Hot-Dip Coating

Institut fr Eisenhttenkunde
der RWTH Aachen

Topic 13:
Continuous hot-dip coating
Dipl.-Ing. Friedrich Luther
13.1 Corrosion basics

Definitions
Electrochemical terms
13.2 Galvanizing Processes
Corrosion protection with zinc
Electrolytic and hot-dip galvanizing process
13.3 Metallurgical Aspects during hot-dip galvanizing
Steel-zinc interface
Hot-dip galvanizing of AHSS
13.4 Coatings
Galvanized, Galvannealed, GALFAN, GALVALUME
Properties: Formability, weldability, paintability, corrosion resistance
Outline

Definitions
13.4 Coatings
Source: Schmitt, G.: Corrosion & Corrosion Protection, Lecture IEHK, 2006.
Outline
Corrosion is the reaction of a material with its

environment which occurs with a measurable change
at the material and/or the environment.
Such reaction can lead to a corrosion damage at the
material and /or the environment.
Definition of the term corrosion

ISO 8044
The corrosion system
This definition is not restricted to metallic material.

It includes all materials:
organic
inorganic (metallic, non-metallic)
Definition of the term corrosion

ISO 8044
A corrosion failure has occured if the material (a

component of a structure or the whole structure) and /
or the environment is impaired in its further use.

Rusted Car
Rusted
Railway Tracks
Corrosion Failure?
Corrosion Failure?
May be !
No !
What is a corrosion failure?

Material related
corrosion failure
Rusted Car
Corrosion Failure?
YES !!
Medium related
corrosion failure
Corrosion failures
chemical
corrosion
chemical
corrosion
electrochemical
corrosion
direct electron-exchange between the reactants

(redox-reaction)
electrical influencing variables are effectless
Corrosion reactions
Chemical corrosion
Every atom tries to gain the 'electron costume of the

nearest noble gas atom in the periodic table of elements
(Nobel Gas Rule):
Surface metal atom A interchanges electronegativity its metallic

property and is converted (oxidized) into a compound A-B.
The atom A has now lost (electrons) with an atom or a molecule B
from the environment.
This can produce a chemical bonding metal ion. The compound A-B
can form a protective layer (scale) on the surface if A-B is not volatile.
next higher position by up-take of electrons or

next lower position by give-away of electrons.
Driving force of chemical reactions
electrochemical
corrosion
Example for a
chemical corrosion reaction
...is the most common corrosion

mechanism
It runs exclusively in presence of a ion-leading

phase; dependent on electrical variables like e.g.
potential
There are two places, one for the electron-absorption
and one for the electron-disposal
Electrochemical corrosion
Schematic electrochemical
corrosion mechanism
Rusting of iron:
Anodic reaction:
Kathodic Reaction:
2Fe 2Fe2+ +4eO2+ 4e- + 2H2O 4OH-
Example for a
electrochemical corrosion reaction
Schematic electrochemical
corrosion mechanism

Definitions
13.4 Coatings
Outline
Nernst equation
Galvanic series
Net Current Density /

Potential of the Single Electrode
Current density-potential curve
Mixed electrodes
Current density-potential curve
Important cathode reactions

Definitions
Economic Importance of Materials Corrosion:
NACE 2002 Study:

Total Direct Costs in USA:
276 Billion US$ (3,14% GNP)
corresp. for Germany:
62 Billion.

13.4 Coatings
(Direct + indirect Costs:

Factor 11 higher)
Outline
What costs corrosion?
DIN EN ISO 8044
Form of appearance
uniform
corrosion
inhomogeneous
attack
corrosion cracks
intergranular transgranular
located
attack
troughs
corrosion
selective
attack
pitting
corrosion
dezincification
intergranular
attack
layers
attack
Corrosion, proceeding over

the whole surface of the metal
exposed to the corrosive
environment at almost the
same rate.
spongiosis
(graphite corrosion)
Uniform corrosion
Corrosions forms of appearance
Corrosion protection means:

Prevention of corrosion failures.
It means not(!):
Prevention of corrosion, because this is simply
impossible!
Selection
of Material
Elimination
of Corrosive
Compounds
Constructive
Measures
Additives
(Inhibitors)
All corrosion protection strategies therefore aim at

Prevention of Corrosion Failures.
Electrochem.
Protection
Coatings
(metallic, organic)
Inhibitors
What is corrosion protection?
Strategies of corrosion protection
Zinc coatings add corrosion resistance to steel in two ways:

Zinc as a barrier layer seperates the steel surface from
the corrosive environment
Zinc as galvanic protection acts as a sacrificial anode to
protect the underlying steel
200
e
at
m
cli
e
in
ate
ar
lim
c
m
an
urb
ate
lim
ry c
t
n
cou
ors
indo
in
du
st
ria
lc
lim
at
Thickness of zinc coating, m
How does it work?
150
100
50
10
20
30
40
50
60
70
80
Protection, years
Source: Merkblatt 400, Korrosionsverhalten von feuerverzinktem Stahl, Stahl-Informations-Zentrum, Dsseldorf
Protection with zinc coatings
Zn Zn2+ + 2 e-
anode:
4e-
cathode:
+ 2H2O + O2 4(OH)Source: Nippon Steel News, No. 307 September2003
Source: Nippon Steel News, No. 307 September2003
Comparison of ionization
tendency among elements
30-40m
30-40m
20-25m
5-20m
Warranty against corrosion damages, Years
Mechanism of sacrificial protection
35
30
mobilo-life
mobilo-life
25
20
15
Year
Share of 10 year old cars with

corrosion damages
1990
25%
2000
5%
Average warranty: 10-12 Years
10
5
0
di
W
en
ler
Au BM
rys Citro
Ch
ler
m
i
Da
Zinc layer + painting
TV-Report 2000:
Fia
)
rd san
ot che ault aab oda ota
lvo
y
Fo
GM ge
s
s
n
S
Vo
Sk
To
Ni pel ( Peu Por
Re
O
VW
Nr.6
Source: Androsch et al, stahl und eisen 121 (2001)
Corrosion warranties
of car producers
Building industry:
fences, rails, roofing sheets, garages, ...
Steel construction:
steel frame construction, bridges, ...
Electrical Engineering:
transformer, pylons, ...
Mechanical engineering:
cases, facilities,
Sheet fabricating industry :
washer, fridges, household equipment, ...
The sacrificial protection of a zinc layer

is limited to a distance of about 1 mm!
Automotive industry:
car body, accesories ,
Relevant for voids, scratches and cut edges.
Usage of galvanized steels
Restriction!

Definitions
13.4 Coatings
Sources:
Feuerverzinken interaktiv, Institut Feuerverzinken GmbH, Dsseldorf
http://www.volkswagen.de
Examples
Electrozinc coating
Continuous
Hot-Dip Galvanizing
Outline
C.C.
Hot-Rolling
Temper
Rolling
Pickling
Cold Rolling
Batch
Annealing
Continuous
Annealing
Hot-Dip
Galvanizing
Electrozinc coating
CoilCoating
Shipment
Sources: http://www.dassnagar.com/ Feuerverzinken interaktiv, Institut Feuerverzinken GmbH, Dsseldorf
Galvanizing of steel strip
Electro-zinc coating
C.C.
Hot-Rolling
Temper
Rolling
Pickling
Cold Rolling
Batch
Annealing
Continuous
Annealing
Hot-Dip
Galvanizing
Electrozinc coating
CoilCoating
Shipment
EU 15
Long Products
Flat Products
Cold rolled sheet steel
Metallic coated
Organic coated
65.799.000 t
90.796.000 t
43.349.000 t
26.739.000 t
4.685.000 t
Germany
Long Products
Flat Products
Cold rolled sheet steel
Hot-dip coated
Electr. coated
Organic coated
12.724.000 t
25.047.000 t
12.004.000 t
5.858.000 t
1.801.000 t
986.000 t
Source: Statistisches Jahrbus der Stahlindustrie 2006/2007, Verlag Stahleisen GmbH, Dsseldorf 2006.
Steel utilization in EU 15
and GER in 2005
Hot-dip galvanizing
Source: http://www.salzgitter-flachstahl.de/
Source: Statistisches Jahrbus der Stahlindustrie 2006/2007, Verlag Stahleisen GmbH, Dsseldorf 2006.
01.) Pay-off reel

02.) Cropping shear
03.) Welding machine
04.) Entry loop accumulator
05.) Strip pretreatment
06.) Tension leveller
07.) Electrolytic cleaning

08.) Rinsing tank
09.) Pickling tank
10.) Electro-zinc coating
11.) Phosphate treatment
12.) Chromate passivation
Development of steel
utilization in Germany
13.) Strip dryer

14.) Exit loop accumulator
15.) Inspection station
16.) Trimming shear
17.) Electrostatic oiler
18.) Tension reel
Electro-zinc coating line
Conductor Roll
Strip width range

Strip thickness range
Speed
Coil weight
Current intensity
Rectifier capacity
Number of cells
Coating range
Capacity
Anode (+)
Electrolyte
Pump
One Side Galvanizing
900 - 1.850 mm
0,5 - 2,0 mm
max. 180 m/min
max. 32 t
50 kA/cell
850 kA
17
2,5 - 15 m
33.000 t/mo
Both Sides Galvanizing
Plating cells
Technical data
cooling tower
loop tower
preheater
jetcooling
shear
RTF
coating gauge
measurement (cold)
welding machine
coiler
skin pass mill

loop
tower
cleaning section
inspection
shear
coiler
coating gauge
measurement (hot)
phosphate coater
/ passivation
electrostatic
oiler
zinc pot
Strip width range:

Strip thickness range:
(cold rolled):
(hot rolled):
Speed:
Coil weight
Coating range:
Capacity:
650 1.600 mm
Pre-cleaning (removing of rolling oils, iron fines, loose soils)

Heat treatment (recrystallization, mech. properties)
Hot-dipping (e.g. Z, ZA, AZ)
Heat treatment of coated strip (ZF)
Skin pass (mechanical properties, roughness)
Post treatments (corrosion protection, )
0,5 3 mm
1,4 3,5 mm
max. 32 t
70 600 g/m 2
33.000 t/mo
Source: voestalpine AG, Linz
Hot-dip galvanizing line
Functions of a hot-dip galvanizing line
Source: A.R. Marder, Progress in Materials Science 45 (2000) 191-271.
Annealing furnace
passivated
Pot region

Definitions
corrosion protection
oiled
corrosion protection
phosphated
improvement of adhesion/protection of coatings,

improvement of forming properties
passivated and oiled
PO
phosphated and oiled
CO
sealed
corrosion protection, improvement of forming properties

13.4 Coatings
Source: Charakteristische Merkmale 095: Schmelztauchveredeltes Band und Blech, Stahl-Informations-Zentrum
Post treatments
Outline
10
Zinc in weight%
0
10
50
40
30
20
70
60
80
90
100
1538 C
1500
Temperature in C
1394 C
1300
( Fe)
1100
900 912 C
770 C
(Fe, Fe)
782 C
42
700
623 C
665 C
magnetic transformation
550C
500
300
530C
0
Fe
10
20
30
40
50
60
70
80
425
1
90
Zinc in atom%
419.58 C
100
Zn
BC Ch. III. 3 Transparency 21
Zinc-rich corner of the

Fe-Zn phase diagram
Phase diagram Fe-Zn
3 peritectic transformations:
S+
S+
S+
phase
Eta
1 peritectoid transformation
+ 1
Zinc is referred to as -Phase. The intermetallic phases , ,
1 and form depending on the annealing and coating
process during and after hot-dip galvanizing.
Phase transformations
Microstructure of Zn coating formed after 300 s immersion in a

450C, 0.00 wt% Al bath on a ULC steel substrate.
(1) gamma ()
(2) delta ()
(3) zeta ()
FeZn intermetallic phases
Fe
space
lattice
formula
hexagonal
micro
hardness
characteristic
52
very ductile
mass%
atom%
Zn
Zeta
monoclinic
FeZn13
5-6.2
6.7-7.2
208
ductile
Delta
hexagonal
FeZn 7
7-10
8.5-13.5
358
brittle
Gamma1 1
fcc
Fe5 Zn21
15.8-23.5
18.5-23.5
505
hard + brittle
Gamma
bcc
Fe3 Zn10
23.2-31
23.2-31
326
brittle
Phases in the phase diagram Fe-Zn
t0 corresponds to zero time

t1 < t2 < t3 <t4
Source: CE Jordan et al., J. Mater. Sci. 32 (1997) 5593.
Fe-Zn phase layer formation in a

0.00 wt-% Al-Zn bath
11
3.0
2.5
Abrasion in g/m2
FeZn gamma () phase, delta () phase, and zeta ()

phase layer growth for a ULC steel substrate hot dipped
at 450C in a 0.00 wt% AlZn bath
2.0
1.5
1.0
0.5
0
7
8
Fe-content in %
10
11
Influence of the Zn-phases

on the forming behavior
Fe-Zn phase layer groth
Isothermal section of the FeAlZn phase diagram at

450C, (left) overall section, (right) zinc rich corner
Source: N.Y. Tang, On determining effective Al in continuous galvanizing baths, Proceedings of GALVATECH 1995, Chicago, 777.
Zinc-rich corner of the 450C isothermal

section of the FeZnAl phase diagram
Fe-Zn-Al phase diagram
t0 corresponds to zero time,

t1 < t2 < t3 < t4
dissolution of
ferrite
precipitation of
Fe2Al5
Source: F. E. Goodwin (Herausgeber): Zinc-Based Steel Coating Systems: Production and Performance, TMS, Warrendale, 1998.
Mechanism of formation
of the inhibiting layers
FeZn phase layer formation

in a 0.20 wt% AlZn galvanizing bath
12
Zinc
EDX-Linescan of the SteelZinc Interface
Fe2Al5Znx
3,50E+03
3,00E+03
Fe
Al
Zn
Steel
Intensitt, Counts
2,50E+03
2,00E+03
1,50E+03
1,00E+03
HAADF-STEM-Picture of the
Steel-Zinc Interface
5,00E+02
Si
Mn
0,00E+00
0
50
100
150
200
250
300
350
400
450
500
Position, nm
Source: N.Y. Tang, Zinc-Based Steel Coating Systems: Production and Performance, TMS, Warrendale, 1998.
Summary of coating microstructure

in continous galvanizing
Al-rich Interfacial Layer
Adhesion for the zinc layer

Diffusion barrier for Iron
Setting of soluted iron as top dross
zinc layer
Fe2Al5Znx-Layer
steel
1 2 3 4
Role of aluminum

Definitions
Quelle: B. Schumacher et al.: Element distribution of aluminium and lead in hot-dip galvanized coatingd and their influences on the
coating properties, in 4th International Conference on Zinc and Zinc Alloy Coated Steel Sheet, September 1998, Chiba, Japan, 819-823.
Industrial zinc coating
ULSAB-AVC
(UltraLight Steel Auto Body - Advandced Vehicle Concepts)

PNGV-Class
Auto Body

13.4 Coatings
Outline
74% dual phase steels

Steel Usage in the
international project ULSAB-AVC
13
Mn2SiO4
12
dual phase steel
10
Gewichtsprozent, %
SiO2
MnAl2O4
MnO
CMnSi
CMnAl
Mn
2
CMnP
Cr
Mahieu, J.; Universiteit Gent, 2004

0
0
0,1
0,2
0,3
0,4
0,5
Tiefe, m
high content of alloying elements (Si, Mn, Cr, Al, P)
TRIP steel
segregation of alloying elements, formation of external oxides

bad wettability by zinc
inhomogeneous formation of inhibition layer and zinc coating
Technical issues during

hot-dip galvanizing of AHSS
Selective oxidation of alloying elements:

REM pictures and GDOES analysis
BF
Si
Mn
BF
Si
Mn
Cr
Al
Cr
Al
Elemental mapping of a CMnCr

DP-steel surface after Rx annealing
Elemental mapping of a CMnAlSi

TRIP-steel surface after Rx annealing
DP600
DP600
TRIP700
TRIP700
Formation of the
Al-rich interfacial layer
Coating quality
14
Mo for Cr
(DP)
Al for Si
(TRIP)
Oxidising
Reducing
Segregation of Mn, Si, Cr during

annealing
Steel substrate
Oxide layer

annealing
Steel substrate
Oxide layer
Inhibition layer (Fe2Al5)
Zinc coating
Zinc coating
Base sheet alloying approaches
Precoating
Reactive
Atmosphere
Pure reduced Fe
Diffusion zone of C or N
Atmospheric approaches
Surface Layer
Removal

Definitions

annealing
Steel substrate
Oxide layer
Precoating, e.g. Fe

Zinc coating
Pretreatment of incoming strip
product
composition
Z
Galvanized
100% Zn
7,1
70-600
(5-42 m/Seite)
ZF
Galvannealed
10% Fe + 90% Zn
7,1
100-140
(7-10 m/Seite)
ZA
GALFAN
5% Al + 95% Zn
+ 0,05% Cer/lanthan
6,6
65-300
(5-23 m/Seite)
AZ
GALVALUME
55% Al + 43,4% Zn
+ 1,6% Si
3,8
75-185
(10-25m/Seite)
AS
FAL
10% Si + 90% Al
3,0
50-150
(8,5-25m/Seite)
density
kg/dm3
coating mass
g/m (both sides)

13.4 Coatings
Outline
surface finishes
Regular spangle
Minimum spangle
Extra-smooth temper roll finish
Galvanized hot-dip coatings often have a structure consisting

of very large grains called spangles. Spangle size is
influenced by the cooling conditions during solidification. The
three surface finishes commonly produced are:
Regular spangle, where the coating solidifies from the
dipping temperature by air cooling, producing the well-known
spangle finish.
Minimum spangle, where the coating is quenched using
water, steam, chemical solutions, or by zinc powder
spraying.
Extra-smooth temper roll finish carried out as an
additional operation with regular and minimum spangle
material.
Coating types
Galvanized
15
Typical spangle structure

of a galvanized coating
Galvanneal coatings are essentially diffusion coatings that

expose the zinc galvanized steel to an annealing temperature
around 500C to produce a fully alloyed coating containing Fe
Zn intermetallic phases.
Effect of lead content on spangle size
t0 corresponds to zero time of the as-galvanized structure

t1 < t2 < t3 < t4 < t5
This is accomplished by inserting heating and cooling capacity

above the liquid zinc pot in order for the galvannealing process
to be continuous.
Variables involved in producing the desired galvanneal
microstructure and properties are heating rate, hold
temperature and time, and cooling rate bath chemistry and
substrate composition.
Galvannealed
Type 0: underalloyed coating containing

predominantly zeta () phase.
Type 1: optimum alloyed coating with
less than a 1 m interfacial gamma ()
layer and an overlay containing delta ()
phase interspersed with a small amount
of zeta () phase.
Source: Jordan CE, Marder AR. A model for galvanneal morphology development. In: Marder AR, editor. The physical metallurgy of zinc coated steel.
Warrendale, PA: TMS, 1994. p. 197.
Schematic of the phenomenological model

of galvanneal morphology development
GALFAN is a Zn5% Al alloy coating, which is near the

eutectic point in the AlZn equilibrium phase diagram. Two
compositions have been reported based on additions to the
eutectic composition:
small mischmetal additions containing lanthanum and cerium
contents up to about 0.5 %
additions of 0.5% magnesium
Type 2: overalloyed coating with a

gamma layer >1 m and an overlay
containing a delta () phase with basal
plane cracks perpendicular to the
coating/substrate interface and an
occasional top layer of zeta () phase.
Source: C.E. Jordan and A.R. Marder, Morphology development in hot-dip galvanneal
coatings. Met Mater Trans 25a (1994), p. 937.
Classification of galvannealed coatings
These additions are made to improve the wettability and

fluidity of the molten bath without affecting the corrosion
resistance of the coating. They also suppress bare spot
formation as well as producing a typical minimized spangle
structure.
GALFAN
16
The microstructure of GALFAN is characterized by a two-phase

structure, a zinc-rich eta () proeutectoid phase surrounded by
a eutectic type phase consisting of beta () aluminum and eta
() zinc lamellae.
GALVALUME, is a 55%Al alloy coating containing about

1.5% Si added for the purpose of preventing an exothermic
reaction at the coating overlay/substrate steel interface. During
the coating process an interfacial FeAlZn intermetallic alloy
layer forms at the interface between the steel substrate and
the overlay coating.
The surface of the GALVALUME coating contains
characteristic spangles that consist of aluminum dendrites with
a clearly measurable dendrite arm spacing (DAS).
Microstructure of GALFAN coating
The coating contains beta ()

aluminum dendrites, Zn-rich
interdendritic regions and a fine
dispersion of Si particles. The Al
dendrites were reported to
contain approximately 18 wt%
Zn and up to 1.8 wt% Si which
is in good agreement with the
AlZn phase diagram
GALVALUME
t1 < t2 < t3 < t4
(a) spangle finish;

(b) dendrite arm spacing
Source: Marder AR. Microstructural characterization of zinc coatings. In: Krauss G, Matlock DK, editors. Zinc-based steel coating systems: metallurgy and
performance. Warrendale, PA: TMS, 1990. p. 55.
Microstructure of GALVALUME coating
Source: Marder AR. Microstructural characterization of zinc coatings. In: Krauss G, Matlock DK, editors. Zinc-based steel coating systems: metallurgy and
performance. Warrendale, PA: TMS, 1990. p. 55.
Schematic of the
solidification of GALVALUME
Hot-dip galvanized (Z)

automotive industry (outer and inner
parts/components)
building industry e.g. insulation
and trapezoidal sheets (roof and wall)
plant engineering e.g. construction
elements, castings for machines
substrate for coil coating
GALFAN (ZA)
automotive area (components)
plant engineering and
mechanical engineering, e.g.
components which are formed
to a high degree.
white goods industry,
home electronics industry
Galvannealed (ZF)
automotive industry
GALVALUME (AZ)
building industry for outdoor roof
and wall elements
accessories and construction
components in the building
sector, plant engineering and
mechanical engineering (special
corrosion forces)
Applications I
Applications II
17

Definitions
In general, the coating microstructure consists of:

substrate
interfacial alloy layer
overlay cast structure
Microstructure and composition of these constituents will
control the desired properties!
13.4 Coatings
Outline
Coating properties
Properties that concern the use of zinc coatings are primarily:

Corrosion resistance
Formability
Weldability
Paintability
Source: Uchima Y, Hasaka M, Koga H. Effect of structure and mischmetal addition on the corrosion behavior of Zn-5 mass%Al alloy.
GALVATECH '89. Tokyo: The Iron and Steel Institute of Japan. 1989. p. 545.
Corrosion loss of coating layer

after atmospheric exposure test
Coating properties II
The deformation and fracture behavior of zinc based coatings on sheet

steels can alter the performance in stamping operations. Zinc coatings fail
as a result of particle removal during forming.
Coating failures are classified as:
Powdering
particles smaller than coating thickness
Flaking
flat particles similar to coating thickness
Galling
damage resulting from particles that bond to the tool surface resulting in
additional coating damage
Source: Marder AR. Effects of surface treatments on materials performance. Materials selection and design. ASM Handbook, vol. 20. 1997. p. 470.
Corrosion losses of hot-dip coatings

in an industrial environment
Formability Coating failures
18
Weldability of zinc coatings is an important property of the coating, since most

galvanized product is joined in this manner.
Arc welding
of galvanized steel sheet produces defects such as gas cavities
(blowholes) and spatters.
Spot welding
zinc coatings reduce the life of welding electrodes due to alloying of the
copper electrode with zinc. In the case of galvanized steel, the electrode
life may be as little as 15002000 welds, compared to a tip life for bare
steel of 10,000 welds
Spot weldability of galvanneal coatings is improved over galvanized
coating since it is more difficult for these FeZn phases to alloy with the
copper electrode, thus improving electrode life.
Source: Arimura M, Urai M, Iwaya J, Iwai M. Effects of press forming factors and flash plating on coating exfoliation of galvannealed steel sheets.
GALVATECH 95. Chicago, IL: Iron and Steel Society, 1995. p. 733
Schematic model for the

coating exfoliation process
Weldability
Although zinc coatings are often used in the as-coated state, some
applications call for a painted surface and therefore paintability is an
important design property of the coating. It has been shown that large
spangle material is difficult to paint, therefore most painted products are
either minimum spangle or temper rolled.
In most painted products, a complex coating composite is used for
corrosion protection. In addition to the Zn coated sheet steel, the composite
includes a zinc phosphate pretreatment or complex oxide thin coating, the
primer and various top coats
ZF
ZA
AZ
AS
best surface
coatability
conventional
coil coating
electrostatic
electrophoretic
acid resistance
alkali resistance
Galvanneal coating paintability is better than galvanized coatings because

of the microscopically rough surface formed as a result of the FeZn alloy
phases throughout the coating
temperature resistance
++
+
Standard
--
Paintability
ZF
Properties: general
ZA
AZ
AS
unpainted
forming
unformed surface
(micro) cracking
formed surface
abrasion
cutting edge
high deformation degrees
painted (coil coating)
joining
unformed surface
spot welding
formed surface
solder
cutting edge
adhere
painted (automotive)
mechanical joining
++
++
Standard
Standard
--
ZF
ZA
AZ
AS
Properties: corrosion resistance
--
Properties: forming and joining
19

Hot-Dip Coating

Hochgeladen von

Dokumentinformationen

Originaltitel

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

Hot-Dip Coating

Hochgeladen von

Copyright:

Verfügbare Formate

Institut fr Eisenhttenkunde

der RWTH Aachen

13.1 Corrosion basics

13.1 Corrosion basics

Corrosion is the reaction of a material with its

Definition of the term corrosion

The corrosion system

This definition is not restricted to metallic material.

Definition of the term corrosion

A corrosion failure has occured if the material (a

A corrosion failure has occured if the material (a

What is a corrosion failure?

A corrosion failure has occured if the material (a

What is a corrosion failure?

What is a corrosion failure?

direct electron-exchange between the reactants

electrical influencing variables are effectless

Every atom tries to gain the 'electron costume of the

Surface metal atom A interchanges electronegativity its metallic

next higher position by up-take of electrons or

Driving force of chemical reactions

...is the most common corrosion

It runs exclusively in presence of a ion-leading

2Fe 2Fe2+ +4eO2+ 4e- + 2H2O 4OH-

13.1 Corrosion basics

Net Current Density /

Current density-potential curve

Current density-potential curve

Important cathode reactions

13.1 Corrosion basics

Economic Importance of Materials Corrosion:

NACE 2002 Study:

13.2 Galvanizing Processes

(Direct + indirect Costs:

What costs corrosion?

DIN EN ISO 8044

Corrosion, proceeding over

Corrosions forms of appearance

Corrosion protection means:

All corrosion protection strategies therefore aim at

What is corrosion protection?

Strategies of corrosion protection

Zinc coatings add corrosion resistance to steel in two ways:

Thickness of zinc coating, m

How does it work?

Corrosion protection with zinc

Protection with zinc coatings

+ 2H2O + O2 4(OH)Source: Nippon Steel News, No. 307 September2003

Source: Nippon Steel News, No. 307 September2003

Warranty against corrosion damages, Years

Mechanism of sacrificial protection

Share of 10 year old cars with

Average warranty: 10-12 Years

Zinc layer + painting

The sacrificial protection of a zinc layer

Relevant for voids, scratches and cut edges.

Usage of galvanized steels

13.1 Corrosion basics

Sources: http://www.dassnagar.com/ Feuerverzinken interaktiv, Institut Feuerverzinken GmbH, Dsseldorf

Galvanizing of steel strip

01.) Pay-off reel

07.) Electrolytic cleaning

13.) Strip dryer