Hot-dip galvanizing

Hot-dip galvanizing is a form of galvanization. It is the process of coating iron, steel, or

aluminum with a thin zinc layer, by passing the metal through a molten bath of zinc at a
temperature of around 860 F !60 "#. $hen e%posed to the atmosphere, the pure zinc
&n# reacts with oxygen '
(
# to form zinc oxide &n'#, which further reacts with carbon
dioxide "'
(
# to form zinc carbonate &n"'
)
#, a usually dull grey, fairly strong material
that stops further corrosion in many circumstances, protecting the steel below from the
elements. Galvanized steel is widely used in applications where rust resistance is needed,
and can be identified by the crystallization patterning on the surface often called a
*spangle+#.
Process
,he process of hot-dip galvanizing results in a metallurgical bond between zinc and steel
with a series of distinct iron-zinc alloys. ,he resulting coated steel can be used in much
the same way as uncoated. .alvanized steel can be welded/ however, one must e%ercise
caution around the resulting zinc fumes. .alvanized steel is suitable for high-temperature
applications of up to )0(F (00"#. ,he use of galvanized steel at temperatures above
this will result in peeling of the zinc at the intermetallic layer. 1lectrogalvanized sheet
steel is often used in automotive manufacturing to enhance the corrosion performance of
e%terior body panels, this is however a completely different process.
2ead is often added to the molten zinc bath to improve the fluidity of the bath thus
limiting e%cess zinc on the dipped product by improved drainage properties#, helps
prevent floating dross, ma3es dross recycling easier and protects the 3ettle from uneven
heat distribution from the burners.
456
2ead is either added to primary &5 .rade &inc or
already contained in used secondary zinc. 7 third, declining method is to use low &8
.rade &inc.
4(6
9teel strip can be hot-dip galvanized in a continuous line. :ot-dip galvanized steel strip
also sometimes loosely referred to as galvanized iron# is e%tensively used for
applications re;uiring the strength of steel combined with the resistance to corrosion of
zinc. 7pplications include< roofing and walling, safety barriers, handrails, consumer
appliances and automotive body parts. 'ne common use is in metal pails. .alvanised
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. 'ther modern techni;ues have largely
replaced hot-dip for these sorts of roles. ,his includes electrogalvanizing, which deposits
the layer of zinc from an a;ueous electrolyte by electroplating, forming a thinner and
much stronger bond.