FLUXING IN HOT DIP GALVANIZING

Nowadays fluxing is one of the most important steps of hot dip galvanizing. Galvanizing process can be
performed by using only hydrochloric acid and molten zinc, but every extra step added to the process
guaranties an increse on the efficiendy, a decrease in the number of rejected materials and most
importantly reduction in consumption of zinc.

A good fluxing process; -reduces the coating thickness,

-increases the quality of the coating, -accelerates the process,

-reduces ash and dross formation.

Fluxing is one of the most important factors that leads to the reduction of galvanizing process costs
ensured that the application is proper and the flux solution is under constant control.

FLUX TYPES USED TODAY

There are two types of flux that are generally used in hot dip galvanizing. Double salt ZnCl2.2NH4Cl and
triple salt ZnCl2.3NH4Cl fluxes. As double salt flux contains more ZnCl2 comparet to the triple salt flux,
less need for sensitive controlling and more efficiency in working of the flux is achieved by using double
salt flux.

Triple salt flux creates excessive fume when it enters the zinc bath due to its high ammonium amount
and especially if the component needs to wait for long times before entering the zinc bath, oxidation
over the steel surface may be seen. Due to the ease of use such as the ones stated above, double salt is
a more popular flux type.

THE ROLE OF FLUXING IN HOT DIP GALVANIZING

-Prevents oxidation of the steel through the drying process. A poorly fluxed component is oxidized
when left waiting after the fluxing process or during drying. Uncoated areas may form and the oxide
layer over the steel surface oxidizes the molten zinc causing an increase in the ash formation.

-As the steel component enters the bath, the flux reacts with the ZnO layer formed over the galvanizing
bath, melts this layer and lets the steel react directly with the molten zinc. For a poorly fluxed
component, galvanizing reaction starts after the thin ZnO layer over the bath that spreads to the
component is dissolved. This causes the component to stay in the bath for longer times. The sections
with less ZnO are coated earlier causing a less homogenous and usually thicker coating.

-Flux prevents transportation of impurities and foreign materials such as iron and oxides, chlorides,
suphides and sulphates to the zinc bath and with this action it reduces the dross formation as well as
inhibiting the effects of these impurities on the iron-zinc reaction.

FLUX CONTROL
Iron, zinc chloride and ammonium chloride in flux, flux temperature and pH must be controlled in order
to work with a flux at optimum conditions. All the parameters can be measured by basic titration
methods.

-Temperature: Ideal temperature is between 60-70oC. If an effective drying is used after fluxing, a flux
at 40oC is also workable. Having a flux temperature of 60oC lets the component to dry quickly and even
with a poor drier, ensures that the component is dry when it enters the bath, which reduces ash
formation, zinc splashes and explosions. The flux layer formed at lower temperatures is less
homogeneous and effective. At higher temperatures, a thick flux layer is formed and causes stains over
the substrate surface and increase in ash formation.

-pH: Ideal pH is between 2 - 3,5. More iron is dissolved in lower pH values and the iron carried to the
zinc bath increases. pH values higher that 5,5 may cause the zinc chloride to precipitate, making the
flux useless. The pH value should be adjusted back to 2-3,5 interval if any value other than these is
observed.

-Iron amount: The iron should be kept below 3g/L to prevent dross formation caused by the iron
carried to the zinc bath after fluxing. In most of the modern flux regeneration systems, this value is
seen to kept below 1g/L. Basically the following can be applied to control the amount of iron:

* Preventing dissolution of iron by keeping the pH under control.

* Controlling the iron amount in the pickling bath by special chemical additions thus letting less iron
into the flux tank.

* Using an effective rinsing after the pickling stage.

* Using a flux regeneration unit that precipitates iron by adding hydrogen peroxide-ammonium or
using electrolysis.

It should be remembered that every 1 g of iron carried to the zinc bath combines with 25g of zinc to
produce dross.

-Zinc chloride and ammonium chloride amounts: Ideal concentration is 550g/L. In double salt flux, zinc
chloride (ZnCl2) amount is 300g/L, ammonium chloride (NH4Cl) amount is 250g/L. If the ratio is altered,
increase in ash formation, non-homogeneous coating thickness and increase in fuming over the zinc
bath may occur.

As ammonium chloride is cheaper than zinc chloride, the proportions of each chemical must be known
when purchasing the flux salt/solution.