Galvanizing process

Hot-dip galvanizing is the process of immersing iron or steel in a bath of

molten zinc to produce a corrosion resistant, multi-layered coating of
zinc-iron alloy and zinc metal.  While the steel is immersed in the zinc,
a metallurgical reaction occurs between the iron in the steel and the
molten zinc.  This reaction is a diffusion process, so the coating forms
perpendicular to all surfaces creating a uniform thickness throughout
the part. 
The hot-dip galvanizing process (Figure 1) has been used since 1742,
providing long-lasting, maintenance-free corrosion protection at a
reasonable cost for decades. Although hot-dip galvanizing has been
utilized to protect steel for generations, the galvanizing process
continues to evolve with new technologies and creative chemistries.  The
three main steps in the hot-dip galvanizing process are surface
preparation, galvanizing, and post-treatment, each of which will be
discussed in detail. The process is inherently simple, which is a distinct
advantage over other corrosion protection methods. 
FIGURE 1
Galvanizing
Once the steel has been completely cleaned, it is ready for immersion
in the zinc bath. The galvanizing kettle contains zinc specified to
ASTM B6, a document that specifies any one of three grades of zinc
that are each at least 98% pure. Sometimes other metals may be added
to the kettle to promote certain desirable properties in the galvanized
coating.
The galvanizing kettle (Figure 5), is heated to a temperature ranging
from 820-860 F (438-460 C), at which point the zinc is in a liquid state.
The steel products are lowered into the galvanizing kettle at an angle,
and stay in the bath until the steel heats to the bath temperature.
 Once the diffusion reaction of iron and zinc is complete, the steel
product is withdrawn from the zinc kettle. The entire dip usually lasts
less than ten minutes, depending upon the thickness of the steel.
The coating, as seen in Figure 6, is typical for low silicon steels with
silicon impurities less than 0.04% and where the thickness of the
coating is limited by the interdiffusion of iron and zinc
 Figure 6
Figure 5
Post-Treatment
When the steel is removed from the galvanizing
kettle, it may receive a post-treatment to enhance
the galvanized coating. One of the most commonly
used treatments is quenching. The quench tank
contains mostly water but may also have chemicals
added to create a passivation layer that protects
the galvanized steel during storage and
transportation. Other finishing steps include
removal of zinc drips or spikes, by grinding them
off.
Filing Zinc Drips
Sherardizing
Sherardizing is a process of galvanization of ferrous
metal surfaces, also called vapour galvanising and dry
galvanizing. The process is named after the British
metallurgist Sherard Osborn Cowper-Coles (son of
naval inventor Cowper Phipps Coles) who invented
and patented the method ca. 1900.This process
involves heating the steel parts up to ca. 500°C in a
closed rotating drum that also contains metallic zinc
dust and possibly an inert filler, such as sand. At
temperatures above 300°C, zinc evaporates and
diffuses into the steel substrate forming diffusion
bonded Zn-Fe-phases.
Sherardising is ideal for small parts and
parts that require coating of inner surfaces,
such as batches of small items. Part size is
only limited by the drum size. It is reported
that pipes up to 6 m in length for the oil
industry are sherardised.[citation needed] If
the metal surface is free of scale or oxides,
no pretreatment is needed. The process is
hydrogen free, therefore a hydrogen
embrittlement is excluded.
Colorizing
Colorizing is a metallurgical process for treating the Process
quality is monitored by testing coupons ( of surface of steels,
stainless steels and alloys, with the same grade of metal) that
are run in the retort with aluminium that provides protection
against elevated- the production materials. The nature of the
process, temperature, scaling and corrosion. the air-tight
retorts and the controlled atmospheres ensure uniform alloy
protection over the entire surface Adding aluminium to
carbon and stainless steel is of the Calorising materials. After
the process is commonly known to improve corrosion
resistance. A completed, the coupons are removed from the
retort, side effect of the process, however, is unfavorable
sectioned and examined in a laboratory for quality and
changes in the mechanical properties of the base steels. depth
of diffusion.
During the Calorising process, the steel is chemically
carburization, scaling and hydrogen permeation. All
cleaned, treated with flux at 700C and then again types
of wrought and cast steels can be Calorised: treated
with another flux at 7300C. After this, the plain carbon
and low alloy grades, ferritic and steel dipped in
molten aluminum alloy at 7700C. austenitic steels,
high-temperature values of the process This results in
an evenly aluminium coated steel. Then determine the
specification of steel to be Calorised.
Technical Benefits • High corrosion resistance. • Case
depth up to .015" for tubing. • Operates in continues
temperatures up to 1750 degrees F. • Retains the base
steel's inherent strength and rigidity, depending on
base material. • Does not change the high-temperature
mechanical properties of the base steel. • Utilizes
Indra Udyog Technologies' patented diffusion alloying
process.
Common Applications • Sulfuric acid/ acid gas
removal : Resists sulfidation from H2S, SO3; increases
tube life up to 20 years. • Refining: Charge heaters,
delayed cokers, sulfur recovery, heat exchangers. •
Petrochemical: Reformers, ammonia, heat exchangers.
• Reformers – DRI: Secondary reformers, waste heat
boilers. • Boilers : PR boiler (pulp and paper),
waterwall panels, traditional boilers.
Alloys with greater nickel contents can withstand even
The replacement piece was Calorised and the pipe
higher working temperatures. There is a limit,
remained sound and unaffected by many subsequent
however, to the maximum amount of nickel that can
exposures to the same reagents at the same be used in
an alloy exposed to high-temperatures temperatures
sulfidation. With nickel contents of 25% or more, the
nickel will preferentially combine with sulfur to create
a low- melting temperature nickel sulfide eutectic.
Chromising
Chromising, or chromising, can protect components
from corrosion, wear, abrasion and oxidation.
Chromide diffusion coatings were originally developed
by Diffusion Alloys for hot section industrial gas
turbine blades and vanes to protect them against high
temperature oxidation and hot corrosion. Over the
years, chromised component applications have
widened considerably and we now coat for a wide
range of industries, including Oil & Gas, Process,
Steel, Textile and Renewables.
Steels with carbon content greater than 0.3% can form a hard dense
diffused chromium carbide surface layer which has high hardness
and excellent wear resistance. Typical materials that are suitable for
chromising / chromizing include:
Low carbon steels:
Oxidation resistance to 650℃; corrosion resistance similar to
ferritic stainless steel
Medium carbon steels:
Light wear and corrosion resistance
High carbon steel:
Wear resistance and corrosion resistance
Stainless steels:
Wear resistance and corrosion resistance
Nickel & Cobalt base super alloys: 
Corrosion and erosion resistance
Questions:
Modified true or false
Write TRUE if it’s correct and if False write the correct to make
the statement correct.
1.) Metallurgy is ideal for small parts and parts that
require coating of inner surfaces, such as batches of
small items.
2.) Oxidation resistance to 610℃; corrosion resistance
similar to ferritic stainless steel.
3.) Chromising can protect components from corrosion,
wear, abrasion and oxidation.
4.) During the Calorising process, the steel is chemically
carburization, scaling and hydrogen permeation.
5.) When the steel is removed from the galvanizing kettle,
it may receive a pre-treatment to enhance the galvanized
coating.
6.) High carbon steel is a wear resistance and corrosion
resistance.
7.) Nickel & Cobalt base super alloys are corrosion and not
erosion resistance.
8.) Hot-dip galvanizing is the process of immersing iron or
steel in a bath of molten zinc to produce a corrosion
resistant, multi-layered coating of zinc-iron alloy and
zinc metal.
9 & 10.) Sherardising is a process of galvanization of ferrous
metal surfaces, also called air galvanising and carbon
galvanizing.