Stop contamination and extend furnace roll life with KarGen 3
Fewer strip defects start at the furnace roll
How KarGen 3 helps steel producers reduce pick-up, protect roll surfaces and keep strip quality under control.
In continuous annealing and heat-treatment lines, one small surface defect can quickly become a costly quality issue. When oxides or other contaminants build up on a furnace roll, they can transfer to the steel strip and create dimples, marks or other surface flaws. The result is familiar: more inspection, more rework and more pressure on production teams.
KarGen 3 was developed to address that exact problem.
Built for the heat. Designed to resist pick-up.
KarGen 3 is a nanotechnology-based thermal spray coating system for furnace rolls and other high-temperature components. It combines cobalt-based sublayers, an oxide-ceramic top layer and proprietary sealing materials in a multilayer structure.
Each layer has a role: mechanical strength, resistance to thermal cycling and shock, protection against oxidation and wear, and a sealed surface that helps prevent contaminant pick-up.
Why this matters on the line
Steel strip is processed at high temperatures, when the surface is more vulnerable to marking. If particles adhere to the roll surface, they can imprint defects directly onto the strip. By improving pick-up resistance, KarGen 3 helps protect surface quality where it matters most: inside the furnace, before defects travel further down the process.
The coating is suitable for rolls in both vertical and horizontal furnaces and can operate at temperatures up to 2400 °F. On water-cooled rolls, it may also help reduce the need for internal cooling water while maintaining roll face performance.
Proven through severe testing
During development, coated samples were exposed to repeated thermal cycling, thermal shock and pick-up trials. Engineers evaluated the coating structure, adhesion and surface condition after exposure to high temperatures, water quenching and contact with contaminated steel strip.
The selected system combined the most successful cobalt-based alloy powder, optimized spray parameters, a multilayer nano oxide-based sealant system and a dedicated heat-treatment schedule.
Beyond furnace rolls
Although KarGen 3 was originally developed for steel mill furnace rolls, the same properties make it relevant for other demanding environments: high-temperature boiler components, industrial mixers and equipment exposed to heat, abrasion, corrosion or impact.
The Takeaway
KarGen 3 is not just a protective coating for furnace rolls. It is a surface-quality tool for demanding thermal processes. By resisting pick-up, thermal shock, wear and oxidation, it helps furnace rolls stay cleaner for longer and supports more consistent strip quality.
Looking for a coating solution for high-temperature rolls or components? Contact Hannecard to discuss your application.
Article reference: Technical Spotlight. (n.d.). Nanotechnology-based thermal spray coating system. Technical Spotlight.
