piece to thereby coat the carbon steel piece with the stainless steel;

after coating the carbon steel piece with the stainless steel, conducting a first cooling of the carbon steel piece;

after conducting the first cooling of the carbon steel piece, strengthening the carbon steel piece;

after strengthening the carbon steel piece, conducting a second cooling of the carbon steel piece; and

after conducting the second cooling of the carbon steel piece, conducting a second cleaning of the carbon steel piece.

13. The method of claim 12 , wherein the steps of conducting the first cleaning, heating, coating, conducting the first cooling, strengthening, and conducting the second cooling, are executed within an inert atmosphere.

14. The method of claim 12 , wherein heating the carbon steel piece comprises heating the carbon steel piece to a first surface temperature of between about 1800 and about 2500 degrees Fahrenheit;

wherein conducting the first cooling of the carbon steel piece comprises cooling the carbon steel piece to a second surface temperature of between about 1100 and about 1400 degrees Fahrenheit; and

wherein conducting the second cooling of the carbon steel piece comprises cooling the carbon steel piece to a third surface temperature below about 400 degrees Fahrenheit.

15. A method of cladding a carbon steel piece with stainless steel, the method comprising:

conducting a first cleaning of the carbon steel piece;

heating the carbon steel piece;

coating the carbon steel piece with the stainless steel, wherein coating the carbon steel piece with the stainless steel comprises:

melting the stainless steel, wherein melting the stainless steel comprises melting two or more stainless steel wires using an electric arc;

atomizing the melted stainless steel, wherein atomizing the melted stainless steel comprises passing through an atomizing passage an inert gas so that the inert gas contacts the melted two or more stainless steel wires; and

spraying the atomized stainless steel so that at least a portion of the atomized stainless steel is deposited on the carbon steel piece to thereby coat the carbon steel piece with the stainless steel; and

strengthening the carbon steel piece.

16. A method of cladding a carbon steel piece with stainless steel, the method comprising:

conducting a first cleaning of the carbon steel piece;

heating the carbon steel piece;

coating the carbon steel piece with the stainless steel, wherein coating the carbon steel piece with the stainless steel comprises:

melting the stainless steel;

atomizing the melted stainless steel, wherein melting the stainless steel and atomizing the melted stainless steel are part of either an electrode induction melting gas atomization (EIGA) process or a plasma melting induction guiding gas atomization (PIGA) process; and

spraying the atomized stainless steel so that at least a portion of the atomized stainless steel is deposited on the carbon steel piece to thereby coat the carbon steel piece with the stainless steel; and

strengthening the carbon steel piece.

17. A method of cladding a carbon steel piece with stainless steel, the method comprising:

conducting a first cleaning of the carbon steel piece;

heating the carbon steel piece;

coating the carbon steel piece with the stainless steel, wherein coating the carbon steel piece with the stainless steel comprises:

melting the stainless steel;

atomizing the melted stainless steel;

spraying the atomized stainless steel so that at least a portion of the atomized stainless steel is deposited on the carbon steel piece to thereby coat the carbon steel piece with the stainless steel;

strengthening the carbon steel piece;

collecting stainless steel overspray; and

recycling the collected stainless steel overspray.

18. A system for cladding a carbon steel piece with stainless steel, the system comprising:

an inert atmosphere chamber;

a first abrasive blasting station to clean the carbon steel piece;

an induction heating station to heat the carbon steel piece;

a spray coating station to coat the carbon steel piece with the stainless steel; and

a peening station to strengthen the carbon steel piece;

wherein each of the first abrasive blasting station, the induction heating station, the spray coating station, and the peening station, are disposed within the inert atmosphere chamber.

19. The system of claim 18 , further comprising:

a first cooling station to cool the carbon steel piece after the carbon steel piece has been coated with the stainless steel; and

a second cooling station to cool the carbon steel piece after the carbon steel piece has been strengthened;

wherein each of the first and second cooling stations is disposed within the inert atmosphere chamber.

20. The system of claim 19 , wherein the inert atmosphere chamber comprises first, second, third, fourth, and fifth chambers therein;

wherein each of the first abrasive blasting station and the induction heating station is disposed within the first chamber; and

wherein the spray coating station, the first cooling station, the peening station, and the second cooling station are disposed within the second, third, fourth, and fifth chambers, respectively.

21. The system of claim 20 , further comprising:

a second abrasive blasting station to clean the carbon steel piece after the carbon steel piece has been strengthened and cooled;

wherein the second abrasive blasting station is disposed outside of the inert atmosphere chamber.

22. The system of claim 21 , further comprising:

a gaseous nitrogen source in fluid communication with each of the first chamber, the induction heating station, the spray coating station, the first cooling station, and the peening station; and

a liquid nitrogen source in fluid communication with each of the first and second cooling stations.

23. The system of claim 22 , wherein the spray coating station comprises:

a housing in which the stainless steel is melted; and

a container positioned proximate the housing;

wherein stainless steel overspray is adapted to be conveyed from the container to the housing.

24. A method of cladding a carbon steel piece with stainless steel, the method comprising:

conducting a first cleaning of the carbon steel piece;

heating the carbon steel piece;

coating the carbon steel piece with the stainless steel, wherein coating the carbon steel piece with the stainless steel comprises:

melting the stainless steel;

atomizing the melted stainless steel; and

spraying the atomized stainless steel so that at least a portion of the atomized stainless steel is deposited on the carbon steel piece to thereby coat the carbon steel piece with the stainless steel;

conducting a first cooling of the carbon steel piece;

strengthening the carbon steel piece; and

at least one of:

conducting a second cooling of the carbon steel piece; and

conducting a second cleaning of the carbon steel piece.

25. The method of claim 24 , wherein the steps of conducting the first cleaning, heating, coating, conducting the first cooling, strengthening, and conducting the second cooling, are executed within an inert atmosphere.

26. The method of claim 24 , wherein heating the carbon steel piece comprises heating the carbon steel piece to a first surface temperature of between about 1800 and about 2500 degrees Fahrenheit;

wherein conducting the first cooling of the carbon steel piece comprises cooling the carbon steel piece to a second surface temperature of between about 1100 and about 1400 degrees Fahrenheit; and

wherein conducting the second cooling of the carbon steel piece comprises cooling the carbon steel piece to a third surface temperature below about 400 degrees Fahrenheit.