Mechanical Plating and Galvanizing

Mechanical Plating and Galvanizing was not invented until almost 200 years after P.J Malouin made his presentation to the French Royal Academy on a method of coating iron with molten zinc (Hot Dip Galvanizing) or 100 years after hot dip was patented, yet it is a valuable process to provide sacrificial protection to steel parts. Developed in the late 1940s and the early 1950s. 3M reduced processing times, substituted glass beads for steel shot as the impact media, developed the first dry promoter package and evolved the process from Claytons concept to a commercial reality. MacDermid purchased the 3M Metal Finishing business in the mid 1980s and completed against (Waldes Tru-Plate was acquired by the McGean-Rohco, and survives today as a brand name Atotech), PS&T continues to advance the techno9logy of mechanical plating and galvanizing. The process of mechanical plating/galvanizing is typically conducted in a barrel similar to a cement mixer. The parts, media (glass beads) and water are tumbled while cleaners, coppering agents, promoter chemicals and metal powders are added. Once desired coating thickness or weight is reached, the parts, media and water (with chemicals) are dumped to a surge hopper for separation. The media media is recycled and used again; the water (with chemicals) goes to water treatment; and the parts are dried and if a post treatment (hexavalent chromate, trivalent chromate, sealant, wax, lacquer and/or dye) is added, it is usually done off-line and often a post treatment will include more than one of the items listed. Mechanically plated or galvanized coatings adhere strongly to a clean base metal through cold welding (impact of glass beads to parts with metal powder between the two) of the powder metal (usually zinc) during processing. It is true that hot dip coatings provide better adhesion, but such adhesion is well in excess of what is required for a functional coating. Mechanical coatings provide enough adhesion to meet specifications from the ASTEM, ICC, GM, Ford and Chrysler- to name a few. At equal coating weights (not thicknesses, since the mechanical coating is less dense than the hot dip coating), mechanical coatings provide equal and often better salt spray results under ASTM B117. Mechanical Plating/Galvanizing and Hot Dip Galvanizing have both served the market for smaller parts, fasteners and steel articles since the mid 1970s. Botha re considered excellent ways to provide a sacrificial zinc coating to a steel part. These are advantages and disadvantages to each; as listed below. The difference between mechanical plating and mechanical galvanizing is only of one thickness, plating is under 1 mil (0.001) and galvanizing is over 1 mil. Both processed can be conducted in the same type of barrel. But galvanizing may take a little more time. Still one can expect that to get about one load per hour out of a mechanical plating/galvanizing barrel. It is not decorative, but a functional sacrificial coating of zinc, zinc-tin, zinc-tin-aluminum or other alloys with zinc making up the largest percentage of metal on the surface of the plated part. As previously mentioned, mechanical competes with hot-dip at the higher coating thicknesses or weights, but at the lower thicknesses it competes electroplating. It is not as cosmetically attractive as electroplate, but is preferred when doing high strength steel parts at coating thicknesses above 5/10 of a mil (0.0005). the main reason for this is because at or above this thickness it is price or cost competitive. Typically, at lower coating thicknesses, electroplating is more cost effective.

States in raw (unplated) and plated forms. This appears to have opened up some additional market for U.S companies to import raw fasteners and plate them here. Every year, about 300 million pounds of parts and small stampings are mechanically plated or mechanically galvanized worldwide. That is over 10 billion pounds in the thirty-five years since mechanical galvanizing was introduced over one trillion parts and small stampings. The simple fact is that mechanical plating and/or mechanical galvanizing, depending on the intended application, are excellent coatings for parts that need sacrificial protection. The next time you are looking for a functional, hydrogen embrittlement free and uniform coating- give mechanical a try. Article by David Rochester Sourced from: Chinese Fastener & Wire 23 June 2008

Mechanical Plating or Galvanizing Better sacrificial protection, no Hydrogen Embrittlement ASTM B695 has Salt Spray Requirement Coating thicknesses from 2/10 of a mil (0.0002) to 3 mils (0.003) Less Common Lead-free deposit Better uniformity and thread profiles on bolts No detempering RoHS Compliant (if not hexavalent chromate) No stickers, no need to chasse threads after galvanizing and no filling of internal threads Often post-treated with chromates, sealants and waxes Room temperature with no dangerous fumes

Hot-Dip Galvanizing Good sacrificial protection No Standard for Salt Spray Coating thicknesses over 2 mils (0.002) thinner coatings are not generally achievable. More Common If using Prime Western Zinc, contains Lead May show red corrosion products prematurely based upon interlayer May detemper hear-treated parts due to temperature of molten zinc Not RoHS Compliant (if done with Prime Western Zinc) Occasionally part types may stick together and create stickers (particularly washers and nails) Usually not post treated