In this research, the reason for fracture and destruction of the galvanized furnace-rollers of the Mobarakeh Steel Company and methods to reduce this problem has been discussed. This reason was studied by employing chemical analysis, metallographic, Vickers micro-hardness, X-ray diffractometer and investigations of the crack propagation path in failed sample. The examination results revealed that the sigma phase embrittlement and an increase of precipitations in the microstructure caused the failure. In order to reduce the fracture, several cycles of homogenization heat treatment were employed. At first, impact samples were prepared from failed rollers and homogenization treatments were carried out at temperatures ranging from 950 to 1100 o C in increments of 50 o C for 2 h. then the samples were cooled in four different medias (furnace, air, oil and water). After performing the impact test on the heat treated samples, in order to investigate the microstructures, the sigma phase and precipitation contents, and fractured surfaces, optical microscopy metallography, X-ray and SEM examinations were performed respectively on fractured samples. The roller surfaces fail because of adhesion, so in this research the idea to use Ni-P electroless coatings was introduced to reduce the adhesion effect. Therefore several Ni-P coatings containing 6 % phosphor with different thicknesses was performed on the surface of the roller's steel. The samples were placed in an inert atmosphere in 400 o C for 1 hour and in 85% N 2 -15% H 2 anneal furnace in 800 o C for 10 hours. The effect of anneal-furnace atmosphere on the morphology, structure variation, and abrasion behavior of coatings was studied by performing SEM, electron distribution spectroscopy, X-ray diffraction and the pin on discs abrasion tests in room temperature and 400 o C. the results show that the effect of furnace atmosphere on the samples behavior varies with coatings thicknesses, so that a heat treated coating with a 30 micron thickness in high temperature abrasion situations and the coatings on the anneal furnace atmosphere in room temperature abrasion situations exhibit excellent abrasion resistance. The role of high-temperature gas nitriding on cyclic oxidation of the roller's steel was also studied. The results indicated that high-temperature gas nitriding process has a suitable and effective influence on the oxidation rate of the roller's steel. The low oxidation rate of the nitrided steel after 100 hours of oxidation was because of the appropriate Cr 2 O 3 growth due to alloys structure-change throughout the nitriding process and the creation of Key Words HH Alloy, sigma phase embrittlement, heat treatment, electroless coating, high-temperature gas nitriding, oxidation.