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Question on Hot Dip Galvanising

+++ In hot dip galvanising, why we use, lower layer of lead along with Zinc with other metal composition in metal pot and what is the basic function of lead in hot dip galvanising.

Vipin Jain galvanised steel manufacturing - Biratnagar, Morang, Nepal +++ Hot-dip Galvanizing is based on alloying Iron with zinc. Traces of iron introduced into the zinc kettle(carry-over with the material to be galvanized from wet pre-treatment, from the steel zinckettle-wall and the material to be galvanized will alloy with the zinc too, thus forming zinc-iron alloy particles called dross. This dross is some heavier than the zinc and will slightly sink to bottom of the kettle. Lead has two functions: 1. dissolved lead in the zinc-melt has influence on the fluidity of the zinc and will help dross particles sink to the bottom - floating dross particles

will cause roughness on the material to be galvanized(bad quality) 2. The lead layer on the bottom of the kettle will prevent dross will be stuck to the iron kettle-bottom and makes it possible to remove the dross from the bottom of the kettle, because lead is heavier than the dross and will not alloy with the dross and zinc - so dross floats on the lead-layer.

Dolf van den Berg - Leusden, The Netherlands +++ In my previous question, I asked, why we use lower layer of lead in zinc kettle, I got satisfactory answer. Now will anyone please tell me, can we use another metal in place of lead in zinc kettle for such functionality in galvanising process. Regards, Vipin Jain galvanised steel manufacturing - Biratnagar, Morang, Nepal +++ Coming back on your second question I don't know the reason why you like to change lead for something else, but in Scandinavia lead will be forbidden for environmental reasons. Bismuth or Tin could be elements to replace the function of dissolved lead. These elements cause a high fluidity of the zinc and a good wetting of the steel. De-drossing of the kettle is hardly a problem. Cominco - Canada made investigations adding Bismuth to Zinc for hot-dip galvanizing. Regards,

Dolf van den Berg - Leusden, The Netherlands +++ Regarding to the question of dross forming, how to minimize the dross forming? Is the

temperature of the zinc bath influence the dross formation? Or should we put some additive element like aluminium to minimize? Catherine Sim Li Ling - Kuching, Sarawak, Malaysia +++ Temperature has influence on dross forming (the higher the more iron loss), but with normal galvanizing temperatures (around 450 degr.C) there is hardly no difference. At a temperature 490-520 degr.C your kettle is in danger (high iron loss. Aluminium makes zinc more fluid, influences the structure of the alloy layer, reduces zinc-ash forming and gives a better color and gloss of galvanized material. Biggest influence on dross forming is carry over of dissolved iron from pickling via rinse and flux. Finally I have to tell you the whole process is too complicated to explain everything via finishing.com. Maybe you need a galvanizing course.

Dolf van den Berg - Leusden, The Netherlands ++++ Aluminium have the function in cleaning oil of cold roll steel sheets. Anyone can rectified this statement? If true, how is the process? FY Fong - Malaysia ++++++ Which of the parameters responsible for dross generation and how to reduce top and bottom dross? actually I'm doing thesis on reduction of dross generation . So I want to know the parameter on which the dross generation depends and also how to reduce the dross generation ? please give the response as soon as possible. Bharat Kumar Lautre SLIET COLLEGE OF ENGG - PUNJAB, INDIA ++++++ Dear Mr LAUTRE Please write Title of your project, & faculty you belong. In research You have to carry out lot of literature survey. & potentiality of investigation has to be ascertained. Hearing from you I may provide little clue & rest is your dedication BEST WISHES, Dr Pradeep kumar Maitra

- BHILAI, Chhattisgarh, INDIA ++++++ SIRI WANT TO KNOW - HOW TO REFINE THE LEAD FROM THE BOTTOM LAYER OF LEAD USED IN HOT DIP GALVANISING TANK I.E ZINC BASED LEAD, CONTAINS DROSS ALSO ? AND WHAT WILL BE THE RECOVERY EFFICIENCY ? GULSHAN RAM - HYDERABAD, INDIA September 25, 2008 Hello Sir, I have seen earlier question & answer for earlier question, its very impressive. I need some clarification. 1. Regarding Coating We are repeatedly facing problem in galvanizing hardened & tempered low alloy steel. Coating will not be uniform, un galvanized patches & all, but in case of mild steel there is no such problem, what shall be the reason. Also if the material is having grinding finish, is galvanizing coating makes any difference. 2. what's the roll of flux in galvanizing & what's the correct fluxing method & how to make & use flux. Hope you will do the needful at the earliest. Thanks & Regards Prashanth PRASHANTH - INDIA August 3, 2009 How to minimize dross formation? Sami Allen - Saudi Arabia August 21, 2009 Hi, Cousin Sami. Mr. Van den Berg has invested a bit of his time answering that question. In the interest of not starting over, and to show thankfulness for his effort, please try your best to express your question in terms of what has already been said. Thanks!

Regards,

Ted Mooney, P.E. finishing.com Brick, New Jersey September 13, 2009 DEAR SIR, IN HOT DIP GALVANIZING, PURE LEAD CHARGES IN POT FOR SAVE THE LIFE OF POT, LEAD BEHAVE AS A CUSHION EFFECT. rajkumar singh - bombay, India October 19, 2010 So what would be the ideal amount of Lead to charge in a Zinc bath (lead layer thickness or % zinc)? Jaydip Atodaria - Harare, Zimbabwe October 19, 2010 Hi, Jaydip. Some people think the ideal amount is zero :-) You can search the site for "lead-free" galvanizing. Good luck. Regards,

Ted Mooney, P.E. finishing.com Brick, New Jersey October 26, 2010 Dear Sir, Thanks for your reply. Our problem is we have a zinc tank 10x1.0x1.5m deep which leaked and

we are in the process of changing the kettle. From the pot wear it seems it weared out due to dross. Will adding a layer of lead increase the effectiveness of drossing? Then in that case we need to know when charging the new bath how much lead should be added? Thanking you. Jaydip Atodaria - Harare, Zimbabwe October 26, 2010 Sorry Jaydip, I can't answer that. You can wait for someone more experienced in this area to stumble across your inquiry, or you can patiently search the site because similar subjects have been discussed at length by true experts several times. Good luck. Regards,

Ted Mooney, P.E. finishing.com Brick, New Jersey

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