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    Hot Dip Coating, Cladding

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    azim turan
    Hot dip coating is a common and cost-effective surface coating process. Key types include hot dip galvanizing (zinc coating), which protects steel from corrosion through the formation of a zinc film and zinc's sacrificial protection. The process involves surface cleaning, fluxing to activate the surface, dipping in molten zinc at 445-465°C, and optional post-treatments like galvannealing. Hot dip aluminium coating also exists but requires higher temperatures that could impact the base metal structure. Cladding uses high pressure and heat to bond a metal coating to another for corrosion protection.

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    Hot Dip Coating, Cladding

    Uploaded by

    azim turan
    44 views18 pages
    Hot dip coating is a common and cost-effective surface coating process. Key types include hot dip galvanizing (zinc coating), which protects steel from corrosion through the formation of a zinc film and zinc's sacrificial protection. The process involves surface cleaning, fluxing to activate the surface, dipping in molten zinc at 445-465°C, and optional post-treatments like galvannealing. Hot dip aluminium coating also exists but requires higher temperatures that could impact the base metal structure. Cladding uses high pressure and heat to bond a metal coating to another for corrosion protection.

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    Cladding and coating basics.

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    Hot+Dip+Coating,+Cladding

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    Hot dip coating is a common and cost-effective surface coating process. Key types include hot dip galvanizing (zinc coating), which protects steel from corrosion through the formation of a zinc film and zinc's sacrificial protection. The process involves surface cleaning, fluxing to activate the surface, dipping in molten zinc at 445-465°C, and optional post-treatments like galvannealing. Hot dip aluminium coating also exists but requires higher temperatures that could impact the base metal structure. Cladding uses high pressure and heat to bond a metal coating to another for corrosion protection.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    44 views18 pages

    Hot Dip Coating, Cladding

    Uploaded by

    azim turan
    Hot dip coating is a common and cost-effective surface coating process. Key types include hot dip galvanizing (zinc coating), which protects steel from corrosion through the formation of a zinc film and zinc's sacrificial protection. The process involves surface cleaning, fluxing to activate the surface, dipping in molten zinc at 445-465°C, and optional post-treatments like galvannealing. Hot dip aluminium coating also exists but requires higher temperatures that could impact the base metal structure. Cladding uses high pressure and heat to bond a metal coating to another for corrosion protection.

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    of 18

    Surface Coating Processes*

    * Processes of covering surfaces with new


    materials. This new materials can be metal,
    ceramic, organic based (like paints and
    plastics) or mixing of them (composite).
    Hot dip coating

    Hot dip coating of metals is the oldest, easiest and


    cheapest technique.
    For hot dip coating:
    • Coating metal must have low melting point. (Zn, Sn,
    Pb, Al)
    • Properties of base metal must not change in bath
    temperature. Steel is the base metal for hot dip
    coating. Also, Sn coated Cu and Al coated Ti or Mo
    are used for special purposes.
    Advantages of hot dip coating
    • Edges, corners and complex shapes can be coated
    easily.
    • Metallurgical bonding occurs between coating and
    base metal and it has resistance to mechanical
    damages.
    • Corrosion resistance to against to many
    atmospheres.
    • Maintenance free.
    • Long service life. (~70 years)
    • Easy to paint.
    * The last three of them are especially for hot dip galvanizing.
    Hot dip galvanizing (Zinc coating)
    It is a commonly used process to protect Fe based products
    against to atmospheric, underground and underwater
    corrosion.
    Zinc coating protects steel in three ways:
    1. Continuous zinc film separates steel from its
    environment.
    2. In case of any discontinuity, zinc behave as a sacrifice
    anode for protect steel. (It is a kind of cathodic
    protection, Zn is more active than Fe in EMF series.)
    3. Zinc provides high corrosion resistance in many
    atmospheres. In open air conditions, almost insoluble
    zinc carbonate layer [3Zn(OH)2.2ZnCO3] occurs on
    galvanized surfaces with time.
    Process stages of hot dip galvanizing

    • Surface cleaning of base metal.


    • Fluxing.
    • Galvanizing.
    • Post galvanizing treatments.

    Surface cleaning: Grease (oil) removing, shot or bead


    blasting, alkali cleaning (caustic) and acid cleaning
    (pickling).
    Fluxing treatments:
    Purpose of fluxing:
    • Prevent oxidation of metal just before galvanizing
    (after cleaning).
    • To activate metal surface for easy reaction.
    • Provide wetting of molten metal to base metal
    surface.
    Composition of flux: 87% ZnCl2 + 13% NH4Cl (solution)
    • Fluxing in a different bath is called dry galvanizing.
    • Fluxing combined with zinc coating is called wet
    galvanizing.
    Dry galvanizing
    • After cleaning, part is dipped into flux solution then
    dried and dipped into molten zinc
    • Separated fluxing is an easy controlling process.
    • It gives more consistent results.
    • Dry galvanizing is necessary if zinc bath includes Al.
    Wet galvanizing
    • Cleaned part is directly dipped into molten zinc.
    • Zinc bath is divided into two parts.
    • Foamy flux layer is placed on the first part. Metal is
    dipped from this part and got out from second part.
    • It provides clean and bubble free coating surfaces.
    Galvanizing process features
    • Tm Zinc: 420 °C
    • Molten zinc bath temperature: 445-465 °C
    • An alloy layer forms between steel and molten zinc.
    Nature and thickness of these alloy layers depend on; steel
    composition, bath composition, bath temperature and dipping
    time.
    1. Steel composition
    Si content of the steel is so important. (0.02-0.20)
    High Si content causes thick and brittle coating layers.

    2. Bath composition (for ordinary galvanizing)


    • Purity of zinc must be 99.0% - 99.98%.
    • To improve surface tension, small amount of Pb can be added.
    • Total amount of additions must not be higher than 1.65%.
    3. Bath temperature
    • If bath contains 0.3% Al, temperature must be between 445-
    465 °C.
    • Galfan* (Zn - Al 5%) coating, bath temperature 420 °C.
    • Galvalume** (Zn - Al 55%) coating, bath temperature 600
    °C. (Take care of base material for structural changes.)

    *Galfan: It is a kind of Zn-Al alloy includes 0.05 % Ce and


    La, 5% Al. It is an eutectic alloy . It has higher corrosion
    resistance also high plastic deformation capability. This coating
    is applied in case of post deformation process is required.

    **Galvalume coated steel panels are especially used for


    roof sidings. It has smoother and brighter appearence than
    ordinay galvanizing.
    4. Dipping time
    • Excessive time causes thicker coatings.
    • Complex shape parts need more time.
    • Addition of 0.2 – 0.4 % Al to zinc bath provide thin,
    more ductile and more bright coatings.
    • Reaction between Al and flux decreases quality of
    flux. So, dry galvanizing is necessary if bath contains
    Al.
    Galvalume
    Post galvanizing treatments
    • Galannealing: Annealing of galvanized coating at ~500 °C.
    It develops diffusion between Fe-Zn phases.
    • The resulting coating has a matte appearance, and is hard
    and brittle.
    • Due to iron present in the surface alloy phase galvanneal
    develops a reddish patina in moist environments - it is
    generally used painted.
    • It brings weldability, paintability, higher hardness and
    higher resistance to heat. In comparison to a zinc
    (galvanized) coating galvannealed has better spot
    weldability, and is paintable.
    • Phosphate, chromate coatings and painting can be carried
    out.
    Hot dip aluminium coating
    Process temp ~700 °C. Base metal structure can be
    changed. Thera are two types coating compositions.

    • Type 1: Al-Si (5-11 %) alloy is used.


    • Type 2: Commercial purity Al is used.

    • Type 1 gives thinner coating and bath temperature is


    lower
    Cladding (Roll bonding)

    Cladding refers to the metallurgical process of coating a


    metal onto another metal under high temperature and
    pressure so as to protect the inner metal from
    corrosion.
    Cladding may be done using, aluminium, stainless steel,
    anodized aluminium or copper. Of the lot aluminium
    cladding is traditionally preferred due to its features
    like flexibility, lightweight and recyclable nature.

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