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Investigation on Effects of Steel Surface Properties on Galvanization Behavior

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Investigation on Effects of Steel Surface Properties on Galvanization Behavior Journal of Engineering Research and Applied Science Available at www.journaleras.com Volume 7 (1), June 2018, pp 861-868 ISSN 2147-3471 © 2018 Investigation on effects of steel surface properties on galvanization behavior E. Toklu1, M. Gur1, M. Celtik2,a 1Duzce University, Mechanical Engineering, Duzce, Turkey. 2Sakarya University, Metallurgical and Materials Engineering, Sakarya, Turkey. Accepted 29 April 2018 Abstract Galvanization is a metal coating process in which a ferrous part is coated with a thin layer of zinc. The zinc coating seals the surface of the part from the environment, preventing oxidation and weathering from occurring. The primary method of galvanization is “hot dip galvanization”, which has been in use for over 150 years. While the idea of coating a part in molten zinc was first proposed by chemist Paul Jacques Malouin in 1742, the process was not put into practice until patented by chemist Stanislas Sorel in 1836. Sorel’s process has changed little since then, and still involves coating a part in molten zinc after cleaning it with an acid solution and coating the part in flux. Galvanization helps to extend the life of steel parts by providing a barrier between the steel and the atmosphere, preventing iron oxide from forming on the surface of the steel. Galvanization also provides superior corrosion resistance to parts exposed to the environment. Galvanization provides a cost-effective solution for coating steel parts, specifically those that will receive significant environmental exposure over their lifetime. Keywords: Galvanization, galvanization behavior, coating, zinc, steel surface 1. Introduction It is known that around 20 BC – 14 AD, brass was physical parameters (eg bath temperature, immersion made by the Romans from zinc and copper. By the time, pre-galvanizing surface temperature) and 14th century, zinc was recognised as the 8th metal by chemical parameters (eg, chemical compositions, the Indians. Zinc was recognized in Europe as a chemical composition of flux). The thickness separate metal in the 16th century when Agricola increase of hot-dip galvanized coatings depends (1490 – 1555) observed when a metal called mainly on the interdifusion mechanism of zinc and “zincum”, produced in Slesia and Paracelsus (1493 – iron atoms between zinc-based melting and bath- 1541), stated clearly that “zincum” was a new metal. soaked iron-based samples. In 1743, the first European zinc smelter was Depending on the different chemical compositions, established in Bristol in the United Kingdom using a the interdifusion of the atoms forms an uneven vertical retort procedure. A major technological coating. In the outer region, the coating is rich in improvement was achieved with the development of zinc, whereas the coating in the inner region is rich in the horizontal retort process in Germany, which led iron [3]. The presence of different iron / zinc ratios to the erection of smelting works in Slesia, Liege, from the inner region to the outside creates different Belgium and Aachen, the Rhineland and the Ruhr intermetallic phases as shown in the phase diagram areas in Germany [3]. (figure 1). For this reason, zinc coating can be considered as a multi-layer system composed of four In 1837, a French engineer Stanislaus Tranquille phases characterized by a different thickness and Modeste Sorel took out a patent for the early mechanical properties: galvanizing process and in 1921, the first galvanizing plant opened in Australia by Lysaght. Galvanizing The outer layer is a ductile phase with a method has been proven as a corrosion protection maximum Fe content of up to 0.03%. method in all important applications involving iron The next layer is an isomorphous phase ( and steel all over the world for over 160 years. phase) characterized by an atomic structure containing a Fe atom and a Zn atom The formation of the coating is influenced by both surrounded by 12 Zn atoms at the corners of a Corresponding author; Phone: +90-380-542-1100, Email: [email protected] Journal of Engineering Research and Applied Science Volume 7 (1), June 2018, pp 861-868 a monoclinic unit cell and a light atomic hexagonal crystal structure with a Fe content icosahedron. Icosahedra is linked together to up to 11.5%. form chains and the linked chains are The inner phase () is a very thin layer collected in a hexagonal sequence [1]. characterized by a Fe content of up to 29% phase is brittle which is characterized by a and an FCC structure. Figure 1. Zinc – iron phase diagram. 2. Galvanization process and Zinc based coating The materials to be galvanized are immersed in a the excess zinc in the surface should be removed by liquid solution of commercially pure zinc containing shaking or by the effect of centrifugal forces (figure a minimum of 98% zinc. The chemical content of the 2.) After the material is removed from the bath, bath is specified in ASTM B 6. The bath temperature chemical reactions on the galvanized surface are should be maintained at approximately 450 ºC. The continue [2]. In order to finish chemical reactions, products must remain in the bath for the appropriate the products must be cooled in water or in air as soon time to reach the bath temperature. Materials should as they are removed from galvanization. be withdrawn slowly from the galvanized bath and Figure 2. Steps of Galvanization Process. In addition to creating a physical barrier to corrosion, corrosion resistance properties through galvanizing, the zinc coating also provides cathodic protection to from nails to steel structures, including bridges. the exposed steel. A wide range of steel products has 862 Toklu et al. / Investigation on effects of steel surface properties on galvanization behavior Journal of Engineering Research and Applied Science Volume 7 (1), June 2018, pp 861-868 Figure 3. Zinc finishes types. Five types of zinc-based coatings can be provided to zinc plating (figure 3). These coatings differ in the achieve corrosion resistance: metallization, hot-dip thickness of the zinc alloy, the application methods galvanizing, zinc-based paint, galvanized coating and and the duration of corrosion resistance (figure 4). Figure 4. Microphotograph of a galvanized coating. 3. Galvanization Methods 3.1. Hot dip galvanizing: aids in removing excess zinc from threads and edges Before immersion hot dip galvanizing, the steel part and provides a smooth, albeit thinner coating than is cleaned, acidified and fluxing [1]. Prepared items batch dipped items (figure 5). are galvanized by immersion in molten zinc. The surface of the work is completely covered, producing 3.1.1. Wet flux galvanizing: a uniform coating of zinc and zinc-iron alloy layers Wet method requires less plant tools and space. This whose thickness is determined principally by the method involves the passage of a thin layer of melt mass of the steel being galvanized. Articles ranging flux salt on the surface of the zinc bath to remove in size from small fasteners to structures hundreds of impurities in the surface of the steel part, and also the metres high may be protected by the use of modular formation of free oxides in a portion of the surface of design techniques. Large galvanizing baths, in the zinc bath during the immersion of the steel. conjunction with modular design techniques and Generally, due to the stripping condition, the wet double-end dipping allow almost any structure to be method tends to form a thinner coating while the galvanized, with greatly reduced maintenance costs piece is drawn through the flux (figure 6). The Flux and extended service life. Small items can be dipped layer can be made with Sodium Aluminum Fluoride into the molten zinc in a container which is spun or or Zinc Ammonium Chloride for higher Al contents centrifuged upon removal of the molten zinc. This with the addition of Ammonium Chloride [7-8]. The 863 Toklu et al. / Investigation on effects of steel surface properties on galvanization behavior Journal of Engineering Research and Applied Science Volume 7 (1), June 2018, pp 861-868 flux layer floats freely on the surface of the bath and Protects from overheating and burning in the the interaction continues while the part is immersed. second immersion. The most important functions of the flux layer: When wet parts are dipped, dangerous Cleans the surface of the component and the splashes are reduced. molten zinc, so that zinc and steel can react. The melt reduces the oxidation of the surface Reduces distortion by preheating thin parts. of the zinc and thus reduces the ash formation Figure 5. Hot dip galvanization process. Figure 6. Wet flux galvanizing pot shematic section. 3.1.2. Galvanizing by dry method: after pre-fluxing and drying. In both processes, the In the Galvanizing with Dry Method, after the parts temperature of the melt zinc galvanizing bath is have been cleaned, the component is pre-quenched in maintained in the range of 445 to 455 °C, and the an aqueous solution, dried and then dipped in the immersion time varies in the range of 3-6 minutes zinc bath. The temperature of the pre-flux solution depending on the thickness of the part. ranges from room temperature to 80 °C. In this process, the part must be absolutely dried before 3.2. Continuous galvanizing processes (In-line immersion in the zinc bath. For drying, the best galvanizing conditions are met at a temperature of 120 °C and up Continuous galvanized products can usually be to 5 minutes. Parts should be galvanized immediately further processed by bending or roll forming, for 864 Toklu et al. / Investigation on effects of steel surface properties on galvanization behavior Journal of Engineering Research and Applied Science Volume 7 (1), June 2018, pp 861-868 example as purlins and girts, without damaging the Electroplating is an economic and effective method coating.
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