Photomicrograph of Galvanized Steel.

ETA LAYER.
100% Zn 70 DPN
AVERAGE HARDNESS
ZETA LAYER. 94% Zn 6% Fe. 180 DPN

AVERAGE HARDNESS
DFGAAAVERAGEHDFHHARDN
DELTA LAYER. 90% Zn 10% Fe, 245
ESSHARDNESS
DPN AVERAGE HARDNESS
GAMMA LAYER. 75% Zn 25% Fe. 350

DPN AVERAGE HARDNESS
BASE STEEL. 160 DPN AVERAGE

HARDNESS
FIG: Photomicrograph of galvanized steel
The above photomicrograph represents a typical cross section of a hot dip galvanized coating . The
outermost layer of the coating is formed as the material is withdrawn from the molten zinc bath. This
layer is a covering of pure zinc. The underlying series of zinc-iron alloys in the coating are the result of
metallurgical reaction between molten zinc and steel or iron material being galvanized. As the zinc-
iron alloys form, they will grow perpendicularly to the steel surface. The effect this has on corners and
edges of material is that the coating there is generally thicker than the surrounding coating, as seen in
the micrograph. This is in sharp contrast to the other type of protective coatings that TEND TO THIN
OUT at the edges and corners of the materials.
The galvanized coating itself is considered to be a self inspecting system. This is because the reaction
between the molten zinc and the steel will not occur unless the steel surface is chemically or Non Ox.
Clean. In effect, a galvanized coating that appears sound and continuous is in fact sound and
continuous. If a coating should become damage however, the zinc will continue to provide cathodic
protection to the exposed steel. Even if areas as much as ¼ inch in length or width become exposed
the surrounding zinc will provide cathodic protection to this area as long as the coating lasts.
As for mechanical protection, the galvanized zinc coating literally becomes part of the steel substrates
thus, in adhesion bond on the order of several thousand psi exits between the two . Also, since the
zinc0iron alloys are harder than the underlying steel, they will provide excellent abrasion resistance to
the galvanized article. The Eta layer is relatively ductile and also contributes to the protection of the
galvanized material by providing good impact resistance. The combination of all all this layers to
produce the galvanized coating provides toughness and resistance to mechanical damage in transport,
erection and service.
The thickness and appearance of the galvanized coating are affected by several factors.
1. The chemical composition of steel :
2. The surface condition of steel : In general, rough steel surfaces will cause the galvanizing
reaction to produce thicker coatings due to the increased surface area. This thicker coatings,
however, will be rough and have a generally poor appearance.
3. Bath immersion time: Galvanizing is a diffusion process . As with all diffusion process, reaction
between the molten zinc and the steel or iron will proceed quickly at first but will slow down
as the alloy layer grow and become thicker. Thus, continued immersion or dipping material
more than once will not produce a significantly thicker coating except in case of reactive
steels.
4. Bath withdrawal rate: The withdrawal rate of material from galvanizing bath has the greatest
effect on the outermost layer of pure zinc. A rapid withdrawal will produce the thickest
coating because the largest amount zinc will be carried out on the material and will
subsequently solidify and become the pure zinc layer. Slower withdrawal allows the zinc to
effectively drain back in the kettle producing smoother , thinner and more uniform coatings.
5. Steel cooling rate: slower cooling rates, such as those experienced with air cooling or even with
thicker sections that have been water quenched, allow the zinc/iron allowing reaction to
continue. The inner alloy layer will use the outer eta layer for their supply of zinc causing the
coating to become dull, matte gray. Quickly reducing the temperature to less than 300 degrees
Fahrenheit will halt the galvanizing reaction and minimize the formation of dull or matte
surfaces.

Photomicrograph of Galvanized Steel.

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Photomicrograph of Galvanized Steel.

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ETA LAYER.

ZETA LAYER. 94% Zn 6% Fe. 180 DPN

GAMMA LAYER. 75% Zn 25% Fe. 350

BASE STEEL. 160 DPN AVERAGE

FIG: Photomicrograph of galvanized steel

1. The chemical composition of steel :

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