HOT DIP GALVANIZATION
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The document outlines the dry galvanization process which consists of three surface preparation stages - degreasing, acid pickling, and fluxing - followed by pre-heating, dipping in a molten zinc bath, and a chromating or passivation stage. It notes that dry process is most commonly used based on the author's experience. Standards for galvanization from various organizations are also cited.
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![*Type of Galvanization Processes, 1) Dry Process; 2) Wet Process; 3) Continuos Process
Mostly, dry process in practice as per my observation and experience. The below mentioned process chart illustrates how dry galvanization process works.
Yes
No
Sodium Hydroxide (Caustic Soda, NaOH) [ 10 -15 Kg / 100 Litres ]
Temperature Range, 85 - 90º C
(Water Rinsing)
Hidrochloric Acid (HCl) / Sulphuric Acid (H2SO4) [ 100 - 150 g/Litre]
Hidrochloric Acid, Ambient Temperature | Sulphuric Acid, 60 - 80º C
(Water Rinsing)
Zinc Ammonium Chloride (ZnCl2.3NH4Cl), [ 200 - 400 g/Litre]
Min: Ambient Temperatre | Max: 80º C
About 120º C [ >150º C Flux decomposes]
Galvanizing Bath NOT < 98.5 % by mass of Zinc (Zn)
550º C Zinc Kettle Temperatre, 450±10º C [ Oil Fire / Coal Fire / Gas Fire ]
(Water Quenching)
Sodium DiChromate, (Na2Cr2O7) + Sulphuric Acid (H2SO4) [ 1 % + 1/2 % ]
Should be < 65º C
Mass of Coating, Uniformity of Thickness, Adhession Test (Pivot Hammer Test & Stout Knife Test)
IS 2629 - 1985 Reaffirmed, 2016 (Indian Standard for Galvanization) , ASTM A 123 / A123M - 2013 (American Standard for Galvanization) ,
EN ISO 1461 - 2009 (International Standard for Galvnization), JIS H 8641 (Japanese Standard for Galvanization) & CSA G164 - 1992 (Canadian Standard for Galvanization)
The American Galvanizers Association (AGA), USA
The Galvanizer's Association (GA), UK
Guidance:
Shri. Vipin Kumar Kalra, Galvanization Expert, M/s Viswas Tubes India Ltd., Mohali (Pb), India.
HOT DIP GALVANIZATION - PROCESS FLOW CHART
Standards:
By: Er. RAM TEJA G, B.Tech.(Mech.), M.N.C.Q.M (Ind.)
STUDY OF MATERIAL TO
BE GALVANIZED
IS THE
MATERIAL
REACTIVE AS
PER STEEL
CHEMISTRY?
SURFACE PREPARATION STAGE - I
- De-Greasing
(Grease, Oils, Panit & Other inorganic substances)
SURFACE PREPARATION STAGE - III
- Fluxing
(Prevent surface oxidation before dipping)
SURFACE PREPARATION STAGE - II
- Acid Pickling
(Mill scales & Other contaminents)
PRE-HEATING
- Heat the material before dipping in to zinc
kettle
ZINC BATH
- Molten Zinc Bath
(Workig Temperature 450º C)
CHROMATING / PASSIVATION
- To prevent surface oxidation
PHYSICAL PROPERTIES:
- Surface Conditions, Joints
- Welded Parts
- Castings
CHEMICAL PROPERTIES:
- Composition of Elements
- If Silicon and Phosporous >
limit, then steel became
"Reactive Steel" to galvanization
INSPECTION / TESTING
STORAGE
*** End of Report ***](https://image.slidesharecdn.com/processflowdiagram-galvanization-171001085057/85/HOT-DIP-GALVANIZATION-1-320.jpg)
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