Scribd Logo
Upload

Welcome to Scribd!

  • 144 views

    Galvanising Process

    Uploaded by

    chepurthi
    The document describes the hot dip galvanizing process used to galvanize steel items. It involves several key steps: loading and jigging the steel items, degreasing, pickling in acid to remove oxides, pre-fluxing in a zinc solution, hot dipping in molten zinc at 450°C to form a galvanized coating, quenching in dichromate solution, and finally characteristics of the galvanized coating. The hot dip galvanized coating provides better corrosion protection than alternative coatings like electroplating due to being thicker, harder, and coating all surfaces.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPT, PDF, TXT or read online from Scribd

    Galvanising Process

    Uploaded by

    chepurthi
    144 views13 pages
    The document describes the hot dip galvanizing process used to galvanize steel items. It involves several key steps: loading and jigging the steel items, degreasing, pickling in acid to remove oxides, pre-fluxing in a zinc solution, hot dipping in molten zinc at 450°C to form a galvanized coating, quenching in dichromate solution, and finally characteristics of the galvanized coating. The hot dip galvanized coating provides better corrosion protection than alternative coatings like electroplating due to being thicker, harder, and coating all surfaces.

    Original Description:

    Webforge Galvanising Presentation

    Copyright

    © Attribution Non-Commercial (BY-NC)

    Available Formats

    PPT, PDF, TXT or read online from Scribd

    Did you find this document useful?

    Is this content inappropriate?

    The document describes the hot dip galvanizing process used to galvanize steel items. It involves several key steps: loading and jigging the steel items, degreasing, pickling in acid to remove oxides, pre-fluxing in a zinc solution, hot dipping in molten zinc at 450°C to form a galvanized coating, quenching in dichromate solution, and finally characteristics of the galvanized coating. The hot dip galvanized coating provides better corrosion protection than alternative coatings like electroplating due to being thicker, harder, and coating all surfaces.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    144 views13 pages

    Galvanising Process

    Uploaded by

    chepurthi
    The document describes the hot dip galvanizing process used to galvanize steel items. It involves several key steps: loading and jigging the steel items, degreasing, pickling in acid to remove oxides, pre-fluxing in a zinc solution, hot dipping in molten zinc at 450°C to form a galvanized coating, quenching in dichromate solution, and finally characteristics of the galvanized coating. The hot dip galvanized coating provides better corrosion protection than alternative coatings like electroplating due to being thicker, harder, and coating all surfaces.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    of 13

    The hot dip galvanizing process

    Technical seminar

    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. Can the item be easily jigged? Will touch marks be a problem? 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

    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. Dichromate 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.

    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

    The hot dip galvanizing process


    Zinc cost versus surface area versus zinc pickup Zinc price 2.00/kg
    Section thickness - mm Surface area/t - m 2 Zinc pickup Cost $/t Zinc pickup Cost $/t Zinc pickup Cost $/t Zinc pickup Cost $/t Zinc pickup Cost $/t - 450 g/m2 - 600 g/m2 - 700 g/m2 - 800 g/m2 - 1000 g/m2 1 255 115 230 153 306 179 357 204 408 255 510 2 128 57 115 77 153 89 179 102 204 128 255 3 85 38 77 51 102 60 119 68 136 85 170 5 51 23 46 31 61 36 71 41 82 51 102 5 51 23 46 31 61 36 71 41 82 51 102 10 26 11 23 15 31 18 36 20 41 26 51 15 17 8 15 10 20 12 24 14 27 17 34 20 13 6 11 8 15 9 18 10 20 13 26

    Good design reduces excessive zinc pick-up

    You might also like