Hot-dip galvanization

Process of coating iron or steel with molten zinc

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Galvanised hand rail Crystalline surface of a hot-dip galvanized handrail, known as "spangle" Protective effect: completely rusted letter box mounted to a hot-dip galvanized wall Steel strip coming out of the zinc pot of a continuous vertical hot-dip galvanizing line

Hot-dip galvanization is a form of galvanization. It is the process of coating iron and steel with zinc, which alloys with the surface of the base metal when immersing the metal in a bath of molten zinc at a temperature of around 450 °C (842 °F). When exposed to the atmosphere, the pure zinc (Zn) reacts with oxygen (O2) to form zinc oxide (ZnO), which further reacts with carbon dioxide (CO2) to form zinc carbonate (ZnCO3), a usually dull grey, fairly strong material that protects the steel underneath from further corrosion in many circumstances. Galvanized steel is widely used in applications where corrosion resistance is needed without the cost of stainless steel, and is considered superior in terms of cost and life-cycle. It can be identified by the crystallization patterning on the surface (often called a "spangle").[1]

Galvanized steel can be welded; however, one must exercise caution around the resulting toxic zinc fumes. Galvanized fumes are released when the galvanized metal reaches a certain temperature. This temperature varies by the galvanization process used. In long-term, continuous exposure, the recommended maximum temperature for hot-dip galvanized steel is 200 °C (392 °F), according to the American Galvanizers Association. The use of galvanized steel at temperatures above this will result in peeling of the zinc at the inter-metallic layer[citation needed]. Electrogalvanized sheet steel is often used in automotive manufacturing to enhance the corrosion performance of exterior body panels; this is, however, a completely different process which tends to achieve lower coating thicknesses of zinc.

Like other corrosion protection systems, galvanizing protects steel by acting as a barrier between steel and the atmosphere. However, zinc is a more electropositive (active) metal in comparison to steel. This is a unique characteristic for galvanizing, which means that when a galvanized coating is damaged and steel is exposed to the atmosphere, zinc can continue to protect steel through galvanic corrosion (often within an annulus of 5 mm, above which electron transfer rate decreases).

Process

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The process of hot-dip galvanizing results in a metallurgical bond between zinc and steel, with a series of distinct iron-zinc alloys. The resulting coated steel can be used in much the same way as uncoated.

A typical hot-dip galvanizing line operates as follows:[2]

• Steel is cleaned using a caustic solution. This removes oil/grease, dirt, and paint.
• The caustic cleaning solution is rinsed off.
• The steel is pickled in an acidic solution to remove mill scale.
• The pickling solution is rinsed off.
• A flux, often zinc ammonium chloride is applied to the steel to inhibit oxidation of the cleaned surface upon exposure to air. The flux is allowed to dry on the steel and aids in the process of the liquid zinc wetting and adhering to the steel.
• The steel is dipped into the molten zinc bath and held there until the temperature of the steel equilibrates with that of the bath.
• The steel is cooled in a quench tank to reduce its temperature and inhibit undesirable reactions of the newly formed coating with the atmosphere.

Lead is often added to the molten zinc bath to improve the fluidity of the bath (thus limiting excess zinc on the dipped product by improved drainage properties), help prevent floating dross, make dross recycling easier and protect the kettle from uneven heat distribution from the burners. Environmental regulations in the United States disapprove of lead in the kettle bath. Lead is either added to primary Z1 grade zinc or already contained in used secondary zinc. A third, declining method is to use low Z5 grade zinc.[3]

Steel strip can be hot-dip galvanized in a continuous line. Hot-dip galvanized steel strip (also sometimes loosely referred to as galvanized iron) is extensively used for applications requiring the strength of steel combined with the resistance to corrosion of zinc, such as roofing and walling, safety barriers, handrails, consumer appliances and automotive body parts. One common use is in metal pails. Galvanised steel is also used in most heating and cooling duct systems in buildings

Individual metal articles, such as steel girders or wrought iron gates, can be hot-dip galvanized by a process called batch galvanizing. Other modern techniques have largely replaced hot-dip for these sorts of roles. This includes electrogalvanizing, which deposits the layer of zinc from an aqueous electrolyte by electroplating, forming a thinner and much stronger bond.

In some cases, it may be desirable to have designates parts of the metal as non-galvanized. This is often desired when metal will be welded after galvanization. To accomplish this, a galvanizer will typically use a masing compound to coat the areas that will not be galvanized during the hot dip process.

History

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In , French chemist Paul Jacques Malouin described a method of coating iron by dipping it in molten zinc in a presentation to the French Royal Academy.

In , Luigi Galvani, for whom galvanizing was named, discovered the electrochemical process that takes place between metals during an experiment with frog legs.

In , Alessandro Volta furthered the research on galvanizing when he discovered the electro-potential between two metals, creating a corrosion cell.

In , French chemist Stanislas Sorel obtained a patent for a method of coating iron with zinc, after first cleaning it with 9% sulfuric acid (H2SO4) and fluxing it with ammonium chloride (NH4Cl).

Specification

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A hot-dip galvanized coating is relatively easier and cheaper to specify than an organic paint coating of equivalent corrosion protection performance. The British, European and International standard for hot-dip galvanizing is BS EN ISO , which specifies a minimum coating thickness to be applied to steel in relation to the steels section thickness e.g. a steel fabrication with a section size thicker than 6 mm shall have a minimum galvanized coating thickness of 85 μm.

Further performance and design information for galvanizing can be found in BS EN ISO -1 and BS EN ISO -2. The durability performance of a galvanized coating depends solely on the corrosion rate of the environment in which it is placed. Corrosion rates for different environments can be found in BS EN ISO -1, where typical corrosion rates are given, along with a description of the environment in which the steel would be used.

See also

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References

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Galvanizing is a manufacturing process where steel or iron is coated with zinc. Galvanized steel, therefore, is zinc-coated steel. There are several galvanizing methods, with the most common method being hot dipped galvanization.

Benefits of Galvanized Steel
Galvanized steel is one of the most popular steels because it is rust-resistant and more affordable than most treated steels. And, it doesn&#;t require any maintenance or refinishing. Since the zinc coating protects it from the elements, the steel can last for 50 years in temperate environments. Even with severe weather exposure, galvanized steel can last for over 20 years.

Galvanizing Methods
As mentioned, there are several galvanizing methods including galvannealing, pre-galvanizing, electrogalvanizing, and hot-dip galvanizing. Hot-dip galvanizing is the most popular, which we will explain in more detail. But first, let&#;s briefly cover the other three.

• Galvannealing: combines hot-dip galvanizing with annealing to produce a dull matte surface that is good for welding and painting.
• Pre-galvanizing: the metal is primed with a cleaning agent and quickly passed through molten zinc which creates a more unified coating than standard hot-dipping.
• Electrogalvanizing: instead of molten zinc, the steel is covered with an electrolyte solution and then an electric current is applied which ultimately bonds the zinc to the steel.

What is the Hot Dip Galvanizing Process?
As the name suggests, the steel is dipped in hot, molten zinc. While the steel is inside the molten zinc, a metallurgical reaction occurs between the iron contained inside the steel and the hot zinc. The reaction is known as a diffusion process. The diffusion process is when the coating collects perpendicular to every surface and creates a uniform thickness.

When the steel is removed from the zinc bath, it reacts with the oxygen in the air to form zinc oxide. It then reacts to carbon dioxide and forms the final protective coating of zinc carbonate. Ultimately, the steel has a corrosion-resistant, multi-layered coating of zinc metal and iron-zinc alloy.
Hot-dipped galvanized steel has a fairly distinct appearance compared to other galvanized steel. It has a mottled, crystalline-like pattern known as a &#;spangle&#; pattern.

What is Hot Dip Galvanizing Used For?
Galvanized steel is very versatile. It is used in a wide range of industries, including agriculture, automotive, construction, solar, telecommunication, and many more. Because of its resistance to corrosion, galvanized steel is preferred in applications that may be exposed to moisture or the elements.

All kinds of screws, nuts, bolts, tools, and wires are galvanized to increase their durability. Entire steel frame buildings use galvanized steel to support the bulk of the structure. Fences, roofs, staircases, and more are often made with galvanized steel. As stated, galvanized steel is very versatile! Galvanized steel offers more than improved functionality; it also offers aesthetic appeal. Many architects incorporate galvanized steel in their designs. The shiny finish gives a clean, modern feel that is popular in contemporary architecture.

Hot Dipped Galvanized vs Galvanized Steel
In summary, hot-dipped galvanized steel is a type of galvanized steel. The hot-dip galvanizing process is relatively cheap, and the resulting product is very durable and versatile. Hot-dipped galvanized steel is most often used in applications that will be exposed to the elements as it is highly corrosion-resistant.

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