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High zinc improves the bath's efficiency (plating speed), while lower levels improve the bath's ability to throw into low current densities. Typically, the Zn metal level varies between 20 and 50 g/L (2.7-6.7 oz/gal). The pH varies between 4.8 and 5.8 units. The following chart illustrates a typical all potassium chloride bath composition:
The British, European and International standard for hot-dip galvanizing is BS EN ISO 1461, which specifies a minimum coating thickness to be applied to steel in relation to the steels section thickness e.g. a steel fabrication with a section size thicker than 6 mm shall have a minimum galvanized coating thickness of 85 μm.
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Galvanization (also spelled galvanisation) [1] is the process of applying a protective zinc coating to steel or iron, to prevent rusting. The most common method is hot-dip galvanizing, in which the parts are coated by submerging them in a bath of hot, molten zinc. [citation needed]
In the 1970s, a new coating system was developed in the United States: zinc flake coating (patent number 1376067). By virtue of a thin coat thickness of typically 8-12 μm this system produced a high level of protection against corrosion and made it possible to avoid hydrogen embrittlement.
The unshaded bars indicate the location on the chart of those steels when in acidic/stagnant water ( like in the bilge ), where crevice-corrosion happens. Notice how the *same* steel has much different galvanic-series location, depending on the electrolyte it's in, making prevention of corrosion .. more difficult.
Mechanical plating, also known as peen plating, mechanical deposition, or impact plating, is a plating process that imparts the coating by cold welding fine metal particles to a workpiece. Mechanical galvanization is the same process, but applies to coatings that are thicker than 0.001 in (0.025 mm). [ 1 ]
Immersion zinc plating is an electroless (non-electrolytic) coating process that deposits a thin layer of zinc on a less electronegative metal, by immersion in a solution containing a zinc or zincate ions, Zn(OH) 2− 4. A typical use is plating aluminum with zinc prior to electrolytic or electroless nickel plating.
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