In some embodiments, a coating applied to steel reinforcement bar (e.g., steel rebar) that could considerably extend the lifetime of concrete structures by reducing steel rebar corrosion is disclosed. The coating includes a thin, passivating steel (e.g., stainless steel) layer that is applied to the outside of conventional steel rebar. The coating can be applied in-line through metal cold spray manufacturing, which is a high throughput coating technique that can be integrated into existing steel manufacturing plants. Furthermore, a novel, high performance ferritic steel with tailored resistance to corrosion from chlorides is described. The new ferritic steel is distinct from other commercial and experimental steels, and is better suited for coating low-cost steel structures like rebar. Multiple alloying elements including Cr, Al, and Si will each form protective oxides independently, increasing the total amount of protection and extending it over much wider ranges of pH and electrical potential.

In some embodiments, a coating applied to steel reinforcement bar (e.g., steel rebar) that could considerably extend the lifetime of concrete structures by reducing steel rebar corrosion is disclosed. The coating includes a thin, passivating steel (e.g., stainless steel) layer that is applied to the outside of conventional steel rebar. The coating can be applied in-line through metal cold spray manufacturing, which is a high throughput coating technique that can be integrated into existing steel manufacturing plants. Furthermore, a novel, high performance ferritic steel with tailored resistance to corrosion from chlorides is described. The new ferritic steel is distinct from other commercial and experimental steels, and is better suited for coating low-cost steel structures like rebar. Multiple alloying elements including Cr, Al, and Si will each form protective oxides independently, increasing the total amount of protection and extending it over much wider ranges of pH and electrical potential.

Provided is an ultra-high-strength reinforcing bar and a method for manufacturing the same are disclosed. In an exemplary embodiment, the ultra-high-strength reinforcing bar includes an amount of 0.10 to 0.45 wt % carbon (C), an amount of 0.5 to 1.0 wt % silicon (Si), an amount of 0.40 to 1.80 wt % manganese (Mn), an amount of 0.10 to 1.0 wt % chromium (Cr), an amount greater than 0 and less than or equal to 0.2 wt % vanadium (V), an amount greater than 0 and less than or equal to 0.4 wt % copper (Cu), an amount greater than 0 and less than or equal to 0.5 wt % molybdenum (Mo), an amount of 0.015 to 0.070 wt % aluminum (Al), an amount greater than 0 and less than or equal to 0.25 wt % nickel (Ni), an amount greater than 0 and less than or equal to 0.1 wt % tin (Sn), an amount greater than 0 and less than or equal to 0.05 wt % phosphorus (P), an amount greater than 0 and less than or equal to 0.03 wt % sulfur (S), an amount of 0.005 to 0.02 wt % nitrogen (N), and the remainder being iron (Fe) and other inevitable impurities.

Provided is an ultra-high-strength reinforcing bar and a method for manufacturing the same are disclosed. In an exemplary embodiment, the ultra-high-strength reinforcing bar includes an amount of 0.10 to 0.45 wt % carbon (C), an amount of 0.5 to 1.0 wt % silicon (Si), an amount of 0.40 to 1.80 wt % manganese (Mn), an amount of 0.10 to 1.0 wt % chromium (Cr), an amount greater than 0 and less than or equal to 0.2 wt % vanadium (V), an amount greater than 0 and less than or equal to 0.4 wt % copper (Cu), an amount greater than 0 and less than or equal to 0.5 wt % molybdenum (Mo), an amount of 0.015 to 0.070 wt % aluminum (Al), an amount greater than 0 and less than or equal to 0.25 wt % nickel (Ni), an amount greater than 0 and less than or equal to 0.1 wt % tin (Sn), an amount greater than 0 and less than or equal to 0.05 wt % phosphorus (P), an amount greater than 0 and less than or equal to 0.03 wt % sulfur (S), an amount of 0.005 to 0.02 wt % nitrogen (N), and the remainder being iron (Fe) and other inevitable impurities.

A method for manufacturing a high-strength steel bar can include the steps of: reheating a steel slab at a temperature ranging from 1000° C. to 1100° C., the steel slab including a certain amount of carbon (C), silicon (Si), manganese (Mn), phosphorus (P), sulfur (S), chromium (Cr), copper (Cu), nickel (Ni), molybdenum (Mo), aluminum (Al), vanadium (V), nitrogen (N), antimony (Sb), tin (Sn), and iron (Fe) and other inevitable impurities, The method can further include finish hot-rolling the reheated steel slab at a temperature of 850° C. to 1000° C., and cooling the hot-rolled steel to a martensite transformation start temperature (Ms (° C.)) through a tempcore process.

A steel reinforcing bar contains 0.06 wt % to 0.11 wt % carbon, more than 0 and not more than 0.25 wt % silicon, 0.8 wt % or more and less than 2.0 wt % manganese, more than 0 and not more than 0.01 wt % phosphorus, more than 0 and not more than 0.01 wt % sulfur, 0.01 to 0.03 wt % aluminum, 0.50 to 1.00 wt % nickel, 0.027 to 0.125 wt % molybdenum, more than 0 and not more than 0.25 wt % chromium, more than 0 and not more than 0.28 wt % copper, more than 0 and not more than 0.01 wt % nitrogen, and the remainder being iron and unavoidable impurities. The reinforcing bar has a surface layer and a core. The surface layer has a hardened layer of tempered martensite, and the core has a mixed structure of bainite, ferrite and pearlite.

A steel reinforcing bar contains 0.06 wt % to 0.11 wt % carbon, more than 0 and not more than 0.25 wt % silicon, 0.8 wt % or more and less than 2.0 wt % manganese, more than 0 and not more than 0.01 wt % phosphorus, more than 0 and not more than 0.01 wt % sulfur, 0.01 to 0.03 wt % aluminum, 0.50 to 1.00 wt % nickel, 0.027 to 0.125 wt % molybdenum, more than 0 and not more than 0.25 wt % chromium, more than 0 and not more than 0.28 wt % copper, more than 0 and not more than 0.01 wt % nitrogen, and the remainder being iron and unavoidable impurities. The reinforcing bar has a surface layer and a core. The surface layer has a hardened layer of tempered martensite, and the core has a mixed structure of bainite, ferrite and pearlite.

The invention relates to a duplex stainless steel having austenitic-ferritic microstructure of 35-65% by volume, preferably 40-60% by volume of ferrite and having good weldability, good corrosion resistance and good hot workability. The steel contains 0.005-0.04% by weight carbon, 0.2-0.7% by weight silicon, 2.5-5% by weight manganese, 23-27% by weight chromium, 2.5-5% by weight nickel, 0.5-2.5% by weight molybdenum, 0.2-0.35% by weight nitrogen, 0.1-1.0% by weight copper, optionally less than 1% by weight tungsten, less than 0.0030% by weight one or more elements of the group containing boron and calcium, less than 0.1% by weight cerium, less than 0.04% by weight aluminium, less than 0.010% by weight sulphur and the rest iron with incidental impurities.

The invention relates to a duplex stainless steel having austenitic-ferritic microstructure of 35-65% by volume, preferably 40-60% by volume of ferrite and having good weldability, good corrosion resistance and good hot workability. The steel contains 0.005-0.04% by weight carbon, 0.2-0.7% by weight silicon, 2.5-5% by weight manganese, 23-27% by weight chromium, 2.5-5% by weight nickel, 0.5-2.5% by weight molybdenum, 0.2-0.35% by weight nitrogen, 0.1-1.0% by weight copper, optionally less than 1% by weight tungsten, less than 0.0030% by weight one or more elements of the group containing boron and calcium, less than 0.1% by weight cerium, less than 0.04% by weight aluminium, less than 0.010% by weight sulphur and the rest iron with incidental impurities.

A process for manufacturing compact coils of ultra-fine grained, martensite-free steel bars, the process comprising the following stages:

a) rolling a steel billet by means of a roughing rolling mill producing a steel bar;

b) performing at least one first cooling stage so that the steel bar has a surface temperature higher than the martensite start temperature, and performing at least one first equalization stage in air;

c) rolling the steel bar by means of at least one intermediate rolling mill;

d) performing at least one second cooling stage always maintaining the surface temperature higher than the martensite start temperature, and performing at least one second equalization stage in air;

e) rolling the steel bar by means of a finishing rolling mill in a non-recrystallization temperature range, maintaining the whole cross-section of the steel bar within said non-recrystallization temperature range, and with a total reduction between 25 and 50% with respect to the cross-section of the steel bar at the entry of the finishing rolling mill, in order to obtain an ultra-fine-grained austenitic matrix;

f) winding the steel bar in a compact coil, by means at least one spooling device, so that the ultra-fine-grained austenitic matrix transforms in a mixture of ferrite and pearlite.

After the winding operation is completed, the compact coil can be transferred to a storage area through a transferring device, for example a walking beam, where a natural or forced or retarded cooling is applied to the coil.