Hot Dip Metallic Coating

Hot dipping is a process in which a metal substrate is immersed in a molten bath of a second
metal. After removal, the second metal is coated into the first. It is essential to have higher
melting temperature of first metal than the second. The most common substrate metals are
steel and iron and the common coating materials are zinc, aluminum, tin and lead.

Prior to coating, cleaning of rust, scale, oil, paint and other surface contaminants is required.
For coating process, immersion in the molten metal is done for periods ranging from a
fraction of a minute for small objects like fasteners to several minutes for large scale
structures. Temperature of approximately 450°C and 700°C need to be maintained (bath
temperature) for galvanizing (zinc coating) and aluminum coating respectively. It is followed
by a post coating treatment depending on the requirement of the coated component. For
example, slow cooling, quenching, conversion coating and painting (preceded by pre-painting
treatments) might be done.

Characteristics
Hot-dip metallic coatings can be considered to have excellent long term corrosion resistance
property when properly sealed. Corrosion resistance comes through two distinct ways.

1. The coating functions as a barrier providing shielding to the base material.

2. The coating may provide sacrificial galvanic protection.

Coatings of metals higher in the electromotive series than the basis metal will corrode in
preference to the basis metal. Protection will be provided even if there is a break in the
continuity of the coating. Table M5.4.1 provides list of common metals in accordance with
their places in the electromotive series.
Table M5.4.1: List of common metals in accordance with their places in the electromotive
series. (Source: Design for Manufacturability Handbook by James G Bralla, 2nd Ed)

Metals

Magnesium

Zinc

Aluminum

Cadmium

More active
More Noble
Steel

Lead

Tin

Copper

Gold

Thickness of coating usually dependent on both process and coating type. Consider a typical
example, in case of hot-dip-galvanized material coating, thickness is customarily specified in
grams per square meter as either a minimum or an average coating weight. Normal values
range from about 150 to 920 g/m2. This is equivalent to a thickness of 0.01 to 0.13 mm. Few
examples of hot dip metallic coating are: fence components, playground equipment, and
tubular condensers.

Suitable materials

Substrates: The most common substrate materials for hot-dip metallic coating are cast iron
and steel. Materials like high-strength low-alloy steel also used under certain situations.

Coatings: Commonly used coating materials for hot-dip coating are zinc, aluminum, tin,
lead, and terne (a lead alloy with 10 to 20 % tin). Zinc, aluminum and terne provide good
corrosion resistance under most atmospheric conditions.
Design recommendations
Access and drainage of molten metal:

Molten coating metal must be able toflow freely to all surfaces of the part to achieve
corrosion protection over full surface. Use of hollow sections for coating is a better choice
andsignificantly reduces the possibility of hidden space.Recommended guidelines to achieve
full,uniform coverage are given below.

 Holes for venting and draining should be as large as possible.

 Holes for venting and draining should be placed diagonally opposite at the high and
lowpoints of the fabrication which are generally not used for the coating process.

 To have free flow of molten metal, corners of internal and external stiffeners, baffles,
diaphragms, and gussets must be cropped.These guidelines have been illustrated in
Figure M5.4.1to Figure M5.4.3.

Figure M5.4.1: Pipe-column venting.

 Figure M5.4.2: Venting and draining of enclosed and semi enclosed products.

Not Recommended Recommended

Figure M5.4.3: Molten-metal bath to all surfaces of welded assemblies

Minimizing distortion:

Due to high temperature, there are chances of stress relief which can lead to distortion of the
workpiece. The following recommendations are to be kept in mind to minimize the distortion:

 Symmetrical rolled sections are to be preferred over angle or channel frames.

 Minimum possible welds are recommended in order to reduce thermal stresses.

 In case of bending of component members, a largest acceptable radius which is not

less than 3 times the material thickness is to be used.

 Assemblies and subassemblies should be built in units suitable for single dipping
whenever possible.

 Distortion of an assembly will be strongly dependent on the design. It can be

significantly reduced by avoiding combinations of extremes in weight and cross-
section of structural members as shown in Figure M5.4.4.
Figure M5.4.4: Avoid a combination of extremes in the weight and cross section of structural
members.
Screw threads: When a threaded member has to be hot-dip-coated, the pitch diameter must
be adjusted in order to allow for the thickness of the coating. Table M5.4.2 summarizes the
recommended oversize tappings for female threads to be used with galvanized bolts.

Table M5.4.2: Recommended Oversize Tapping for threaded Holes to be used with
Galvanized Bolts (Source: Design for Manufacturability Handbook by James G Bralla, 2nd
Ed)

Bolt or stud diameter (mm) Minimum oversize tapping required (mm)

11 and smaller +0.4
Over 11 to 25 +0.5
Over 25 +0.8

Post-coating treatments:Post-coating treatment is recommended for the parts which are

prone to wet-surface stain (e.g., prolonged stacking in a moist or wet environment). One of
the most effective post-coating treatments is immersion of the workpiece in a solution of
sodium dichromate.

Coating-thickness recommendations: ASTM specifications for zinc-coating weight are

summarized in Table M5.4.3. Minimum coating thicknesses for various pre-coated sheets
ranges from 0.05 to 0.08 mm, 0.006 to 0.026 mm and 0.007 to 0.043 mm for aluminum,
terne, and zinc respectively.
 Table M5.4.3: Recommended Coating Weight for Hot-Dip-Galvanized Products (ASTM
Specifications) (Source: Design for Manufacturability Handbook by James G Bralla, 2nd Ed)

Minimum weight of zinc coating of

Class Of Material
any individual specimen (g/m2)

Products fabricated from rolled, pressed,and forged steel shapes, plates, bars,and strips

3-5 mm thick 550

6 mm and heavier 610

Hardware
Castings - gray iron,malleable iron, steel 550

Rolled, pressed, and forgedarticles (5 mm andover

550
in thickness and over 200 mm in length)

Rolled, pressed, and forgedarticles (under 5 mm

380
inthickness and over 200 mm in length)
Rolled, pressed, and forgedarticles (200 mm and
340
underin length and any thickness)