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Mechanical Galvanizing
Unbrako Standard Products Unbrako Special Engineered Fasteners Durlok Vibration Resistant Nuts & Bolts
General
Mechanical Galvanizing is similar to Hot-Dip Galvanizing in that they both apply a thick coating of zinc metal which provides sacrificial or cathodic protection to the steel. Because zinc is more reactive than iron, the zinc galvanized coating corrodes first, protecting the steel substrate. Mechanical Galvanizing results in a very uniform coating thickness reducing thread fit issues at assembly, making it a preferable coating for structural applications. Not only does Mechanical Galvanizing provide excellent coating uniformity, but the process is consistent from batch to batch and within each batch.
Application
Mechanical Galvanizing may be specified on a wide range of structural products including ASTM A325 Structural Bolts, A563 Grade DH Heavy Hex Nuts, A307 Bolts & Studs, A449 Hex Cap Screws, F1852 Tension Control Assemblies, F436 Hardened-Steel Washers, DIN 6914, DIN 6915, DIN 6916 and for Small Diameter Bolts, as well as fine thread Bolts.
Excellent Adhesion & controlled uniformity of Coating thickness. No hydrogen embrittlement. No detempering. Eliminate retapping of units. No Galling. No Sticking. Excellent Corrosion Protection. Pos-Plate Treatment. Batch to batch conformity. Overall Appearance. The below table provides comparative properties of five well known zinc coating methods. Characteristic of the Coating Adhesion Hot Dip Galvanizing Coating is integral with the steel because the formation process produces zinc/iron alloy layers over coated with zinc. Good - any discontinuities are readily visible as "black spots". Some excess zinc at drainage points on products. Normally about 50-125 m on tube and products; thicker coatings up to 250 m obtained by silicon killed steel or grit blasting Electroplating Good, comparable with other electroplated coatings. Mechanical Coatings Good, comparable with electroplated coatings. Zinc Spraying Good mechanical interlocking provided the abrasive grit blasting pretreatment is carried out correctly. Depends on operator skill Coatings are porous but The pores soon fill with zinc corrosion products and are thereafter impermeable. Thickness variable at will generally 100 - 150 m but coatings of up to 500 m can be applied. Zinc Dust Painting Good - abrasive grit blasting of the steel gives best results.
Uniform within limitations of "throwing power" of bath. Pores not a problem, as exposed steel protected by adjacent zinc.
Thickness
Thickness variable at Variable at will, will; generally 3 - 5 usually between m. Thicker layers 10 - 80 m. are possible but generally
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before galvanizing. Coatings 10 -30 m applied to continuous wire and sheet. Form ability and Conventional coatings Mechanical applied to finished Properties articles, not formable; alloy layer is abrasive resistant but brittle on bending. Special coatings with little or no alloy layer readily formed (e.g. on sheet) & resistance welded. Extra Treatments Conversion coatings chromate prevent wet storage stain; phosphates good on new sheet as a base for paints. Weathered coatings often painted (after 10 - 30 years) for longer service. Size of bath available. Parts up to about 25 meters long can dipped at some works. Care required at design stage for best results. Conti-nuous wire and sheet available.
uneconomical.
coat
Electroplated steel has excellent formability and can be spot welded. Small components are usually finished before plating.
When applied to finished articles, forming not required. Can weld through thin coating if necessary but preferable to mask edges to be welded and spray these afterwards. Coating with sealants that can provide a base for paints to give long life structures.
Abrasion resistance better than conventional paints. Painted sheet can be formed and resistance welded with minor damage.
Conversion Can have coatings (e.g. conversion Chromates coatings applied. used to prevent wet storage stain) Frequently used as a base for paints.
Other Considerations
Size of bath available. Process normally used for simple, fairly small components suitable for barrel plating or for conti-nuous sheet & wire. No heating except for hydrogen embrittlement relief on high strength steels.
Ideal for small parts including washers and springs (e.g. up to 15 cm or 250 g). Access difficulties (e.g. inside tubes).
No size or shape limitations very economi-cal for work with high weight to area ratio. Uneconomical on open mesh. Access difficulties may limit application (e.g. inside tubes). Best method of applying very thick coatings. Little heatings on the steel.
Suitable for anything that can be painted though there may be difficulties of access in narrow tubular structures. Can be brush, spray or dip applied. No heating involved. Performance varies with media used & percentage of zinc dust.
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