Galvanization
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Galvanization or galvanizing ( also spelled galvanisation or galvanising) is the process of applying a protective
zinc Zinc is a chemical element with the symbol Zn and atomic number 30. Zinc is a slightly brittle metal at room temperature and has a shiny-greyish appearance when oxidation is removed. It is the first element in group 12 (IIB) of the periodi ...
coating to
steel Steel is an alloy made up of iron with added carbon to improve its strength and fracture resistance compared to other forms of iron. Many other elements may be present or added. Stainless steels that are corrosion- and oxidation-resistant ty ...
or
iron Iron () is a chemical element with symbol Fe (from la, ferrum) and atomic number 26. It is a metal that belongs to the first transition series and group 8 of the periodic table. It is, by mass, the most common element on Earth, right in f ...
, to prevent
rusting Rust is an iron oxide, a usually reddish-brown oxide formed by the reaction of iron and oxygen in the catalytic presence of water or air moisture. Rust consists of hydrous iron(III) oxides (Fe2O3·nH2O) and iron(III) oxide-hydroxide (FeO(OH ...
. The most common method is
hot-dip galvanizing Hot-dip galvanization is a form of galvanization. It is the process of coating iron and steel with zinc, which alloys with the surface of the base metal when immersing the metal in a bath of molten zinc at a temperature of around . When expose ...
, in which the parts are submerged in a bath of hot, molten zinc.


Protective action

The zinc coating, when intact, prevents corrosive substances from reaching the underlying iron. Additional
electroplating Electroplating, also known as electrochemical deposition or electrodeposition, is a process for producing a metal coating on a solid substrate through the reduction of cations of that metal by means of a direct electric current. The part to be ...
such as a
chromate conversion coating Chromate conversion coating or alodine coating is a type of conversion coating used to passivate steel, aluminium, zinc, cadmium, copper, silver, titanium, magnesium, and tin alloys. The coating serves as a corrosion inhibitor, as a primer t ...
may be applied to provide further
surface passivation A surface, as the term is most generally used, is the outermost or uppermost layer of a physical object or space. It is the portion or region of the object that can first be perceived by an observer using the senses of sight and touch, and is t ...
to the substrate material.


History and etymology

The earliest known example of galvanized iron was encountered by Europeans on 17th-century Indian armour in the
Royal Armouries The Royal Armouries is the United Kingdom's national collection of arms and armour. Originally an important part of England's military organization, it became the United Kingdom's oldest museum, originally housed in the Tower of London from ...
Museum collection. The term "galvanized" continues to be used metaphorically of any stimulus which results in activity by a person or group of people. In modern usage, the term "galvanizing" has largely come to be associated with zinc coatings, to the exclusion of other metals. Galvanic paint, a precursor to
hot-dip galvanizing Hot-dip galvanization is a form of galvanization. It is the process of coating iron and steel with zinc, which alloys with the surface of the base metal when immersing the metal in a bath of molten zinc at a temperature of around . When expose ...
, was patented by
Stanislas Sorel Stanislas Sorel (born 1803, Putanges, France; died 18 March 1871, Paris) was a French civil engineer, inventor, and chemist, raised the son of a poor clock-maker.Beach, Alfred Ely (1871). Stanislas Sorel. Sci. Am, 25, 151. A poorly known aspect ...
, of
Paris Paris () is the capital and most populous city of France, with an estimated population of 2,165,423 residents in 2019 in an area of more than 105 km² (41 sq mi), making it the 30th most densely populated city in the world in 2020. S ...
, on June 10, 1837, as an adoption of a term from a highly fashionable field of contemporary science, despite having no evident relation to it.


Methods

Hot-dip galvanizing Hot-dip galvanization is a form of galvanization. It is the process of coating iron and steel with zinc, which alloys with the surface of the base metal when immersing the metal in a bath of molten zinc at a temperature of around . When expose ...
deposits a thick, robust layer of zinc iron alloys on the surface of a steel item. In the case of
automobile A car or automobile is a motor vehicle with Wheel, wheels. Most definitions of ''cars'' say that they run primarily on roads, Car seat, seat one to eight people, have four wheels, and mainly transport private transport#Personal transport, pe ...
bodies, where additional decorative coatings of paint will be applied, a thinner form of galvanizing is applied by electrogalvanizing. The hot-dip process generally does not reduce strength to a measurable degree, with the exception of high-strength steels where
hydrogen embrittlement Hydrogen embrittlement (HE), also known as hydrogen-assisted cracking or hydrogen-induced cracking (HIC), is a reduction in the ductility of a metal due to absorbed hydrogen. Hydrogen atoms are small and can permeate solid metals. Once absorbed ...
can become a problem. Thermal diffusion galvanizing, or
Sherardizing Sherardising is a process of galvanization of ferrous metal surfaces, also called vapour galvanising and dry galvanizing. The process is named after British metallurgist Sherard Osborn Cowper-Coles (son of naval inventor Cowper Phipps Coles) who ...
, provides a zinc diffusion coating on iron- or copper-based materials.


Eventual corrosion

Galvanized steel can last for many decades if other supplementary measures are maintained, such as
paint Paint is any pigmented liquid, liquefiable, or solid mastic composition that, after application to a substrate in a thin layer, converts to a solid film. It is most commonly used to protect, color, or provide texture. Paint can be made in many ...
coatings and additional
sacrificial anode A galvanic anode, or sacrificial anode, is the main component of a galvanic cathodic protection system used to protect buried or submerged metal structures from corrosion. They are made from a metal alloy with a more "active" voltage (more n ...
s. The rate of corrosion in non-salty environments is caused mainly by levels of
sulfur dioxide Sulfur dioxide (IUPAC-recommended spelling) or sulphur dioxide (traditional Commonwealth English) is the chemical compound with the formula . It is a toxic gas responsible for the odor of burnt matches. It is released naturally by volcanic activ ...
in the air.


Galvanized construction steel

This is the most common use for galvanized metal, and hundreds of thousands of tons of steel products are galvanized annually worldwide. In developed countries most larger cities have several galvanizing factories, and many items of steel manufacture are galvanized for protection. Typically these include: street furniture, building frameworks, balconies, verandahs, staircases, ladders, walkways, and more. Hot dip galvanized steel is also used for making steel frames as a basic construction material for steel frame buildings.


Galvanized piping

In the early 20th century, galvanized piping replaced previously-used
cast iron Cast iron is a class of iron–carbon alloys with a carbon content more than 2%. Its usefulness derives from its relatively low melting temperature. The alloy constituents affect its color when fractured: white cast iron has carbide impuriti ...
and
lead Lead is a chemical element with the symbol Pb (from the Latin ) and atomic number 82. It is a heavy metal that is denser than most common materials. Lead is soft and malleable, and also has a relatively low melting point. When freshly cu ...
in cold-water
plumbing Plumbing is any system that conveys fluids for a wide range of applications. Plumbing uses pipes, valves, plumbing fixtures, tanks, and other apparatuses to convey fluids. Heating and cooling (HVAC), waste removal, and potable water delivery ...
. Typically, galvanized piping rusts from the inside out, building up layers of plaque on the inside of the piping, causing both water pressure problems and eventual pipe failure. These plaques can flake off, leading to visible impurities in water and a slight metallic taste. The life expectancy of galvanized piping is about 40–50 years, but it may vary on how well the pipes were built and installed. Pipe longevity also depends on the thickness of zinc in the original galvanizing, which ranges on a scale from G01 to G360.


See also

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Aluminized steel Aluminized steel is steel that has been plated with aluminium or aluminium-silicon alloy, in a process analogous to hot-dip galvanizing. The steel workpiece is immersed in molten aluminum to produce a tight metallic bond between the steel and co ...
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Cathodic protection Cathodic protection (CP; ) is a technique used to control the corrosion of a metal surface by making it the cathode of an electrochemical cell. A simple method of protection connects the metal to be protected to a more easily corroded "sacrific ...
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Corrugated galvanized iron Corrugated galvanised iron or steel, colloquially corrugated iron (near universal), wriggly tin (taken from UK military slang), pailing (in Caribbean English), corrugated sheet metal (in North America) and occasionally abbreviated CGI is a bu ...
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Galvanic corrosion Galvanic corrosion (also called bimetallic corrosion or dissimilar metal corrosion) is an electrochemical process in which one metal corrodes preferentially when it is in electrical contact with another, in the presence of an electrolyte. A sim ...
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Galvannealed Galvannealed or galvanneal (galvannealed steel) is the result from the processes of galvanizing followed by annealing of sheet steel. Galvannealed steel is a matte uniform grey color, which can be easily painted. In comparison to galvanized stee ...
– galvanization and annealing *
Prepainted metal According to EN 13523-0, a prepainted metal (or coil coated metal) is a ‘''metal on which a coating material (e.g. paint, film…) has been applied by coil coating''’. When applied onto the metallic substrate, the coating material (in liquid, in ...
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Rust Rust is an iron oxide, a usually reddish-brown oxide formed by the reaction of iron and oxygen in the catalytic presence of water or air moisture. Rust consists of hydrous iron(III) oxides (Fe2O3·nH2O) and iron(III) oxide-hydroxide (FeO(OH ...
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Rustproofing Rustproofing is the prevention or delay of rusting of iron and steel objects, or the permanent protection against corrosion. Typically, the protection is achieved by a process of surface finishing or treatment. Depending on mechanical wear or env ...
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Sendzimir process Sendzimir process (named after Tadeusz Sendzimir) is used to galvanize a steel strip by using a small amount of aluminum in the zinc bath and producing a coating with essentially no iron-zinc alloy. The process guarantees high resistance and durab ...
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Sherardizing Sherardising is a process of galvanization of ferrous metal surfaces, also called vapour galvanising and dry galvanizing. The process is named after British metallurgist Sherard Osborn Cowper-Coles (son of naval inventor Cowper Phipps Coles) who ...
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Corrosion Corrosion is a natural process that converts a refined metal into a more chemically stable oxide. It is the gradual deterioration of materials (usually a metal) by chemical or electrochemical reaction with their environment. Corrosion engine ...
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Sacrificial metal A sacrificial metal is a metal used as a sacrificial anode in cathodic protection that corrodes to prevent a primary metal from corrosion or rusting. It may also be used for galvanization. Equation When two metals touch each other and water is p ...
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Corrosion engineering Corrosion engineering is an engineering specialty that applies scientific, technical, engineering skills, and knowledge of natural laws and physical resources to design and implement materials, structures, devices, systems, and procedures to mana ...


References


External links

{{Authority control Chemical processes Corrosion prevention Metal plating Zinc Bimetal