.

ANBUROSE.S M.E (CIM) 200721521 CEG, ANNA UNIVERSITY

.
hot

dip galvanizing

hot dip galvanizing

Galvanized coatings are formed by a metallurgical reaction between the steel and the zinc.
This reaction occurs when the steel reaches the temperature of the molten zinc 455oC. This reaction forms a zinc-iron alloy of crystalline form, that grows from the steels surface. The thickness of this alloy layer is determined by the time the steel is immersed in the molten zinc alloy.

Zinc is among single most widely used coating materials used to protect steel from corrosion. It is applied to steel components by a number of industrial processes. These include zinc electroplating, the continuous galvanizing of sheet, wire and hollow sections, and the hot dip galvanizing of fabricated steel items.

Zinc is the primary anti-corrosion component for protecting steel in its various forms, and is used for electroplating, continuous galvanizing of wire, sheet and tube. hot dip galvanizing of structural steel.

The hot dip galvanizing process

Hot-dip Galvanizing Process

The hot-dip galvanizing process consists of three basic steps: surface preparation, galvanizing, and inspection.

Surface Preparation

It is essential for the steel surface to be clean and uncontaminated in order to obtain a uniform, adherent coating. Surface preparation is usually performed in sequence by caustic (alkaline) cleaning, water rinsing, pickling, a second water rinsing, and fluxing. The caustic cleaner removes organic contaminants including dirt, water-based paint markings, grease, and oil. Next, scale and rust are removed by a pickling bath of hot sulfuric acid (150 F / 66 C) or room-temperature hydrochloric acid. Water rinsing usually follows both caustic cleaning and pickling.

The hot dip galvanizing process

Loading - jigging Degreasing Pickling Pre-fluxing Hot dip galvanizing Quenching
Hot caustic

Hydrochloric acid Zinc am. chloride Molten zinc

Dichromate

The hot dip galvanizing process

Loading - jigging
The steel items need to be supported during the hot dip galvanizing process. Solutions and molten zinc must be able to flow into all sections and drain off all sections. Steel items must be designed to prevent air, solutions and molten zinc becoming trapped

Check design for possible problems

The hot dip galvanizing process

Degreasing
A hot (90oC) caustic bath is used to remove Oil, grease, paint another organic compounds
If these contaminating materials are not removed, the next stage of the process (pickling) is affected Check if any paint is on item - some paints are not easily removed and may require abrasive blasting before galvanizing Some pipes and pipe fittings have a black varnish coating that cannot be removed in the caustic bath.

The hot dip galvanizing process

Acid pickling
The steel items are immersed in hydrochloric acid to remove - rust, mill scale and other metal oxides The steel surface must be perfectly clean of these oxides for the molten zinc to react with the steel Very heavy rust may not be easily removed by pickling badly rusted items should be abrasive blasted or mechanically cleaned first.

The hot dip galvanizing process

Pre-fluxing
Steel items are water rinsed after pickling and immersed in hot (70-80oC) zinc ammonium chloride (ZAC) solution. The ZAC solution conditions the clean steel surface ready for hot dip galvanizing. Good pre-treatment = good quality galvanizing

Surface Preparation
Zinc-iron metallurgical bond only occurs on clean steel

Degreasing Removes dirt, oils, organic residue Pickling Removes mill scale and oxides
Fluxing Mild cleaning, provides protective layer
Degreasing/Caustic cleaning

The hot dip galvanizing process

Quenching
After hot dip galvanized steel item is removed from the galvanizing bath, it is immediately quenched in a sodium dichromate solution The dichromate quenching cools the item so that it can be quickly handled and passivates the surface of the galvanized coating to maintain its bright appearance.

The hot dip galvanizing process

Hot dip galvanizing
The steel is immersed in molten zinc (temp 4500C)
The clean steel surface reacts with the molten zinc to form a zinc-iron alloy which is very strongly bonded to the surface.

The hot dip galvanized coating forms in 3-5 minutes, depending on the steel thickness.
Free zinc layer Galvanized coating Alloy layers

Steel

Micrograph - 100 X

The hot dip galvanizing process

Quenching
After hot dip galvanized steel item is removed from the galvanizing bath, it is immediately quenched in a sodium dichromate solution The dichromate quenching cools the item so that it can be quickly handled and conditions the surface of the galvanized coating to maintain its bright appearance. Chromate quenching will reduce white rusting problems. White rust forms when rainwater reacts with newly galvanized steel to form zinc hydroxide. Poor storage or HDG steel will also promote white rust.

Galvanizing

Steel articles are immersed in a bath of molten zinc ( 830 F) > 98% pure zinc, minor elements added for coating properties (Al, Bi, Ni)
Zinc reacts with iron in the steel to form galvanized coating

Zinc bath removal

Inspection

Steel articles are inspected after galvanizing to verify conformance to appropriate specs.
Surface defects easily identified through visual inspection. Coating thickness verified through magnetic thickness gauge readings.

The hot dip galvanizing process

Characteristics
Typically 65 - 150 microns thick (1 mm = 1000 microns)
Zinc iron alloy layers make up 80% - 100% of the coating. The zinc-iron alloy layers are harder than 250 grade steel

Zinc Zinc-iron alloys Steel

Micrograph of hot dip galvanized coating

The hot dip galvanizing process

Coating comparisons
Compared to zinc electroplating (ZEP) and continuous galvanizing (CG), hot dip galvanizing (HDG) is better because.. - HDG is thicker and will last over 50 years or more without rusting - HDG is harder and is 5 times more abrasion resistant than ZEP and CG - HDG coats all external and internal surfaces and edges. All CG coatings have cut, exposed edges after processing.

Coating thickness of coatings on galvanized products

100 90 80 70 60 50 40 30 20 10 0

Z350 Gal. sheet

Metallurgical Bond

Edge Protection

Same thickness at corner

Micrograph of galvanized edge

Influencers of Coating Development

Steel Surface Conditions

Steel Chemistry Silicon Phosphorous

The Sandelin Curve

Coating Appearance
Newly Galvanized No Spangle Newly Galvanized Dull Coating

Newly Galvanized Highly Spangle

Newly Installed Shiny & Dull Coating

The Zinc Patina

Forms as zinc reacts with the environment

Consists of zinc oxide, zinc hydroxide, and zinc carbonate Protects the galvanized coating by providing an additional layer of corrosion resistance

Passivation Cycle
Time 0 48 hrs.
48 hrs. 6 mo

6 mo. 2 yrs.

Environmental Performance

Atmospheric Liquid (Chemicals, Fresh H2O, Salt H2O) Soil High Temperature Low Temperature Concrete

Liquid: Effect of pH on HDG steel

Performance in Soil
> 200 different soil types Complex corrosion kinetics in soil Variables include: Porosity Resistivity Organic material Moisture content pH Temperature

Performance in Various Temps High Temperature < 392 F (200 C) Low Temperature > -75 F (-60 C)

Metallurgical Bond

Hot-dip galvanizing is a applied coating that provides a combination of properties unmatched by other coating systems because of its unique metallurgical bond with the steel.
Typical zinc-iron alloy layers

Fatigue Strength

the fatigue resistance of galvanized steel reinforcement that deformed reinforcing steel, exposed to an aggressive environment prior to testing under cyclic tension loading, performs better galvanized.

Barrier Protection

Paint Powder Coatings Galvanizing

Cathodic Protection
Impressed Current Galvanic Sacrificial Anode Galvanic Zinc Application Zinc Metallizing Zinc-rich Paints Hot-dip Galvanizing

Cathodic Protection
Impressed Current
External source of direct current power is connected (or

impressed) between the structure to be protected and the ground bed (anode).

Ideal impressed current systems use ground bed material that can discharge large amounts of current and yet still have a long life expectancy.

Cathodic Protection
Galvanic Sacrificial Anode
Pieces of an active metal such as magnesium

or zinc are placed in contact with the corrosive environment and are electrically connected to the structure to be protected Example: Docked Naval Ships

Cathodic Protection
Galvanic Zinc Application
Zinc Metallizing (plating)

Feeding zinc into a heated gun, where it is melted and sprayed on a structure or part using combustion gases and/or auxiliary compressed air.

Zinc-rich Paints Zinc-rich paints contain various amounts of metallic zinc dust and are applied by brush or spray to properly prepared steel. Hot-dip Galvanizing Complete immersion of steel into a kettle/vessel of molten zinc.

Galvanic Zinc Applications

Zinc Metallizing

Zinc-rich Paints

Concrete: Rebar Corrosion

Cracking Staining

Spalling

Complete Failure

Concrete: Galvanized Rebar

Unprotected Rebar Galvanized Rebar

Features of HDG Coatings

Zinc-iron intermetallic layers Harder than the substrate steel Zinc patina Barrier protection Cathodic protection Metallurgical bond to the substrate steel Paintable Edge and corner protection Zinc is a natural and healthy metal

Benefits of HDG Coatings

Maintenance-free for 50 100 years in most atmospheric environments Long term performance in soils, water, and chemical environments No touch-up required High & Low temperature performance Application independent of weather 100% recyclable

Dry Bridge Road Bridge

Date Galvanized 1999
Sector Bridge & Highway Environment Rural Location Alexander, NY

Harrisburg Airport Transportation Facility

Date Galvanized 2004 Sector Building & Architecture Environment Urban Location Harrisburg, PA

AES-PR Total Energy Power Plant

Date Galvanized 2002 Sector Electrical, Utility & Communication Environment Industrial Location San Juan, Puerto Rico

Leprino Foods

Date Galvanized 2002 Sector Food & Agriculture Environment Rural Location Waverly , NY

Aspinwall Water Treatment Plant

Date Galvanized 2001 Sector Water & Marine Environment Industrial Location Pittsburgh, PA