Chapter 23 Blm 23

Non Liquid Coatings Sv Olmayan Kaplamalar

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Hot-Dip Galvanizing Scak Daldrmal Galvanizleme

Process of coating iron or elii erimi bir inko
steel with a thin zinc layer banyosundan geirmek
by passing the steel suretiyle demir veya eliin
through a molten bath of ince bir inko tabakas ile
zinc kaplanmas ilemi
Temperature of bath is Banyo scakl yaklak 438-
around 438-460C (820- 460Cdir (820-860F)
860F) inko ve elik arasnda
Results in a metallurgical metalurjik bir ba olumas
bond between zinc and ile sonulanr
steel
Hot-Dip Galvanizing Kettle Scak Daldrmal Galvanizleme
Kazan

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The usual galvanized coating consists of three distinct iron- Olaan galvanizli kaplama ayr demir-inko bileeninden
zinc compounds: oluur:
Gamma 75% zinc and 25% iron Gamma %75 inko ve %25 demir
Delta %90 inko ve %10 demir
Delta 90% zinc and 10% iron
Zeta %94 inko ve %6 demir
Zeta 94% zinc and 6% iron
Eta (d tabaka) %100 inko (ayr bir tabaka olarak kabul
Eta (Outer layer) 100% zinc (not considered separate layer) edilmez)

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Coating Inspector Program NACE International

Level 2 Chapter 23
July 2012 1
 Various Layers of Hot-Dip Galvanizing eitli Scak Daldrmal Galvaniz Tabakalar

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The inspector should learn and observe site safety Enspektr saha gvenlii kurallarn renmeli ve
rules. kurallara dikkat etmelidir.

The inspector should know that: Enspektr aadakileri bilmelidir:

Hot-dipped articles stay hot and to make sure
the article is cool before touching it.
Molten metal can splash out of the kettle and
travel some distance.
Scak daldrmal nesneler scak kalr ve bunlara
dokunmadan nce nesnenin souduundan
emin olunmas gerekir.
Erimi metal kazandan srayp uzaa gidebilir.

Nascent hydrogen may burn off in the air above Aa km hidrojen, kazann zerindeki havada
the kettle. yanabilir.

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Standards Standartlar
There are a number of standards regarding Hot Aadakiler dahil olmak zere Scak Daldrmal
Dipped Galvanizing including: Galvanizleme ile ilgili bir takm standartlar mevcuttur:
Surface preparation and application Yzey hazrlama ve uygulama
Material Materyal
Coating Kaplama
Film thickness measurements Film kalnl lmleri

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Coating Inspector Program NACE International

Level 2 Chapter 23
July 2012 2
 Two of the terms inspectors may hear when
describing galvanizing are:
Heavy galvanizing - can provide a complete
coating of heavy zinc, both externally and
internally, if required by specification
Light galvanizing - has a significantly lower level of
protection in corrosive environments, and often
requires supplementary coatings for outdoor
exposure
Galvanizlemeyi aklarken enspektrlerin duyabilecei iki
terim:
Ar galvanizleme Spesifikasyonun gerektirmesi
halinde gerek dardan gerekse ieriden tam bir ar
inko kaplamas salayabilir
Hafif galvanizleme Korozif ortamlarda nemli
lde daha dk seviyede koruma salar ve
genellikle ak hava maruziyeti iin ek kaplamalar
yaplmasn gerektirir.

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Hot-Dip Process Scak Daldrma lemi

The hot-dip process includes: Scak daldrma ilemi aadakileri ierir:

Surface preparation Yzey hazrl

Fluxing Eritkenleme

Dipping Daldrma

Post treatments Sre sonras ilemler

Inspection Denetim

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Surface Preparation Yzey Hazrl

Solvent cleaning (SSPC-SP1) Solvent temizlii (SSPC-SP1) ve
and abrasive blasting may be andrc kumlama
specified. belirlenebilir.
Caustic cleaning The steel is Kostik temizleme elik,
immersed in caustic solution to yzeyinin kir, ya ve gresten
remove the dirt, oil, and grease arndrlmas iin kostik
from the surface of the steel. zeltiye batrlr.
Pickling The process where Paklama Hazrlanan maddenin
the item being prepared is oksitleri veya mil skalasn
immersed in a tank filled with ortadan kaldran hidroklorik
Acid Pickling Tank Asitli Paklama Tank
either hydrochloric or sulfuric veya slfrik asit ile
acid, which removes oxides and doldurulmu bir tanka batrlma
mill scale. ilemi.

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Coating Inspector Program NACE International

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July 2012 3
 Video Video

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Fluxing cleans the steel of all oxidation developed Eritkenleme, elii paklama srasnda gelien tm
during pickling. oksidasyondan arndrr.

Fluxing process is one of two types: Eritkenleme ilemi iki trldr:

Immersion in a pre-flux solution that is slightly
acidic and contains a combination of zinc chloride
and ammonium chloride
Passed through a molten layer, top flux, that floats
on top of the liquid zinc in the galvanizing kettle
Biraz asidik olan ve inko klorr ile amonyum
klorrn birleimini ieren bir eritkenleme ncesi
zeltiye batrma
Galvanizleme kazannda sv inkonun zerinde
yzen erimi tabaka, st eritkenden geirme

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Video Video

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Coating Inspector Program NACE International

Level 2 Chapter 23
July 2012 4
 Zinc Bath inko Banyosu
Zinc that are each at least En az %98 orannda saf inko
98% pure Scaklk 438-460C (820-
Temperature ranging from 860F) arasnda deiir
438-460C (820-860F) Galvanizciler, kazann
Galvanizers prefer to keep mrn uzatmak iin
the temperature of their kazanlarnn scakln daha
kettles on the cooler side to alt seviyede tutmay tercih
prolong the life of the kettle ederler

Fabricated Piece Being Dipped into mal edilmi para inko banyosuna
the Zinc Bath daldrlr

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Video Video

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In most cases, dip lasts less than ten minutes ou durumda, daldrma on dakikadan az srer
When process is complete, the steel is removed and lem tamamlandnda, elik alnr ve su verme
cooled by quenching or air veya hava ile soutulur

Steel Beam Leaving Bath elik Kiriin Banyodan k

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Coating Inspector Program NACE International

Level 2 Chapter 23
July 2012 5
 Post Treatments Sre Sonras lemler
Post treatments may consist of: Sre sonras ilemler:

Chromating Renkseme

Phosphating Fosfatlama

Light rolling Hafif haddeleme

Roller leveling Makaral dzeyleme

Fabricated Steel Leaving Galvanizing Bath mal Edilmi eliin Galvanizleme Banyosundan k

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Hot-dipped zinc coatings are sometimes annealed Scak daldrmal inko kaplamalar bazen tm
to convert the whole of the coating into an alloy. kaplamay bir alama dntrmek iin tavlanr.

Aluminum coatings intended for heat resistance Is dayanm iin tasarlanan alminyum
may be converted into an alloy in the same way. kaplamalar da ayn ekilde bir alama
dntrlebilir.

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The basic finish requirements of the galvanized Galvanizli kaplamann temel bitirme ilemleri
coating include that it be relatively smooth, kaplamann nispeten przsz, kesiksiz, parlak ve
continuous, lustrous, and free from gross surface byk yzey kusurlarndan arnm olmasn kapsar.
imperfections.

Typical Galvanized Surface Tipik Galvanizli Yzey

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Coating Inspector Program NACE International

Level 2 Chapter 23
July 2012 6
 General Roughness Genel Przllk
Galvanized components with markedly rough nemli derecede przl yzeyleri olan galvanizli
surfaces bileenler

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Excess Aluminum Fazla Alminyum

A condition sometimes referred to as black spots
may occur if the aluminum content of a bath, on
which a flux blanket is used, is too high.
The aluminum content of the bath should be
maintained below 0.01%.
zerinde eritken rtnn kullanld bir banyonun
alminyum ieriinin fazla yksek dzeyde olmas
halinde bazen siyah nokta olarak ifade edilen durum
gerekleebilir.
Banyonun alminyum ierii %0.01in altnda
tutulmaldr.

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Dross Protrusions Cruf kntlar

Small, hard lumps result from agitation of the dross Banyonun tabanndaki cruf tabakasnn kartrlmasndan
layer at the bottom of the bath or from dragging veya materyalin cruf tabakasnn iinden srklenmesinden
material through the dross layer. dolay kk, sert yumrular oluur.

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Coating Inspector Program NACE International

Level 2 Chapter 23
July 2012 7
 Lumpiness - A lumpy and uneven coating results Yumrular - Geri ekme hz ok yksek olduunda
when the speed of withdrawal is too fast or the bath veya banyo scakl inkonun banyoya geri
temperature is too low to allow surplus zinc to run kamasna izin vermeyecek kadar dk olduunda
back into the bath. yumrulu ve dzgn olmayan bir kaplama ortaya kar.

Runs - Caused by delayed drainage from bolt holes, Dklmeler - inkonun biriktii cvata delikleri,
folds, seams, and other pockets where zinc collects, kvrmlar, balant yerleri ve dier ceplerde drenajn
and are usually a direct consequence of the product gecikmesinden kaynaklanr ve genellikle rn
design. tasarmnn dorudan sonucudur.

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Uneven Drainage Dzgn Olmayan Drenaj

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Flux Inclusions Eritken Kalntlar

Spent flux adhere to the steel instead of separating Harcanan eritken, alma daldrldka yzeyden
cleanly from the surface as the work is dipped. temiz bir ekilde ayrlmak yerine elie yapr.

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Coating Inspector Program NACE International

Level 2 Chapter 23
July 2012 8
 Ash Inclusions Kl Kalntlar
Zinc ash: The oxide film that sometimes develops on the inko kl: Bazen galvanizleme banyosunun yzeyinde gelien
surface of the galvanizing bath. oksit film.

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Dull-Gray Galvanized Coating Kl Rengi Galvanizli Kaplama

A gray or mottled appearance develops during Soutma srasnda inko-demir alam faznn
cooling that is caused by diffusion of the zinc-iron kaplamann yzeyine yaylmas nedeniyle gri veya
alloy phase to the surface of the coating. alacal bir grnm oluur.

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Rust Stains Pas Lekeleri

Caused by seepage from joints and seams after galvanizing or Pasl eliin altnda veya pasl elikle temas edecek ekilde saklanan
materyal nedeniyle veya galvanizleme sonrasnda balant
by material being stored under or in contact with rusty steel. noktalarndan veya dikilerden sznt olmas nedeniyle oluur.

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Coating Inspector Program NACE International

Level 2 Chapter 23
July 2012 9
 Wet Storage Stain (White Rust) Islak Depolama Lekesi (Beyaz Pas)
Occurs when the steel is exposed to a humid or moist Serbeste dolaan havaya eriimi olmakszn eliin nemli bir
environment without access to freely circulating air. ortama maruz kalmas halinde oluur.

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Faying Surfaces Kontak Yzeyleri

Shear Force Kesme Kuvveti

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Substrat zelliklerinin
Alteration of Substrate Properties
Deitirilmesi
Alteration of the properties of certain types of steel Belirli elik trlerinin zelliklerinin deitirilmesi,
may be affected by certain processes incidental to scak daldrma sonrasnda su verme gibi scak
the hot-dip galvanizing process, such as quenching daldrmal galvanizlemeye zg belirli ilemlerden
after hot dipping. etkilenebilir.

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Coating Inspector Program NACE International

Level 2 Chapter 23
July 2012 10
 Work Piece Design and Fabrication Parasnn Tasarm ve malat
Design of the work piece relates to: parasnn tasarm aadakilerle balantldr:
Skip welds/crevices Atlamal kaynak/yarklar
Pockets/Air bubbles Cepler/hava kabarcklar
Piece too large for dip tank Daldrma tank iin ok byk para
Warping Yamulma
Dissimilar metals Benzer olmayan metaller

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Coating Thickness and Service Life Kaplama Kalnl ve Hizmet mr

Service life is directly associated with coatings thickness. Hizmet mr dorudan kaplama kalnl ile balantldr.

Coatings thickness of hot-dipped galvanized items can be
performed utilizing four separate techniques:
Magnetic thickness gauge (most common)
Stripping
Weighing (before and after galvanizing process)
Optical microscopy
Scak daldrmal galvanizlenen maddelerin kaplama kalnl
drt farkl teknikten yararlanlarak yaplabilir:
Manyetik kalnlk lm aleti (en yaygn)
Kazma
Tartma (galvanizleme ileminden nce ve sonra)
Optik mikroskopi

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Video Video

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Coating Inspector Program NACE International

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July 2012 11
 Video Video

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Video: Repairs Video: Onarmlar

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Spray Metalizing/Thermal Spraying Sprey Metalleme/Isl Spreyleme

Coating steel by spraying molten metal on substrates Erimi metalin korozyondan koruma ekli olarak substratlarn
zerine spreylenmesi yoluyla eliin kaplanmas
as a form of corrosion protection.

Video Video

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Coating Inspector Program NACE International

Level 2 Chapter 23
July 2012 12
 Surface Preparation Yzey Hazrl

The best performance of the metalized coating can be Metalize edilmi kaplama en iyi performans 1/SSPC-SP 5
gained by blast cleaning to NACE No. 1/SSPC-SP 5 White No.lu NACE Beyaz Metale uygun olarak (ISO Sa 3) kumlama
Metal (ISO Sa 3). temizlii yaplarak elde edilebilir.

Anchor pattern may vary from 50 to 150 m (2 to 6 mils) or Ankraj modeli, uygulanacak olan metalize edilmi
more, depending upon the thickness of the metalized kaplamann kalnlna bal olarak 50-150 m (2-6 mil) veya
coating to be applied. daha fazlas arasnda deiiklik gsterebilir.

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Flame Spraying Alev Spreyleme

Oxygen and a fuel gas fed into torch; used to create
flame
Powder or wire is injected into the flame; melted
Sprayed onto the work piece creating the layer of
protective coatings
alomann iine beslenen oksijen ve yakt gaz; alev
yaratmak iin kullanlr
Toz veya tel aleve enjekte edilir ve eritilir
paras zerine spreylenerek koruyucu kaplama
tabakas oluturur

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Arc Spraying Ark Spreyleme

Two wires inserted into the torch, contact at the ki tel alomaya sokulur; nozle temas eder ve temas
nozzle, wires melt when they touch ettiklerinde teller erir.
Carrier gas is used to strip the molten material off Erimi materyali tellerden soymak ve i parasna
wires and transport it to the work piece ulatrmak iin tayc gaz kullanlr.

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Coating Inspector Program NACE International

Level 2 Chapter 23
July 2012 13
 Plasma Spraying
Most versatile of all the thermal spray processes
Plasma core temperatures are typically greater than
10,000C (18,032F)
Powder is injected into this flame, melted, and
accelerated to the work piece
Ceramics, metals, and plastics can be sprayed
Plazma Spreyleme
Isl spreyleme ilemleri arasnda en ok ynl olandr
Plazma i scaklklar tipik olarak 10,000Cden
(18,032F) fazladr
Toz bu aleve enjekte edilir, eritilir ve i parasna
uygulanr
Seramik, metal ve plastiklere spreyleme yaplabilir

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High-Velocity Oxyfuel Yksek Hzl Oksi Yakt

Gases injected into torch at high pressure and ignited Gazlar alomaya yksek basnta enjekte edilir ve
atelenir
Gas velocities achieve supersonic speeds
Gazlar speksonik hzlara ular
The powder injected into the flame also accelerated Aleve enjekte edilen toz ayn zamanda spersonik
to supersonic speeds hza ulaacak ekilde hzlandrlr
Results are the densest thermal spray coatings Mevcut olan en youn sl spreyleme yaplan
available kaplamalar elde edilir

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Sealers Szdrmazlar
In service, corrosion products of zinc or aluminum Kullanm halinde, inko veya alminyum korozyon
develop and seal the porosity of the thermal- rnleri gelierek sl spreylemeli kaplamalarn
sprayed coating. gzenekliliini kapatrlar.

However, the application of a seal coat immediately Bununla birlikte, metalleme uygulamasndan hemen
after application of the metalizing extends the life of sonra szdrmazlk tabakasnn uygulanmas,
the coating. kaplamann mrn uzatr.

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Coating Inspector Program NACE International

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July 2012 14
 Successful sealers include thin coats of: Baarl szdrmazlar, aadakilerin ince
katmanlarn ierir:
Vinyl
Vinil
PVBA
PVBA
Silicone (high-heat surfaces)
Silikon (yksek sl yzeyler)
Epoxy
Epoksi

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Spray Metalizing Inspection Sprey Metalleme Denetimi

Major concerns would be in the areas of: Denetime ilikin nemli konular:
Yzey hazrl (temizlik ve profil)
Surface preparation (cleanliness and profile)
Substratn n stmaya tabi tutulmas
Pre-heating of the substrate Substratn nemden arndrlm olduunun
Verification of a moisture free substrate dorulanmas,
Application procedure and technique Uygulama prosedr ve teknii
Belirtilmesi halinde szdrmazlarn ve son katlarn
Application of sealers and topcoats when specified
uygulanmas
DFT (using common DFT gauges) DFT (yaygn DFT lm aletlerinin kullanlmasyla)
Handling and storage Kullanm ve depolama

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Other Methods of Metalizing Dier Metalleme Yntemleri

Sherardizing: inko ile galvaniz yapma:

Sherardizing is a metalizing alternative for fastener
coatings. The fasteners are rotated in a drum for
long periods at moderate heat with zinc dust.
Aluminizing:
Aluminizing is similar to hot-dip galvanizing except
the bath metal is an aluminum-zinc alloy.
inko ile galvaniz yapma, balayc kaplamalara
ilikin alternatif bir metalleme yntemidir.
Balayclar, inko tozuyla orta sda uzun sre
boyunca bir tamburda dndrlr.
Alminyumlama:
Alminyumlama, banyo metalinin bir alminyum-
inko alam olmas haricinde scak daldrmal
galvanizlemeye benzerdir.

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 Chapter 23 Blm 23
Non Liquid Coatings Sv Olmayan Kaplamalar

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