Steel Armor Wire Coatings

Abstract

A wire includes a ferrous core. The ferrous core can be coated. The coatings can include nickel, molybdenum, zinc and Fe. A process of forming a wire can include placing a metal strip alongside a ferrous wire core, bending the strip around the core, and seam welding the strip to form a metal tube around the core. The process of forming a wire can include applying a metal layer to a ferrous metal rod to form a plated rod, placing a metal strip alongside the rod, bending the strip around the rod, and seam welding the strip to form a metal tube around the rod. The process of forming a wire can include coating a ferrous wire core with a layer of nickel, molybdenum or a nickel alloy that circumferentially surrounds the ferrous wire core.

What is claimed is: 
     
         1 . A process of forming a wire comprising:
 coating a ferrous wire core with an interface layer of nickel, molybdenum or a nickel alloy,   wherein the interface layer circumferentially surrounds the ferrous wire core; and   coating the interface layer with an outer layer.   
     
     
         2 . The process of  claim 1 , wherein the ferrous wire core is steel. 
     
     
         3 . The process of  claim 1 , wherein the interface layer has a thickness of between 2 and 60 microns. 
     
     
         4 . The process of  claim 1 , wherein outer layer has a thickness of between 1 and 50 microns. 
     
     
         5 . The process of  claim 1 , wherein the outer layer comprises a zinc alloy, and wherein the zinc allow comprises:
 binary Zn—Ni or Zn—Co alloy; or   ternary Zn—Ni—Co, Zn—Ni—Mo or Zn—Co—Mo alloy.   
     
     
         6 . The process of  claim 1 , further comprising an Fe layer, wherein the Fe layer circumferentially surrounds the interface layer and is circumferentially surrounded by the outer layer. 
     
     
         7 . The process of  claim 6 , wherein the Fe layer has a thickness of between 2 and 20 microns. 
     
     
         8 . The process of  claim 1 , further comprising a galvanized zinc coating.