• Corrosion Science and Technology
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• v.10 no.1
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• pp.30-36
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• 2011

The effect of dynamic flow or forced convection were investigated and compared on the formation of inhibition layer, galvanizing and galvannealing reactions through the hot-dip galvanizing simulator with the oscillation of specimen in zinc bath, continuous galvanizing pilot plant with zinc pumping system through the snout and continuous galvanizing operation with Dynamic $Galvanizing^{TR}$ system. The interfacial Al pick-up was not consistent between the results of simulator, pilot plant and line operation, but the morphology of inhibition layer became compact and refined by the forced convection. The growth of Fe-Zn intermetallics at the interface was inhibited by the forced convection, whereas the galvannealing rate would be a little promoted.

• Journal of Advanced Marine Engineering and Technology
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• v.31 no.2
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• pp.173-181
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• 2007

Recently, galvanizing method is predominantly being used not only a economical point of view but also due to it s stability and long life. For example, guard rail of high way, all kinds of structures for ship etc. were protected with galvanizing and demand of galvanized structural materials was being increased with more and more. However, galvanized structures were inevitably being deteriorated with time eventually because they were corroded with solution of galvanizing film and exfoliation of it s film in the present severe corrosive environment. Therefore, it is necessary to improve the corrosion resistance of the galvanizing film through various methods such as variation of chemical composition of galvanizing bath, chromate treatment and coating treatment. In this study, three test specimens such as pure galvanizing, galvarium, and chromate treatment were submerged at tap water with inhibitor addition. And the effect of their corrosion resistance improvement was comparatively investigated with electrochemical method. Corrosion current density of the galvanized steel was the largest among three specimens, however, the galvarium steel showed the lowest corrosion current density. Futhermore, these three kinds of test specimens indicated considerably excellent corrosion resistance by dipped at tap water with inhibitor addition. Especially, the galvanized steel showed the best effect of corrosion resistance improvement than other test specimens.

• Journal of Surface Science and Engineering
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• v.49 no.3
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• pp.245-251
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• 2016

Galvanizing method has been extensively used to the numerous constructional steels such as a guard rail of high way, various types of structural steel for ship building and various types of steels for the industrial fields etc.. However, the galvanized structures would be inevitably corroded rapidly with increasing exposed time because an acid rain due to environmental contamination has been much dropped more and more. Therefore, it has been made an effort to improve the corrosion resistance of the galvanizing film through various methods. In this study, comparison evaluation on the corrosion resistance of three types of the samples, that is, the hot dip galvanizing with pure zinc(GI), the hot dip galvanizing of alloy bath with zinc and aluminum(GL) and the pure zinc galvanizing steel immersed again to chromate treatment bath(Chro.)were investigated using electrochemical methods in 1% $H_2SO_4$ solution. The Chro. and GI samples exhibited the highest and lowest corrosion resistance respectively in 1% $H_2SO_4$ solution, however, the GI sample revealed the highest impedance at 0.01 Hz due to its high resistance polarization caused by corrosion products deposited on the surface, while Chro. sample exhibited the lowest impedance at 0.01 Hz because of little corrosion products on the surface. Consequently, it is suggested that the chromate treated steel has a better corrosion resistance in acid environment compared to pure galvanizing(GI) or galvalume(GL) steels.

• Corrosion Science and Technology
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• v.10 no.2
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• pp.43-46
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• 2011

Zinc consumption in a continuous galvanizing line is one of the highest operating cost items in the facility and minimizing zinc waste is a key economic objective for any operation. One of the primary sources of excessive loss of zinc is through the formation of top dross and skimmings in the coating pot. It has been reported that the top skimmings, manually removed from the bath, typically consist of more than 80% metallic zinc with the remainder being entrained dross particles ($Fe_2Al_5$) along with some oxides. Depending on the drossing practices and bath management, the composition of the removed top skimmings may contain up to 2 wt% aluminum and 1 wt% iron. On-going research efforts have been aimed at in-house recovery of the metallic zinc from the discarded top skimmings prior to selling to zinc recycling brokers. However, attempting to recover the zinc entrapped in the skimmings is difficult due to the complex nature of the intermetallic dross particles and the quality and volume of the recycled zinc is highly susceptible to fluctuations in processing parameters. As such, an efficient method to extract metallic zinc from top skimmings has been optimized through the use of a specialized thermo-mechanical process enabling a continuous galvanizing facility to conserve zinc usage on-site. Also, through this work, it has been identified that filtration of discrete dross particles has been proven effective at maintaining the cleanliness of the zinc. Future efforts may progress towards expanded utilization of filters in continuous galvanizing.

• Corrosion Science and Technology
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• v.9 no.6
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• pp.247-253
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• 2010

The characteristics of selective oxidation prior to hot-dip galvanizing with the annealing atmosphere dew point and chemical composition in dual-phase steels and their effect on the inhibition layer formation relevant to coating adhesion have been studied using a combination of electron microscopic and surface analytical techniques. The annealed and also galvanized samples of 3 kinds of Si/Mn ratios with varied amounts of Si addition were prepared by galvanizing simulator. The dew point was controlled at soaking temperature $800^{\circ}C$ in 15%$H_2$ -85%$N_2$ atmosphere. It was shown that good adhesion factors were mainly uniformity of oxide particle distribution of low number density and low Si/Mn ratio prior to hot-dip galvanizing. Their effect was the greatly reduced coating bare spots and the formation of uniform inhibition layer leading to good adhesion of Zn overlay. The mechanism of good adhesion is suggested by two processes: the formation of inhibition layer on the oxide free surface uncovered with no $SiO_2$-containing particles in particular, and the inhibition layer bridging of oxide particles. The growth of inhibition layer was enhanced markedly by the delayed reaction of Fe and Al with the increase of Si/Mn ratio.

• Journal of Surface Science and Engineering
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• v.48 no.1
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• pp.27-32
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• 2015

Advanced high strength steels undergo recrystallization annealing in reducing gas atmosphere before galvanizing to improve mechanical properties. The selective oxidations of elements such as Mn, Si, Cr and Al during annealing decrease wettability of liquid zinc, resulting in bare spots and other defects. In this work, Fe-3wt%Mn steel sheet was annealed at $780^{\circ}C$ for 1200 sec. in 5% $H_2-N_2$ atmosphere and then dipped into zinc bath held at $460^{\circ}C$, which contained 0.2wt% dissolved Al. MnO crystallines in the average size of 200 nm were formed on the surface after annealing. It is estimated that MnO has been detached into bath with the formation and growth of inhibition layer with longer immersion time during galvanizing. No evidence of aluminothermic reduction of MnO has been found in this study.

• Journal of Surface Science and Engineering
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• v.33 no.5
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• pp.387-397
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• 2000

Antimony in the galvanizing bath had greater effect on the growth of grains in the solidification of molten coating layer and on the decrease of its surface roughness than lead. Particularly 0.01 wt % antimony in the galvanizing bath showed much stronger effect than expected considering its low surface tension value. These effects were seemingly originated from the development of preferred orientation of (0002) plane parallel to steel surface. Antimony was found to be widely distributed in form of orderly arrangement throughout the coating layer unlike lead from the results of surface analyses on coating layers as received and on those as etched in chromating solution. In addition, supercooling in the 0.07 % antimony and the 0.2 % lead galvanizing bath was also measured to be in the range of$ 2~4^{\circ}C$ and $9~11^{\circ}C$ respectively, and it indicates that antimony forms fine dendrite expanded rapidly on the steel surface.

• Corrosion Science and Technology
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• v.10 no.1
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• pp.6-12
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• 2011

The selective surface oxidation of a transformation-induced-plasticity (TRIP) steel containing 1.6 wt.% Mn and 1.5 wt.% Si during annealing at $800^{\circ}C$ was investigated for its influence on the formation of an inhibition layer during hot-dip galvanizing. The selective oxidation of the alloying elements and the oxide morphology were significantly influenced by the annealing atmosphere. The pure $N_{2}$ atmosphere with a dew point $-40^{\circ}C$ promoted the selective oxidation of Mn as a crystalline $Mn_{2}SiO_{4}$ phase, whereas the $N_{2}$ + 10% $H_{2}$ atmosphere with the same dew point $-40^{\circ}C$ promoted the selective oxidation of Si as an amorphous Si-rich oxide phase. During hot-dip galvanizing, the $Mn_{2}SiO_{4}$ phase was reduced more readily by Al in the Zn bath than the Si-rich oxide phase. Consequently, the pure $N_{2}$ atmosphere resulted in a higher formation rate of $Fe_{2}Al_{5}$ particles at the Zn/steel interface and better galvanizability than the $N_{2}$ + 10% $H_{2}$ atmosphere.

• Transactions of the Korean Society of Mechanical Engineers B
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• v.28 no.7
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• pp.763-770
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• 2004

The problem of edge overcoating developed near the edge of the steel strip is studied quantitatively in the gas wiping process of continuous hot-dip galvanizing. It has been assumed that the edge overcoating occurs due to the reduced impact pressure of wiping gas on the strip edge and it is one of detrimental problems to the quality of coating products. In order to analyse the edge overcoating problem numerically, three-dimensional unsteady flows due to the gas wiping are calculated by using a commercial code, STAR-CD. Standard $\kappa$-$\varepsilon$ model is used as a turbulence model. The 1D code for calculation of coating thickness is constructed by using continuity and Navier-Stokes equations. The calculation results have shown good agreement with measurements of edge overcoating thickness, taken from galvanizing line trials. Therefore it is conformed that the major cause of edge overcoating is the reduced impact pressure of wiping gas on the strip surface.

• Korean Journal of Metals and Materials
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• v.47 no.7
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• pp.423-432
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• 2009

In the galvanizing coating process, the effects of the silicon content on the coatability and wettability of molten zinc were investigated on Dual-Phase High Strength Steels (DP-HSS) with various Si contents using the galvanizing simulator and dynamic reactive wetting systems. DP-HSS showed good coatability and a well-developed inhibition layer in the range of Si content below 0.5 wt%. Good coatability was the results of the mixed oxide $Mn_{2}SiO_{4}$, being formed by the selective oxidation on the surface, with a low contact angle in molten zinc and a large fraction of oxide free surface that provided a sufficient site for the molten zinc to wet and react with the substrate. On the other hand, with more than 0.5 wt%, DP-HSS exhibited poor coatability and an irregularly developed inhibition layer. The poor coatability was due to the poor wettability that resulted from the development of network-type layers of amorphous ${SiO}_{2}$, leading to a high contact angle in molten zinc, on the surface.