Hot-dip galvanizing is a method of coating the surface of a metal product with a layer of zinc, second in popularity only to galvanic galvanizing technology. Meanwhile, in terms of the cost of implementation, as well as the durability of the formed zinc coatings, this method is superior to electrochemical galvanizing.
Test results of bolts with different galvanization in hydrochloric acid solution
You can familiarize yourself with the GOST requirements for hot-dip galvanized coatings by downloading the document in pdf format from the link below.
GOST 9.307-89 Unified system of protection against corrosion and aging. Hot zinc coatings. General requirements and control methods
Introduction
Metal products are used everywhere. But, unfortunately, nothing is eternal in the world! Even metal is destroyed naturally, leading to billions in losses. Therefore, it is not surprising that scientists are developing various technologies that can protect steel structures and products from corrosion.
Note that hot galvanizing is the simplest and most popular way to combat rust. Today we will talk in detail about this technological process, its properties, strengths and weaknesses, etc.
Hot-dip galvanized rod and wire
Hot-dip galvanizing makes steel rods and wires highly resistant to corrosion.
The use of such elements is very wide today and includes, among other things, the production of:
- Panels and nets for fencing;
- Technical grids,
- Filters;
- Slings for hanging elements;
- Hangers;
- Bucket handles;
- Barbed, shepherd's and coated wire;
- Fences.
Hot-dip galvanizing: what is it and a little history
Hot-dip galvanizing is the coating of a metal product with a layer of zinc to protect it from corrosion by immersing it in a bath of molten zinc. Metal temperature is 450 degrees Celsius.
The founder of hot-dip galvanizing is Paul Jacques Malouin (French chemist). It was he who, in 1742, came up with the idea of “bathing” steel parts in molten zinc. Paul announced his discovery at the Royal Academy.
And only after almost a hundred years this technology was modernized and patented. Sorel was able to achieve such success in 1836, proving the effectiveness of the method through multiple studies.
Properties of zinc coating. What products is it used for?
The coating is a barrier that protects against the formation of rust upon contact with the environment. Hot-deposited zinc has been proven to effectively protect products for 20 to 120 years, depending on the environment. In addition, elements and structures do not need to be repainted, which is a real savings!
Typically, hot-dip galvanizing is used to coat large products with simple shapes. These can be pipes, angles, sheets, beams, wire, etc. This method is not effective for products with threads, small holes or complex shapes.
Pipe galvanizing lines
— Full automatic galvanization of pipes.
— Automatic galvanizing based on “recipes” and controlled by a local and remote computer.
— Extremely limited intervention by operators only for changing the sizes of the internal and external purge rings.
— Just 3 operators can produce up to 1,100 pipes or 25 tons of pipes per hour.
— The equipment is suitable for pipes with a length of 4 to 9.5 meters.
— Semi-automatic lines with operator support for square and rectangular pipes.
Hot-dip galvanizing: description of process technology
How long the part will be under reliable protection from corrosion depends on the quality of the work. After all, the galvanizing process is quite capacious and takes place in several stages. Let's take a closer look at each of them.
Stage 1 - Degreasing
Before proceeding with galvanizing, it is necessary to prepare the surface of the target product. First, the base metal must be degreased, because it may have oily stains, lubricant residues and various organic contaminants. For these purposes, special alkaline or acidic solutions are used. There is no universal remedy; experts choose it based on the level of contamination of the product. It must be said that the optimal temperature for this process is 60-80ºС.
Stage 2 - Washing
This procedure should not be neglected! It is used to ensure that all residues of fat, foam and degreasing agents are removed. The second reason is that the solution from the degreasing bath should not get into subsequent baths.
Stage 3 - Etching
This operation allows you to remove rust and scale from the part before galvanizing. It needs to be immersed in a bath containing a solution of hydrochloric acid with a concentration of 120-210 g/l. By the way, the air temperature in the workshop at this moment should be within 20 - 25ºС. Etching is one of the most effective ways to achieve a smooth and relatively shiny surface.
Keep in mind that hydrochloric acid can also harm the metal itself, so special inhibitors should be added to the solution (additives that allow the acid to dissolve only rust and scale without damaging clean steel).
Stage 4 - Washing
After etching, particles of the solution components remain on the surface. They need to be removed. Therefore, washing is needed again.
Stage 5 - Fluxing
It sounds paradoxical, but after washing, iron oxides will again appear on the product. They can be eliminated by fluxing. This operation allows you to obtain a passive film on the surface of the product, which protects against subsequent oxidation and provides excellent wetting at the time of galvanizing.
To create a solution, zinc and ammonium chlorides are used. You can give an example of one of the popular compositions - 55.4% NH4Cl, 6% glycerol, 38.4% ZnCl2. For fluxing, a temperature of around 60ºC is required. The concentration of the solution should be 410 - 590 g/l and it must be kept under constant control! Periodically it is necessary to clean the bathtub by adding hydrogen peroxide to it. Ferric iron salts will remain at the bottom. The resulting sediment is sent to settling tanks and then filtered.
Stage 6 - Drying
If a wet product is immersed in molten zinc, the remaining water will begin to evaporate, causing “micro-explosions.” As a result, untreated or uneven areas may be observed!
In addition, the wet product will begin to lower the temperature of the molten zinc. This means that more energy will be required to maintain it. Therefore, it is important to first place the product in a drying oven at a temperature of about 100ºC.
Stage 7 - Galvanizing
If you want to end up with a product with a high-quality protective layer, then there are a number of factors to consider. Namely:
- the quality of the materials, as well as the temperature to which they were heated;
- time and speed of immersion of the product;
- the speed at which the products are removed from the bath and the method of cooling them.
Note that when dipped into the bath, the flux begins to melt, thereby ensuring the wettability of the molten zinc. The speed at which the part is lowered is critical. If it is insufficient, the flux will have time to melt ahead of time and oxides will remain on the surface. And if you immerse quickly, the flux will not melt and the quality of adhesion of the zinc to the product will sharply deteriorate.
The optimal technology for hot-dip galvanizing metal involves keeping the product in a bath of melt for 3 to 10 minutes. Keep in mind that during the above process, a layer of slag appears on the surface of the melt in the bath. It must be removed using a special scraper before you begin to lift the product. Otherwise, this slag will settle on the galvanized surface of the part.
But the thickness of the metal layer will depend directly on the lifting speed of the product. It's all about the rate of crystallization of the melt. This means that the slower the galvanized part rises, the thicker the protective layer. It is worth considering the dimensions and shape of the product. Based on them, the speed and inclination of the climb are calculated individually.
Stage 8 - Drying
At the end, the metal product is left to cool. This procedure is carried out in two stages. First in the open air in the workshop, then in a warm warehouse.
Areas of application
Metal structures used outdoors need protection. Hot zinc coating is used for the following products:
- power line supports, especially high-voltage ones;
- anti-corrosion coating of the lower part of the ship's hull;
- metal structures of bridges and pipelines;
- street lighting poles;
- building frames;
- steps of stairs;
- railings, balcony railings and other building elements;
- ventilation system pipes.
The method of hot-dip galvanizing metal is used for pipelines and various elements of garden and facade design.
Coating quality control, rejection criteria
After completion of work, the product should be inspected for flaws and defects. The quality of hot-dip galvanizing is regulated by GOST 9.307-89. The following criteria must be met.
- Smooth or rough coating is allowed;
- The zinc layer must be continuous;
- The color is matte in dark gray tones or silver-glossy;
- Sagging is not allowed on the surface of a galvanized product. Insertion of hartzink (sediment), if present, is no more than 2 mm.
A number of signs that are not considered defects:
- rippling and minor surface irregularities;
- rainbow shades or spots in light gray tones;
- minor metal scratches of the protective layer if the base metal is not visible to the naked eye.
In addition, if there are areas with gaps, the area of which does not exceed 2% of the total, they can be treated with compounds for cold galvanizing or thermal spraying. Similarly, areas not coated with zinc, up to two centimeters in diameter, are eliminated.
According to the above-mentioned GOST, the thickness of the protective zinc layer should be in the range of 40 - 200 microns. Or it is written in the product passport, based on its features and operating conditions.
This parameter should be checked before chroming (applying an additional protective film over zinc) or applying preservative lubricants. There are two ways:
- using magnetic thickness gauges;
- metallographic analysis.
And finally, the quality of adhesion of the zinc layer is checked. Particular attention is paid to areas with threads or welding points! To control adhesion, one of the following four methods is used:
- scratch grid;
- heat;
- brushing;
- blows with a rotary hammer.
Advantages and disadvantages of hot-dip galvanizing
Advantages:
- excellent corrosion resistance;
- relatively inexpensive process;
- high-performance lines;
- galvanized product has good thermal conductivity;
- the galvanized layer does not lose its protective properties even if it is damaged;
- The workshop is easy to maintain.
Flaws:
- this technology does not allow the application of thin layers of zinc, and is not intended for threaded products and high-precision parts;
- not suitable for small piece orders;
- it is difficult to maintain uniform coverage;
- high zinc consumption;
- unpresentable appearance – gray matte color, not suitable for decorative items;
- It is impossible to coat products that exceed the dimensions of the bath for immersion.
GALVANIZED
— Up to an outer diameter of 4”, two pipes are processed simultaneously.
— Pipes with a diameter of more than 4” are processed one at a time.
— When processing one or two pipes, all pipes exit from the same side.
— Internal pipe blowing can be done both horizontally and at an angle.
— The immersion unit is replaceable for quickly changing pipe sizes.
- The same screws are suitable for driving pipes with diameters from 2" to 3/8" to avoid screw replacement.
Cost of hot galvanizing. Factors influencing price formation.
The cost of the service is individual and depends on a number of parameters. This takes into account the dimensions, shape of the product, complexity of processing, and amount of work. There are also additional “options” for which you need to pay extra. For example, creating technological holes or “ears” for fastenings, removing old coating, etc.
One of the main parameters of price formation will be zinc consumption; the higher it is, the more expensive it is.
Today, the average price in Russia for hot galvanizing will be in the range from 22,000 to 40,000 rubles per ton. Also keep in mind that many companies charge an additional fee for urgency. The cost of galvanizing parts weighing up to 100 kilograms, light but large products or those that have cavities, pockets, corners, etc. is separately discussed. Here the price can vary from 30,000 to 50,000 rubles per ton.
Centrifuge hot dip galvanizing lines
Manual and automatic galvanizing using a centrifuge
- Manual type with "Monorail cycle"
- Automatic robot top centrifuge 40 baskets per hour
- Automatic robot top centrifuge 80 baskets per hour
Innovative high-performance and high-quality galvanizing plant using a centrifuge.
Net productivity up to 4 tons per hour.
100% zinc return directly above the mirror surface without operator intervention to clean it.
Very important zinc saving.
Drum filling device and feed conveyors.
Closed pre-treatment tunnel with automatic double gantry valve operating according to the entered “recipe”.
Drum unloading and material moving conveyor.
Belt dryer.
Fully automatic processes of material weighing, basket filling, immersion, zinc surface cleaning, zinc exit.
Ceramic oven with top heating.
Software for adjustment and monitoring of an automatic transport system.
