Comparative Properties of various Zinc Metal Coating

Characteristic of the coating

Adhesion

Hot Dip Galvanizing

Coating is integral with the steel because the formation process produces zinc/iron alloy layers over coated with zinc. Good any discontinuities are readily visible as black spots. Some excess zinc at drainage points on products. Normally about 50-125 Microns on tube and products; thicker coating up to 250 Microns obtained by silicon killed steel or grit blasting before galvanizing. Coatings 10 30 Microns applied to continuous wire and sheet Conventional coatings applied to finished articles, not formidable; alloy layer is abrasive resistant but brittle on bending. Special coating with little or no alloy layer readily formed (e.g. on sheet) and resistance welded. Conversion coatings chromates prevent wet storage stain; phosphates good on new sheet as a base for paints. Weathered coatings often painted (after 10 30 years) for long service. Size of bath available parts up to about 25 meters long can dipped at some works. Care required at design stage for best results. Continuous wire and sheet available.

Electro Coating
Good, comparable with other electroplated coatings. Uniformity within limitations of throwing power of bath. Pores not a problem, as exposed steel protected by adjacent zinc Thickness variable at will; generally 3 -15 Microns Thicker layers are possible but generally uneconomical. Electroplated steel has excellent formability and can be spot welded. Small components are usually finished before plating. Conversion coatings (e.g. chromates used to prevent wet storage stain ) Frequently used as a base for paints. Size of bath available. Process normally used for simple, fairly small components suitable for barrel plating or for concontinuous sheet and wire. No heating except for hydrogen embrittlement relief on high strength steel

Mechanical Coating
Good, comparable with electroplated coatings. Thin at corners the opposite of hot-dip galvanized coatings.

Zinc Spraying
Good mechanical interlocking provided the abrasive grit blasting pretreatment is carried out correctly. Depends on operator skill Coating are porous but the pores soon fill with zinc corrosion products and are thereafter impermeable. Thickness variable at will generally 100 150 Microns but coatings of up to 500 Microns can be applied

Zinc Dust Painting

Good abrasive grit blasting of the steel gives best result Good-any pores fill with reaction products. Thin at corners.

Continuity and Uniformity

Thickness

Variable at will, usually between 10 80 Microns.

Up to 40 Microns of paint (and more with special formulations can be applied in one coat

Formability and Mechanical Properties

Good. Does not causes em-brittlement of high strength steels.

When applied to finished articles, forming not required. Can weld through thin coating if necessary but preferable to mask edges to be welded and spray these afterwards Coating with sealant that can provide a base for paints to give long life structures.

Abrasion resistance better than conventional paints, Painted sheet can be formed and resistance welded with minor damage. Can be used alone or as primer under conventional paints.

Extra Treatment

Can have conversion coatings applied..

Other Considerations

Ideal for small parts including washers and springs (e.g. up to 15 cm or 250g). Access difficulties (e.g. inside tubes).

No size or shape limitations very economical for work with high weight to area ration. Uneconomical on open mesh. Access difficulties may limit application (e.g. inside tubes). Best method of applying very thick coatings. Little heating on the steel.

Suitable for anything that can be painted though there may be difficulties of access in narrow tubular structures. Can be brush, spray or dip applied. No heating involved. Performance varies with media used and percentage of zinc dust Prepared By M.Sreedhar Patnaik

Visakha Steel Allieds Hot-dip Galvanizers