Galvanizing Process G6

Galvanizing
Process of Steel
Materials
Material Engineering II
Group members
Name. IDno
1. nathan wake
2. natnael andualem
3. Oliyad tesfaye
coating (Galvanizing)
• Introduction
• What is galvanizing of steels
• What are galvanizing processes/operation on steels
• Type of galvanizing
• Advantage and Disadvantage of Galvanizing
• Application of galvanizing
What is Galvanizing? Features
of Galvanized Steels
• galvanized steels and aluminum alloys are
industrially important metals that are produced in
large quantities. Of these materials the corrosion
protection of steel is most challenging, even if iron
is nobler than zinc or aluminum. To prevent steel
parts from rusting there are two options:
• Switch to a metal that will not corrode when
exposed to water
• Coat the steel with a physical barrier to prevent
water from reacting with the iron
cont...
• As with most decisions in manufacturing, both of
these options are primarily evaluated in terms of
cost. Galvanization or galvanizing is the process of
applying a protective zinc coating to steel or iron, to
prevent rusting. The most common method is hot-
dip galvanizing, in which the parts are submerged in
a bath of molten zinc
Galvanic protection
• also known as cathodic protection, protects the
underlying steel substrate by corroding
preferentially, thus sacrificing itself in the process.
This type of protection is especially useful for
situations where the protected steel may become
exposed due to scratches, cuts, dents or coating
damage. Because zinc is a highly reactive and
electronegative metal, it will assume the role of the
anode, therefore corroding first in the event that
the adjacent steel is unprotected.
Types of Galvanizing
• Batch hot dip galvanizing
• Continuous galvanizing processes (in-line
galvanizing)
• Thermal spray (or metallising)
• Electroplating
• Sherardizing and thermal diffusion
• Mechanical plating
• Zinc rich paints
• Cold Dip Galvanizing
Batch hot dip
galvanizing
• In hot dip galvanizing, the metal is dipped into a
bath of molten zinc. This creates a much thicker
layer and is usually used for much larger pieces of
metal, such as highway barriers. The galvanizing
process consists of three basic steps: surface
preparation, galvanizing and in-spection. The
coating thickness of hot dip galvanization generally
is about 80-100 µm.
Continuous galvanizing
processes (in-line galvanizing)
• Cleaned steel wire is passed through a lead/zinc

bath at high speed (180 m/minute) to produce a
continuously galvanized wire. It is comparable to
those of continuously galvanized sheet. The
thickness of the coating changes according to the
coating grade and diameter of the wire from 3 µm
in the thinnest standard gauge to 43 µm in the
thickest (8 mm) heavy galvanized grade.
Thermal spray (or
metallising)
• Thermal spraying techniques are coating processes in
which melted materials are sprayed onto a surface. The
“feedstock” (coating precursor) is heated by electrical
or chemical means (combustion flame). Coating
materials available for thermal spraying include metals,
alloys, ceramics, plastics and composites. They are fed
in powder or wire form, heated to a molten and
accelerated towards substrates in the form of
micrometer-size particles. Combustion or electrical arc
discharge is usually used as the source of energy for
thermal spraying. Resulting coatings are made by the
accumulation of numerous sprayed particles. The
surface may not heat up significantly, allowing the
coating of flammable substances.
Electroplating
• One type of galvanization is called electroplating,
where the metal is exposed to an electric current in
a solution of zinc ions. The electric current causes
the zinc ions to migrate onto the metal, coating it in
a thin layer. The layer of zinc can be varied by the
length of time it is kept in bath. These coatings
typically have a thickness of 10-12 µm.
Sherardizing and
thermal diffusion
• In sherardizing, the items to be coated in zinc
powder are heated to about 400 ○C at which
temperature diffusion bonding of the zinc with the
steel takes place. Sherardized coatings are said to
be diffusion coatings whose thickness can be
significantly altered up to over 300 µm and whose
components can be customized by adding inorganic
compounds or other metals to the zinc powder.
Mechanical plating
• In mechanical plating, the items to be coated are
tumbled in zinc powder with special reducing
agents and glass beads to bind the zinc particles to
the surface of the steel. These coatings typically
have a thickness of 15–20 µm.
Zinc rich paints
• Zinc rich paint coatings consist of metallic zinc dust
in organic or inorganic vehicle/binders. Surface
preparation by abrasive blast cleaning or by using
power tools to expose bare steel with a profile is
necessary, and coatings may be applied by brush or
spray. Zinc rich coatings are barrier coatings which
also provide cathodic protection to small exposed
areas of steel, provided the steel surface is properly
prepared, and the paint conforms to relevant
standards.
Cold Dip Galvanizing
• Cold galvanizing is simply the application of a zinc-
rich paint to the surface of a steel element to
protect it from corrosion. As such, the term “cold
galvanizing” is considered to be a misnomer among
some professionals in the coating industry. Like hot-
dip galvanizing, cold galvanizing can provide barrier
protection and also some degree of cathodic
protection. However, the zinc dust present in the
paint or coating must be in high enough
concentrations to promote electrical conductivity
between the steel and the zinc.
Manufacturing Process
of Galvanization
• Zinc protects steel against corrosion because it
does not rust. Manufactures create galvanized steel
by immersing the metal in a tank of molten zinc
called “hot dip galvanizing” at temperatures of 820
to 860 degrees Fahrenheit.
• Zinc reacts with the iron molecules in the steel to
form surface layers which have both elements.
When the galvanizing finishes, the steel will be
protected by a topmost layer of pure zinc, followed
by an additional three layers of zinc mixed with iron
molecules, with each layer in decreasing amounts
of zinc.
Galvanizing Process
includes following steps
• Continuous Operation
• Cleaning & Preheating
• Heat Treatment
• Galvanizing
• Galvannealing
• Flatness Correction
• Final Processing
• Inspection
Advantages of
Galvanization
The zinc coating, when intact, prevents corrosive substances from
reaching the underlying steel or iron.
•
• The zinc protects iron by corroding first. For better results,
application of chromates over zinc is also seen as an industrial
trend.
•
• In the event the underlying metal becomes exposed, protection
can continue as long as there is zinc close enough to be
electrically coupled. After all of the zinc in the immediate area is
consumed, localized corrosion of the base metal can occur.
•
• Galvanized Steel is food safe.
Disadvantages of
Galvanization
Galvanized metal is difficult to paint because it’s
coated with a layer of oil to prevent white rust.
•
• Galvanized steel is suitable for high-temperature
applications of up to 200 °C (392 °F). The use of
galvanized steel at temperatures above this will
result in peeling of the zinc, galvanized fumes; at
the inter metallic layer.
Applications of
Galvanized Pipes
• Galvanized steel plays an essential role in our everyday
lives. It is frequently used in several sectors including
construction, transportation, agriculture and power
generation industries, etc. Coating services such as
thermal spraying are used in almost every industry. Wire
drawing, wind energy, valves, textile manufacturing,
solar energy, rubber manufacturing, pump repair, paper
and pulp, printing machinery, energy and power, medical
processing of pharmaceuticals, petrochemical, dies and
molds, mining, processing and metal production,
material handling, marine, industrial machinery,
beverage and food processing, fluid handling, semi-
conductor and electronics, military and defense,
converting, compressor, chemical, canning and bottling,
biomedical, automotive, rotorcraft and aerospace, and
agriculture are all industries that can benefit from
thermal spraying coating processes.

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Galvanizing

• Cleaned steel wire is passed through a lead/zinc

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