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There are two types of galvanization processes: electro galvanization and hot-dip galvanization. Both methods apply a protective coating of zinc to steel or iron to prevent rust and corrosion. The major difference between the two types is the production method. In hot-dip galvanization, steel is dipped into a vat of molten zinc, forming a strong, thick coating with a dull finish. In electro galvanization, a thin layer of zinc is electrically and chemically bonded to steel, creating a uniform, smooth, and shiny finish.
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What You'll Learn
Electro galvanization is a form of zinc electro plating
There are two types of galvanised steel available: hot-dipped and electro-galvanised. Electro galvanisation is a form of zinc electro plating. During the electro galvanisation process, bare steel wires are fully immersed in a saline/zinc bath and electricity is used to move electrons from the zinc (anode) and bond them to the steel (cathode). This process results in a thin layer of zinc being electrically and chemically bonded to the steel, creating a barrier layer that protects against rust and corrosion.
The process of electro galvanisation can be broken down into several steps. First, raw metal is submerged into an electrolytic solution. An electrically charged anode composed of pure zinc is then placed into the solution. Current flows from the zinc anode, through the solution, and into the metal cathode. Tiny particles of zinc dissolve in the electrolytic solution and bond to the surface of the metal.
Electro galvanisation is often used for coiled sheet steel, which can be formed into shapes such as c-purloins, corrugated sheets, or welded into pipes and tubes. It is also used for architectural applications due to its naturally bright and shiny finish. Products that are easily replaceable, like outdoor furniture and gardening tools, are more likely to be electro galvanised.
Compared to hot-dipped galvanisation, electro galvanisation produces a more uniform coating. It also yields a superior finish, which is smooth, shiny, and aesthetically pleasing. However, the layer formed by electro galvanisation is extremely thin, resulting in a shorter life expectancy than hot-dipped materials.
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Hot-dipped galvanization yields a strong, thick coating
There are two types of galvanised steel available: hot-dipped galvanisation and electro-galvanisation. The major difference between these two types is the production method and the thickness of the coating.
Hot-dipped galvanisation yields a strong, thick coating, but generally has a dull grey finish. The process involves dipping steel into a vat of molten zinc, coating the steel. The coated steel is then removed and allowed to cool. The British, European and International standard for hot-dipped galvanisation is BS EN ISO 1461, which specifies a minimum coating thickness to be applied to steel in relation to the steel's section thickness. For example, a steel fabrication with a section size thicker than 6mm shall have a minimum galvanised coating thickness of 85 μm.
Hot-dip galvanisation is known to have a very long life, averaging between 20 to 50 years. It is one of the most common ways of protecting steel elements against corrosion due to its cost-effectiveness and low impact on the environment. Its main advantages include long-term corrosion protection, a high level of mechanical resilience, and perfect all-round protection in cavities and on edges.
In contrast, electro-galvanisation involves a plating process where the steel is placed in an electrically charged solution of zinc and saline. This causes the zinc to chemically bond to the conductive steel. The layer formed by electro-galvanisation is extremely thin and therefore has a shorter life expectancy than hot-dipped galvanisation.
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Electro galvanization has a low life of several months to a few years
Galvanization is the process of applying a protective coating of zinc to iron or steel to prevent rusting. There are two types of galvanization: electro galvanization and hot-dip galvanization. The major difference between these two types is the production method.
Electro galvanization, or zinc electroplating, is a plating process where steel is placed in an electrically charged solution of zinc and saline, causing the zinc to chemically bond to the conductive steel. This process results in a thin layer of zinc that protects the steel from corrosion. However, one of the disadvantages of electro galvanization is its low life expectancy, typically ranging from several months to a few years. This is primarily due to the thin layer of zinc that is formed during the electroplating process. The thickness of this layer can range from 10 to 12 um, and it is susceptible to corrosion over time.
In contrast, hot-dip galvanization involves dipping steel into a vat of molten zinc, resulting in a strong, thick coating that provides superior protection against corrosion. The average lifespan of hot-dip galvanized steel is significantly longer, ranging from 20 to 50 years.
The choice between electro galvanization and hot-dip galvanization depends on the specific requirements of the application. Electro galvanization is often used for products that are easily replaceable, such as outdoor furniture and gardening tools, as it provides adequate protection for a shorter period. On the other hand, hot-dip galvanization is commonly used for structural shapes and building materials that require long-term durability and corrosion resistance.
It is worth noting that the life expectancy of galvanized steel can vary depending on environmental factors such as air quality, exposure to salt spray, and pollution levels. Additionally, proper maintenance is necessary to prevent deterioration and ensure the longevity of galvanized steel in any form.
In summary, electro galvanization offers a cost-effective solution for short-term applications, while hot-dip galvanization is the preferred choice for long-term durability and corrosion protection.
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Hot-dip galvanization is cheaper than electro galvanization
There are two types of galvanised steel available: hot-dipped and electro-galvanised. The major difference between the two is the production method.
Hot-dip galvanisation is the process of coating steel by dipping it into a bath of molten zinc. The steel goes through a series of steps to ensure complete coverage of a good-quality zinc layer. This includes caustic cleaning, rinsing, acidic cleaning, and dipping. The thickness of the coating can be controlled but is typically around 80 to 100 µm. Hot-dip galvanisation yields a strong, thick coating with a dull grey finish and a long life, averaging between 20 to 50 years.
Electro-galvanisation is a plating process where steel is placed in an electrically charged solution of zinc and saline. This causes the zinc to chemically bond to the conductive steel. The zinc acts as a barrier layer on top of the steel to prevent corrosive substances from reaching the underlying material. The thickness of the coating is determined by the current density and the temperature of the electrolyte and is typically around 10 to 12 µm. Electro-galvanisation produces an excellent, uniform, and shiny finish. However, it has a very low life, ranging from several months to a few years.
Hot-dip galvanisation is typically used for structural shapes such as angles and channels, as well as for building materials designed for structural support, to ensure durability and longevity. Electro-galvanisation, on the other hand, is used for more specialised applications that require a smooth finish or tight tolerances. It is also used for coiled sheet steel, which is later formed into shapes such as corrugated sheets or welded into pipes and tubes.
The cost of galvanisation depends on the type of process used. Hot-dip galvanisation is the cheaper of the two methods as it is better suited for mass production. Electro-galvanisation, on the other hand, tends to be more expensive and is used for more specialised applications.
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Electro galvanization is used for replaceable products
Galvanization is a manufacturing process where a protective layer of zinc is applied to iron or steel to prevent rusting. The process is named after the Italian physician, physicist, biologist, and philosopher Luigi Galvani. The two main types of galvanization are hot-dip galvanization and electro-galvanization.
Hot-dip galvanization involves dipping steel into a vat of molten zinc, resulting in a strong, thick coating with a dull grey finish. This process yields a long-lasting product with a lifespan of 20 to 50 years.
On the other hand, electro-galvanization is a plating process where steel is placed in an electrically charged solution of zinc and saline. This method creates a chemical bond between the zinc and the conductive steel, resulting in a uniform coating. Electro-galvanization is often used for coiled sheet steel, which can be formed into various shapes, pipes, or tubes.
While hot-dip galvanization is commonly used for structural shapes, electro-galvanization is typically employed for products that are easily replaceable. These may include outdoor furniture, gardening tools, and construction site applications. The main advantage of electro-galvanization is its cost-effectiveness. It also offers a bright and shiny finish, making it suitable for architectural applications where exposure to the elements is minimal.
In summary, electro-galvanization is favoured for replaceable products due to its lower cost, shorter lifespan, and aesthetically pleasing finish. By contrast, hot-dip galvanization is chosen for structural items that require maximum durability and longevity.
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Frequently asked questions
Galvanization is the process of applying a protective coating of zinc to steel or iron to prevent rust and corrosion.
Electro galvanization is a form of galvanization that uses electroplating to chemically bond zinc to steel. The other type of galvanization is hot-dip galvanization, which involves dipping steel into a vat of molten zinc.
Electro-galvanized steel has a lifespan ranging from several months to a few years.
The zinc coating on electro-galvanized steel is typically between 10 to 12 µm.
Electro-galvanized steel is more cost-effective than hot-dipped galvanized steel. It also provides a smoother, more uniform, and aesthetically pleasing finish.
