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Hence, what is this process all about? Why can't we make an endeavor to tell our readers and those associated with the industry in layman's language? Galvanizing is the process of applying a protective zinc coating or layer to steel or iron. The objective behind the process is to protect the iron metal from corrosion. The process makes the metal rust-proof!
Since the Hot dip galvanizing process offers numerous benefits, it has been used in numerous industrial applications. Its versatility makes it favourite among many industries using an iron-on large scale for a wide range of processes.
Why do most of the galvanizing processes rely on zinc across the globe? This question assumes significance in the context of this significant article. There are obvious reasons behind choosing zinc over others. Here are a few features that make the zinc stand out from the rest:
• The corrosion of zinc is very slow
• Durable
• Provides cathodic protection
• Even corners and smaller areas get protected
The process of galvanizing is carried out through tried and tested machinery and tools. Industry experts are of the opinion that machines play an important role during the process. For example, surface treatment tanks, acid room enclosure, chemical pump, dry unit, galvanizing furnace and kettle, heat exchanger, waste gas washing system, baghouse filter, helping equipment, loading, and offloading equipment, conveyor systems, transfer car, and a host of others.
The machines' terminology may vary from company to company. However, more or less, these are the same.
The various reasons support the exponential rise of the use of galvanization. These are:
• Affordable and reliable
• Lower cost
• Minimum maintenance
• Prolongs the life of the coated metal
• Provides exceptional resistance to mechanical wear and tear of the metal made items
• Even minor areas get protected
• Saves precious time of painting the metal made space
• Saves money needed for replacing the corroded metallic items
The hot-dip galvanizing process has found application in countless industries and sectors. These include:
• Wind and solar industries
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• Automotive industry
• Construction industry
• Energy industry
• Telecommunication industry
First step: Preparation of the metal/ steel for the process
The sophisticated scientific process begins by executing the preparation of steel/ iron to accommodate zinc coating. It takes place through pickling. The metal piece goes through washing in an alkaline solution. Through this process rust, grease, and similar impurities get removed.
Second step: Immersing the metal in a bath of molten zinc
The second step comprises numerous processes and stages to form the zinc coating over the metal. Subsequently, the metal is immersed in a bath of molten zinc. Also, different parameters must match.
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There are various methods of galvanizing, with each type having its unique features and advantages. Here’s a look at them:
As the name suggests, this method is carried out by dipping the base metal in a molten pool of zinc. Before the actual galvanizing, the machinists must clean the base metal chemically, mechanically, or both. The cleaning is a preparation process to ensure a quality bond between the metal and the zinc coating. After cleaning, the metal is fluxed to remove any residual oxides.
The dipping process then follows in a pool of heated zinc, often maintained at a temperature of about 460°C (860°F). A metallurgical bond then begins between the zinc and the metal substrate. After pulling the metal from the bath, it reacts with oxygen to form zinc oxide. This zinc oxide also reacts with carbon dioxide to form zinc carbonate, which is the final protective coating.
Hot-dip galvanization is a quick and economical method, and you can perform it on simple and complex sheet metal designs. However, you may notice some inconsistent coatings on the metal.
The pre-galvanizing process is similar to hot-dip galvanizing. However, it is carried out in the first stage of production (at the steel mill). This process involves rolling metal sheets through a mechanical or chemical cleaning agent to prepare the metal for galvanizing. After cleaning, the machinist passes the base metal through a pool of molten zinc before recoiling it immediately.
This process ensures the rapid galvanization of large coils of steel sheets, creating a more uniform coating. However, some uncoated and exposed areas may become present when the fabrication of the pre-galvanized metal starts. For example, edges are left exposed when longer coils of sheet metal are cut into smaller pieces.
Unlike the other two processes discussed above, electrogalvanizing does not involve using a molten zinc bath. Instead, it involves the introduction of an electric current into an electrolyte solution before applying it to the steel material. The electric current works to transfer the zinc ions onto the metal substrate.
This method of galvanizing metal involves the electrical reduction of positively charged zinc ions to zinc metal. The zinc metal is then deposited on positively charged metal (steel or iron). Manufacturers also add grain refiners to ensure smooth zinc coatings on the metal. Like pre-galvanizing, electrogalvanizing is also applied on long rolls of sheet metal at the first stages of the product development process.
This process confers a precise and uniform coating thickness on the metal. However, coatings from this method are typically thinner than those of hot-dip galvanization.
Galvannnealing is a combination of the hot-dip galvanizing and annealing processes. This process aims to create galvanized steel with a specialized coating. The annealing and hot-dipping processes occur instantaneously to produce a matte gray finish.
The hot-dipping process normally occurs before passing the coated metal through air knives. The air knives help remove excess zinc from the metal. This is then followed by brief heating of the metal in an annealing furnace at 500 to 565 °C. The zinc and iron layers then diffuse into each other, creating laters of zin-iron alloy.
The galvanized steel produced through this method can withstand welding well, and the surfaces ensure excellent paint adhesion.
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