7/10/2019 Effects of Adding Pure or Scrap… | American Galvanizers Association

» E ects of Adding Pure or Scrap Aluminum to the Zinc Bath

E ects of Adding Pure or Scrap Aluminum to the Zinc Bath

September 30, 2015
Authored by Alana Hochstein

I have heard of galvanizers using scrap aluminum plate or pure aluminum to add to the zinc bath as an
alternative to purchasing Zn/Al brightener bars to change the concentration. Are there any adverse e ects
caused by the addition of scrap or pure aluminum in the zinc bath?
Aluminum is a very common bath additive and is typically added to the kettle at concentrations between 0.001% - 0.005%
to:

Increase brightness of the galvanized coating

Reduce zinc ash formation
Improve zinc flow/drainage
Reduce spangle size
Control coating overgrowth on high-silicon steels

However, it is important to note the aluminum content of the zinc melt

for the wet galvanizing process must not exceed 0.002%. This is because
aluminum can react with the zinc-ammonium chloride flux used in wet
galvanizing. Higher concentrations of aluminum than the maximum
recommended value can cause defects such as bare/black spots in the
galvanized coatings. For the dry process, this maximum value is higher
(0.007%) since the reaction between the aluminum and the top flux
(forming aluminum chloride) is not an issue.

For adjusting the aluminum content in the zinc-bath to acquire these

benefits, the aluminum must be evenly distributed until the desired
concentration is reached.

Because pure aluminum is less dense than zinc and has a melting temperature (1220F) higher than a typical zinc bath,
wasted aluminum will float to the top of the zinc melt and there will likely be issues distributing the aluminum consistently
within the bath. In order to avoid sections of the zinc melt containing a higher aluminum concentration than desired, pure
aluminum should be carefully distributed and well mixed within the bath as it dissolves.

It is not recommended to use scrap aluminum due to the additional concern of undesired and uncontrolled amounts of
impurities such as iron, copper, chrome, manganese, and magnesium found in common aluminum alloys.
https://galvanizeit.org/knowledgebase/article/effects-of-adding-pure-or-scrap-aluminum-to-the-zinc-bath 1/2
7/10/2019 Effects of Adding Pure or Scrap… | American Galvanizers Association

In order to best distribute aluminum and avoid bare spots, it is recommended to add aluminum to the zinc bath in the form
of Zn/Al alloy bars (brightener bars) because the lower melting points of Zn/Al alloys more closely coincide with the zinc
bath temperature. Zn/Al brightener bars should not be floated on top, but instead plunged beneath the surface of the bath
to the bottom and mixed well to promote even distribution as the aluminum rises. ASTM B860 lists the recommended
varieties of brightener bars (4, 5 or 10% Al content) and also the maximum allowable impurity contents.

© 2019 American Galvanizers Association. The material provided herein has been developed to provide accurate and
authoritative information about a er-fabrication hot-dip galvanized steel. This material provides general information only
and is not intended as a substitute for competent professional examination and verification as to suitability and
applicability. The information provided herein is not intended as a representation or warranty on the part of the AGA.
Anyone making use of this information assumes all liability arising from such use.

https://galvanizeit.org/knowledgebase/article/effects-of-adding-pure-or-scrap-aluminum-to-the-zinc-bath 2/2