Galvanization ( also spelled galvanisation) is the process of applying a protective

zinc Zinc is a chemical element; it has symbol Zn and atomic number 30. It 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 periodic tabl ...

coating to

steel Steel is an alloy of iron and carbon that demonstrates improved mechanical properties compared to the pure form of iron. Due to steel's high Young's modulus, elastic modulus, Yield (engineering), yield strength, Fracture, fracture strength a ...

iron Iron is a chemical element; it has symbol Fe () 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, forming much of Earth's o ...

, to prevent rusting. 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 expos ...

, in which the parts are coated by submerging them in a bath of hot, molten zinc.

Protective action

The zinc coating, when intact, prevents corrosive substances from reaching the underlying iron. It's main function is to act as a sacrificial anode to prevent the iron from rusting by

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 " sacrifi ...

. Zinc is more reactive than iron, so the zinc coating preferentially oxidizes to zinc carbonate, preventing the iron from corroding, even if there are gaps in the zinc coating. Additional

electroplating Electroplating, also known as electrochemical deposition or electrodeposition, is a process for producing a metal coating on a solid substrate through the redox, reduction of cations of that metal by means of a direct current, direct electric cur ...

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 pri ...

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 ...

to the substrate material.

History and etymology

The process is named after the Italian physician, physicist, biologist and philosopher

Luigi Galvani Luigi Galvani ( , , ; ; 9 September 1737 – 4 December 1798) was an Italian physician, physicist, biologist and philosopher who studied animal electricity. In 1780, using a frog, he discovered that the muscles of dead frogs' legs twitched when ...

(9 September 1737 – 4 December 1798). The earliest known example of galvanized iron was discovered on 17th-century Indian armour in the Royal Armouries Museum collection in the United Kingdom. The term "galvanized" can also 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

, was patented by Stanislas Sorel, of Paris, 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 expos ...

deposits a thick, robust layer of zinc iron alloys on the surface of a steel item. In the case of

automobile A car, or an automobile, is a motor vehicle with wheels. Most definitions of cars state that they run primarily on roads, Car seat, seat one to eight people, have four wheels, and mainly transport private transport#Personal transport, peopl ...

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 Permeation, permeate solid metals. O ...

can become a problem. Thermal diffusion galvanizing, or

Sherardizing Sherardising or Zinc thermal diffusion 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 ...

, 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 a material or mixture that, when applied to a solid material and allowed to dry, adds a film-like layer. As art, this is used to create an image or images known as a painting. Paint can be made in many colors and types. Most paints are ...

coatings and additional sacrificial anodes. 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 colorless gas with a pungent smell that is responsible for the odor of burnt matches. It is r ...

in the air.

Galvanized construction steel

This is the most common use for galvanized metal; 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 swiftly took the place of previously used

cast iron Cast iron is a class of iron–carbon alloys with a carbon content of more than 2% and silicon content around 1–3%. Its usefulness derives from its relatively low melting temperature. The alloying elements determine the form in which its car ...

and

lead Lead () is a chemical element; it has Chemical symbol, symbol Pb (from Latin ) and atomic number 82. It is a Heavy metal (elements), heavy metal that is density, denser than most common materials. Lead is Mohs scale, soft and Ductility, malleabl ...

in cold-water

plumbing Plumbing is any system that conveys fluids for a wide range of applications. Plumbing uses piping, pipes, valves, piping and plumbing fitting, plumbing fixtures, Storage tank, tanks, and other apparatuses to convey fluids. HVAC, Heating and co ...

. 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.

References

External links

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