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Zinc Coatings

Zinc Coatings

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Published by 123vigen
The material included in this publication has been developed to provide information regarding zinc coatings on iron and steel products. Every effort has been made to ensure that the information is technically correct. This
material is for general information only and is not intended as a substitute for competent professional examination and verification as to accuracy, suitability and/or applicability. The publication of the material contained herein is not intended as a representation or warranty on the part of the American Galvanizers Association. Anyone making use of this information assumes all liability arising from such use.
The material included in this publication has been developed to provide information regarding zinc coatings on iron and steel products. Every effort has been made to ensure that the information is technically correct. This
material is for general information only and is not intended as a substitute for competent professional examination and verification as to accuracy, suitability and/or applicability. The publication of the material contained herein is not intended as a representation or warranty on the part of the American Galvanizers Association. Anyone making use of this information assumes all liability arising from such use.

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Published by: 123vigen on Sep 10, 2011
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07/01/2014

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 Zinc Coatings
Microstructures of Various Zinc Coatings
H
OT
-D
IP
G
 ALVANIZED
M
ETALLIZED
Z
INC
P
 AINT
G
 ALVANIZED
S
HEET
E
LECTROPLATED
 
Contents
Introduction.......................................................................................................1Production Processes for Zinc Coatings..............................................................2Batch Hot-Dip Galvanizing ............................................................................2Continuous Sheet Galvanizing........................................................................3Electrogalvanizing..........................................................................................3 Zinc Plating...................................................................................................3Mechanical Plating ........................................................................................3 Zinc Spraying (Metallizing).............................................................................4 Zinc Painting .................................................................................................4Characteristics of Zinc Coatings..........................................................................5Batch Hot-Dip Galvanizing ............................................................................5Continuous Sheet Galvanizing........................................................................5Electrogalvanizing..........................................................................................5 Zinc Plating...................................................................................................6Mechanical Plating ........................................................................................6 Zinc Spraying (Metallizing).............................................................................6 Zinc Painting .................................................................................................6Selection of Zinc Coatings..................................................................................7Coating Thickness vs. Coating Weight............................................................7Economic Considerations..............................................................................7
The material included in this publication has been developed to provide information regarding zinc coatings oniron and steel products. Every effort has been made to ensure that the information is technically correct. Thismaterial is for general information only and is not intended as a substitute for competent professional examina-tion and verification as to accuracy, suitability and/or applicability. The publication of the material containedherein is not intended as a representation or warranty on the part of the American Galvanizers Association.Anyone making use of this information assumes all liability arising from such use.
© 2000 American Galvanizers Association6881 South Holly Circle, Suite 108Englewood, CO 801121-800-468-7732FAX 720-554-0909E-mail: aga@galvanizeit.orgWeb site: www.galvanizeit.org
 
I
NTRODUCTION
Zinc metal has a number of characteristics thatmake it well-suited for use as a coating for protect-ing iron and steel products from corrosion. Itsexcellent corrosion resistance in most environmentsaccounts for its successful use as a protective coat-ing on a variety of products and in many exposureconditions. The excellent field performance of zinccoatings results from their ability to form dense,adherent corrosion product films and a rate of cor-rosion considerably below that of ferrous materials,some 10 to 100 times slower, depending upon theenvironment. While a fresh zinc surface is quitereactive when exposed to the atmosphere, a thinfilm of corrosion products develops rapidly, greatlyreducing the rate of further corrosion.
 Figure 1
shows the expected service life to first maintenance(5% red rust) of iron and steel based on the zinccoating thickness and the environment.In addition tocreating a barrier  between steel and theenvironment, zincalso has the ability tocathodically protectthe base metal. Zinc, being anodic to ironand steel, will prefer-entially corrode and protect the iron or steel against rustingwhen the coating isdamaged
(see Figure2).
A number of dif-ferent types of zinccoatings are com-mercially available,each of which hasunique characteris-tics. These character-istics not only affectapplicability but alsothe relative econom-ics and expected ser-vice life. The methodof processing, adhe-sion to the base
 A 
MERICAN
G
 ALVANIZERS
SSOCIATION
 Z
INC
C
OATINGS
Service Life* vs. Thickness of Zinc
11 21 32 43 54 65 75 86 97 108 118 129Thickness of Zinc in Micrometers80706050403020100
   S  e  r  v   i  c  e    L   i   f  e ,   Y  e  a  r  s
Oz. of Zinc/Sq. Ft. of Surface.25 .50 .75 1.00 1.25 1.50 1.75 2.00 2.25 2.50 2.75 3.00Thickness of Zinc in Mils0.4 0.8 1.3 1.7 2.1 2.6 3.0 3.4 3.8 4.2 4.7 5.1*Service Life is defined as the time to 5% rusting of the steel surface.
  R   u  r a   l
 T r o p i c a l  M a r i n e T e m p e r a t e  M a r i n e
 S u b u r b a n M o d e r a t e l y  I n d u s t r i a l
 Figure 1. Service Life vs. Zinc Coating Thickness
1
 Figure 2. Cathodic Protection from Zinc
 ARRANGEMENT OF METALSIN GALVANIC SERIES
CORRODED END
 Anodic or less noble
(ELECTRONEGATIVE)
Magnesium Zinc AluminumCadmiumSteelLeadTinNickelBrassBronzesCopperNickel-Copper AlloysStainless Steels (passive)SilverGoldPlatinum
PROTECTED END
Cathodic or most noble
(ELECTROPOSITIVE)
Cathodic protection canoccur when two metalsare electrically connected. Any one of these metalsand alloys will theoretical-ly corrode while offering protection to any other which is lower in theseries, so long as both areelectrically connected.
In actual practice, how-ever, zinc is by far themost effective in thisrespect.

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