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Failure Mechanisms During Galvanizing

Failure Mechanisms During Galvanizing

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Published by: xevi00 on Jun 19, 2012
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The overall objective of the Famega project was to identify the mechanisms controllingliquid metal assisted cracking (LMAC) of high-strength structural steels during hot-dipgalvanising.Sixteen steel sections were obtained and classified in terms of chemical composition,microstructure and mechanical properties, including high-temperature properties asinputs for FE modelling. Measurements of web residual stress showed predominantlycompressive values of up to 50 % of yield. In contrast, welding processes resulted intensile residual stresses close to yield near the weld.Details of the galvanising process considered important to FE models were obtainedfrom operators in Germany, Spain, Luxembourg and the United Kingdom.Eighty full-scale galvanising tests were carried out on 2 m long beams with welded half-cover plates. Beams without welded plates did not crack. Techniques to reduce LMACshowed that thermal stress relief with a hand-held torch was highly effective, while sandblasting, ultrasonic peening and additional weld beads proved ineffective with compres-sive stresses confined to surface layers.LMAC tests in three laboratories were carried out using newly developed and conven-tional test piece types and a variety of Zn alloys. Factors which contributed to LMACincluded: Zn–Sn baths, lower strain rates and steel. High hydrogen levels were foundat the steel/zinc alloy interface but did not contribute to cracking. Combining thresholdstress and stress intensity using an FAD approach showed that fracture mechanics wasonly appropriate for cracks > 2 mm.Modelling of welding and galvanising showed the importance of stress concentrationnear the half cover plate, residual stress, dipping speed and angle, and the heat transfercoefficient associated with a Zn–Sn alloy bath. 
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Failure mechanisms during galvanising 
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European Commission
Research Fund for Coal and Steel
Failure mechanisms during galvanising
W. J. Rudd, S. W. Wen
Corus UK
Swinden Tecnology Centre, Moorgate, Roteram S60 3AR, United Kingdom
P. Langenberg
IWT Aachen
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B. Donnay
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T. Pinger, M. Feldmann
Universität Kaiserslautern
J. Carpio, J. A. Casado, J. A. Alvarez, F. Gutierrez-Solana
Universidad de Cantabria
Departmento de Ciencia e Ingenieria del Terreno y de los MaterialesETS de Ingenieros de Caminos, Canales y Puertos, Avenida de los Castros s/n, E-39005 SantanderContract No RFSR-CT-2003-000211 September 2003 to 28 February 2007
Final report
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