How to coat with zinc at home

Do-it-yourself metal galvanizing and galvanizing technologies - Ice advice

The galvanizing method is one of the most common for creating reliable protection for metal from corrosion. It is simple and cheap. Therefore, this processing method can be performed at home, for which you only need to comply with certain conditions.

Galvanizing as a common method of corrosion protection of metals

When creating high-quality and durable metal coatings, galvanizing technology is most often used. This is due to the low cost of consumables and excellent results. Galvanizing itself occurs using the simplest technology. Its implementation does not require additional costs and a lot of effort, which allows such processing to be carried out at home.

Cold galvanizing – protecting metal from corrosion

The zinc coating is formed as a result of the fact that zinc enters into an oxidation reaction with oxygen present in the air. Subsequently, a strong protective film is formed on the surface of the metal being processed, which protects it from the negative influence of the external environment.

Zinc is a more active metal than iron or steel. Therefore, it primarily interacts with oxygen and water, preventing corrosion. Even if at least part of the coating is present on the surface of metal products, it protects it from destruction.

Where to find electrolyte

Any solution of zinc salts can be used as an electrolyte. The most popular and easily accessible are zinc chloride and hydrochloric acid. Also, an electrolyte with the necessary properties can be obtained by etching zinc in sulfuric acid. This reaction must be carried out very carefully. It is accompanied by the release of a large amount of thermal energy and explosive hydrogen.

Pickling of zinc in sulfuric acid with the release of hydrogen and obtaining zinc salts

How to get zinc

To galvanize at home, you need to prepare zinc, which can be obtained in the following ways:

• using regular salt batteries;
• fuses from the times of the Soviet Union;
• any parts with zinc coating;
• pure metal, which can be found in appropriate stores where chemical reagents are sold.

Scheme for obtaining zinc from batteries

Preparing for the procedure

To create a high-quality metal coating, several preparatory operations should be performed:

• prepare a galvanic bath. Any glass or plastic container can play its role;
• install stands for the anode and cathode;
• the electrolyte should not contain undissolved salt crystals , for which distilled water is additionally introduced;
• The role of the anode is performed by a zinc plate. The larger its area, the better the quality of the coating;
• The plus from the power source is connected to the anode. There can be several of these elements if desired;
• A minus is connected to the cathode. Zinc particles will be deposited on its surface;
• The cathode must be cleaned of rust and any contaminants. Before processing, it is additionally dipped in an acid solution;
• the cathode must be at the same distance from the anode to ensure uniform coverage on all sides;
• with a constant current output is used as a power source
• the greater the current and voltage, the faster the reaction will occur and the looser the protective film will be;
• when using a car battery, an incandescent light bulb of up to 20 W is included in the circuit to reduce the current.

Device for galvanizing at home

Technology for creating zinc film

To create a high-quality protective coating on the metal surface, after the preparatory operations have been carried out, the current source is connected to the network, and the cathode is dipped into a galvanic bath.

This process should take place without violent boiling. If this is observed, you may suspect too much current in the system.

To reduce it, several additional consumers are connected to the electrical circuit.

Gradually, a metal coating will form on the surface of the cathode. The longer this process takes place, the thicker the protective layer on the metal will be.

Popular methods

There are many effective chemical methods for performing galvanizing, each of which has its own advantages and disadvantages. In any case, the created coating will serve for a long time if it is not subjected to mechanical stress and the thickness of the protective layer is chosen correctly, taking into account the characteristics of the product’s operation.

Features of cold galvanizing

Hot method

This galvanizing method is one of the most effective. After such processing, it is possible to create a reliable coating that remains on the surface of metal products for a long time. The disadvantage of the hot method is that it is harmful to the environment.

To perform this processing, you must adhere to the following technology:

Hot-dip galvanizing stages

• Preparation. The metal surface is degreased and etched;
• after completing the preparatory procedures, the part is washed and dried;
• metal products are dipped into a container with a zinc solution.

This galvanizing method is not suitable for processing large-area parts and requires certain preparation and searching for suitable containers.

Cold method

This processing method involves painting metal products with special mixtures. They contain zinc, which allows them to form a reliable coating on the surface in the shortest possible time. This paint is applied in the usual way - with a roller, brush, or spray gun. This processing method is ideal for parts that cannot be coated with a protective layer using conventional hot-dip galvanizing.

Purpose of cold galvanizing

Galvanic galvanizing

Galvanizing scheme

Such galvanizing at home is carried out using electrochemical effects on the metal. When it is performed, a thin protective film is formed on the metal surface, which effectively protects the metal from external negative influences.

For processing, the product is placed in a special container containing a zinc plate. After this, electricity is supplied. It is this that transfers zinc particles from the plates to the surface of the workpiece.

The main disadvantage of this method is its high cost. Also, during metal processing, dangerous poisons remain that require special disposal.

Thermal diffusion galvanizing

When performing thermal diffusion galvanizing, an environment is created that is characterized by the presence of high temperatures. At approximately +2600°C, zinc breaks down into small particles that settle on the surface of metal products. The main advantage of this galvanizing method is that it results in the formation of a particularly thick protective layer.

Advantages of thermal diffusion galvanizing

The process of applying a protective coating to metal products is carried out in a special closed chamber. First, zinc powder is applied to the surface of the part, after which it is heated. This technology is used exclusively in industrial settings. It is very difficult, expensive and unsafe to use at home.

The advantage of thermal diffusion galvanizing is its safety for the environment. The created coating has a significant thickness, which provides excellent protective qualities.

Gas thermal galvanizing

The application of zinc is carried out using an intense gas flow. After performing such treatment, the surface must be painted. Despite the peculiarities of this technology, it ensures high quality and long service life of the processed parts.

Source: https://LEDsovet.ru/cinkovanie-metalla-svoimi-rykami-i-tehnologii-ocinkovki/

Galvanic galvanizing at home: what is required, sequence of steps, feasibility of self-processing, video

  page » Metalworking - galvanizing » Galvanic galvanizing

Galvanic galvanizing in production conditions. Photo PKF Color

Galvanizing metal using the galvanization method is a useful and interesting process. quite easy to do it at home , especially in situations where it’s more rational to do everything yourself and save money at the same time. Before starting work, it is important to understand the essence of the process .

When is it more profitable to do it yourself than to order a service?

Considering that the galvanic galvanizing method is expensive, in some cases it is reasonable to create a small chemical laboratory at home and do everything yourself. You can use the method at home :

Small parts after zinc treatment. Photo EnergoStal

• for small metal parts , the size of which will allow them to be immersed in a container with a zinc solution;
• for decorating metal surfaces;
• treat the most vulnerable areas of the car body or small areas of other metal structures.

What you will need

For the galvanic galvanizing method at home, you will need the following devices and substances:

• current source. This could be a charger or a car battery. Its parameters should be in the range from 2 to 6 A and from 6 to 12 V;
• zinc sulfate – 200 g;
• ammonium or magnesium sulfate – 50 g;

Reference. Performers have the opportunity to purchase equipment for galvanic galvanizing by contacting employees of the companies that are presented in the section “Where to buy equipment (on credit, leasing).”

• sodium acetate – 15 g;
• water – 1 l.;
• container into which the parts will be immersed;
• wires for connecting to a power source.

Important. During work, be sure to use protective equipment (respirator, rubber gloves and exhaust device).

Galvanizing can be divided into the following stages :

• First of all, the solution is prepared in a glass container of a suitable size;
• the zinc solution is heated to a temperature ranging from 18 to 25 degrees;
• after this, the anodes are immersed in the solution, which are connected to the positive on the current source;
• At a safe distance from the zinc solution, fix the product that needs to be galvanized, and connect the “negative” wire (cathode) to it;
• after this, the galvanization process should begin, in which a zinc composition is deposited on the product through the negative wire.

Important. The current should not exceed 1 A, otherwise the coating will be of poor quality.

Source: https://ipmet.ru/galvanicheskoe-cinkovanie-v-domashnix-usloviyax/

Do-it-yourself cold galvanizing technology

Galvanizing is one of the most effective ways to protect metal structures from corrosion. There are several methods by which the result is achieved, ranging from electrochemical deposition to thermal gas spraying. However, the most popular and simplest is cold galvanizing of metal - a method suitable for processing parts of any size, profitable and affordable even for use at home.

Principle of the method

Cold galvanizing of metal structures is a method of painting metal using a special composition containing a large amount of zinc (from 89 to 95%).

The result is the formation of a durable coating by drying paint. Moreover, the protection of the metal is not only physical, preventing mechanical stress, but also cathodic, preventing the development of corrosion by reducing the potential.

The technique is characterized by the following features:

• performing the process using a roller, sprayer or regular brush;
• ensuring a high level of water resistance, fire safety and electrical conductivity of the processed material;
• minimal probability of metal deformation due to high temperatures - when galvanizing, the surface heats up to only 5°C–40°C;
• the possibility of applying almost any paint and varnish material to the surface of the structure - the exception is alkyd paints, which have a risk of peeling;
• no need to move the workpiece.

Using this technique, bridge structures, pipes, elements of railway tracks and road barriers are protected. In addition, galvanizing provides protection for tanks, reservoirs and oil pipelines. And one of the most popular areas of application of the method is the processing of parts for passenger cars and trucks.

Differences from hot-dip galvanizing

The cold galvanizing method has a number of differences from the hot galvanizing method, making it more popular. One of the main advantages is the ability to solve corrosion problems efficiently and safely. Other advantages include:

• The principle of applying a zinc-containing composition. With the hot method, metal structures are immersed in a container filled with zinc alloy, which limits the size of the part. It is more convenient to process large objects using a cold method, reminiscent of painting;
• The temperature at which the cold galvanizing composition is applied is no more than 40 degrees, that is, more than 10 times less compared to the hot method. In most cases, even standard room conditions are suitable;
• Possibility of adjusting the quality of the coating. Thus, when using the hot method, the work performer regulates only the temperature, obtaining an almost unpredictable result. Cold galvanizing requires care, but allows for a more aesthetic appearance.

The advantages of cold metal processing are complemented by lower cost of work. And the only disadvantage is the increase in time for their implementation. But do-it-yourself cold galvanizing can be carried out even at home - without the use of specialized equipment and special conditions.

Galvanizing process

The process of processing metal structures using cold galvanizing technology requires preparing the surface before applying a protective composition.

According to GOST, this preparation consists of the following stages:

1. First of all, the surface is washed to remove contaminants from it;
2. A waterjet, hydrodynamic or sandblasting method is used, thanks to which the metal acquires the required degree of roughness, and scale and rust are removed;
3. If the first two methods were used, the structure is dried;
4. The metal is manually cleaned to remove sharp edges, cooking splashes and corners;
5. The structure is cleaned of dust using compressed air.

If there are fatty and oily inclusions on the metal, the surface is degreased using solvents.

The degree of degreasing is controlled by GOST 12.2.052, dust content is controlled by ISO 8502-3. The roughness is checked with a comparator or profilometer and compared with the values ​​from ISO 8503-1.

Application Features

When the surface is prepared and its quality is checked, the process itself begins. To obtain a high-quality result, the cold galvanizing technology of metal involves maintaining a certain air temperature in the work area.

It must exceed the dew point value by no less than 3°C, which avoids the appearance of moisture on the metal and, accordingly, a decrease in the quality of protection and a reduction in its service life.

The parameter is determined by special instruments - thermometers, hygrometers or psychrometers, the readings of which are compared with the values ​​​​from special tables.

The protective coating is applied in several layers, each subsequent one only after the previous one has completely dried. The application method can be airless or pneumatic. Elements requiring stripe painting are finished using rollers and brushes. And after the work is completed, the quality of the coating is checked - for this they use special measuring devices and a visual method.

Popular materials for galvanizing

Cold galvanizing is performed using various materials, which are selected depending on a number of factors.

Popular compositions suitable for both industrial use and home work include:

• the preparation “Galvanol”, which has good adhesion to products made of ferrous metals and is characterized by ease of application, the possibility of use in the temperature range of –30°C – +50°C and galvanizing even rusty surfaces;
• “Tsinotan”, used for processing tanks for storing petroleum products, pipes and tanks of the hot water supply system, power line supports and hydraulic structures;
• paint for cold galvanizing "AnticorZinc™", characterized by resistance to petroleum products, solvents, fresh and sea water, high adhesion to the metal surface, mechanical strength and good aesthetic characteristics;
• “Master AK-100” is a composition suitable for corrosion protection of automotive parts, including body elements, building and railway structures and supports for power lines;
• “Cinotherm” is a solution used in combination with any paint and varnish materials, which allows not only to protect the metal, but also to change the color of its surface;
• “ZVES” is a paint whose compositional features (the inclusion of zinc powder and ethyl silicate) allow it to be used to increase the protective properties of alloy steel.

Almost all substances used for cold galvanizing are characterized by the same gray color and consumption in the range of 0.25–0.3 liters per 1 m2.

And when choosing a specific product, you should pay attention to their price and specified characteristics such as service life, drying time to a strength level suitable for applying the next layer and temperature range of use.

Another important parameter is the zinc content in the material, which is in the range of 85–96%. While the service life can reach 10 years, the drying period is from 0.5 to 6 hours, and the processing price is 1 sq. m of surface starts from 55–60 rubles.

Features of performing work at home

Due to the simplicity of the technique and the absence of special conditions, galvanizing metal with your own hands is easier than using other metal processing options. When preparing the composition, it should be taken into account that it is not ordinary paint, but rather a type of liquid zinc. And its storage is carried out in two forms - in the form of zinc powder and a liquid binder component.

DIY stairs to the second floor in a private house. - there is more useful information here.

It should be noted that before galvanizing, the material is first diluted and then thoroughly mixed until a homogeneous mass is obtained, which avoids delamination of the two-component substance.

It is also necessary to take into account that the strength of the resulting coating largely depends on its preparation.

Carefully performed mechanical stripping of the metal and subsequent degreasing can increase the service life of the protective layer several times. And applying special compounds not in one, but in 2-3 layers will provide protection for at least 10 years without the need for additional processing.

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When working at home, it is recommended to apply layers at intervals of at least 30 minutes - but no more than an hour. The ambient temperature should be in the range of 5–40 degrees, which allows you to carry out work at almost any time of the year, outdoors or indoors.

If galvanizing occurs inside a building (garage or workshop), good ventilation should be ensured. And before applying finishing finishes and varnishes to the galvanized coating, it is advisable to wait at least 24 hours to ensure final setting of the composition.

Properly performed cold galvanizing at home allows you to obtain protection for the metal surface no worse than the result of factory processing of metal structures. To do this, all process conditions must be observed. Although they are already simple compared to other methods. And the appearance of the protected metal is quite impressive, even if the person performing the work has never done galvanizing before.

You can learn more about cold galvanizing of metal at http://spektrlkm.ru/

Source: https://DimDom.ru/tehnologiya-holodnogo-cinkovaniya-metalla-svoimi-rukami.html

Metal galvanizing technology at home

At home, [galvanizing metals] is quite feasible. First of all, it is necessary to protect the metal from corrosion, which is the most destructive “disease”.

Some types of metals, when in contact with air, begin to oxidize.

As a result of this process, a film appears on the surface that can protect the surface from harmful influences.

As for iron, a film also forms here, but it is not the same density, and therefore does not provide the material with the necessary protection. As a result, the air penetrates deeper and deeper over time, affecting a larger surface.

To preserve metal products from rust, in addition to galvanizing, you can perform chrome plating, coat the metal with copper, tin or lead. Special factories today produce many options for different coatings.

The technology of coating metal with zinc is quite simple, so you can do it yourself.

Galvanizing metal can be carried out using various methods:

• Hot galvanizing.
• Cold paint.
• Galvanic.
• Gas thermal spraying.
• Thermal diffusion.

Regardless of what classes of galvanizing are used, it is necessary to correctly select the thickness of this coating, which is affected by the time and temperature of the technological process.

Hot galvanizing

Hot galvanizing of metal products is considered the most effective and durable method of combating corrosion.

However, from an environmental point of view, this method cannot be called harmless and safe, since the zinc is melted and the metal surface is treated chemically.

The technology of this method involves two stages: preparatory and direct galvanization.

Preparation consists of first degreasing the metal surface, then etching.

After this, the surface is washed, fluxed and everything is thoroughly dried.

Hot galvanizing is carried out using special equipment.

After the product has dried, the galvanizing process is carried out: the dried material is lowered into a special container where hot zinc is located.

Hot-dip galvanizing, although the most effective method of protecting iron from rust, has its drawbacks.

Firstly, you need to have special equipment - baths, drying chamber, oven.

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Secondly, its dimensions are often limited, as a result of which it becomes impossible to process large-sized material.

Although, it should be noted that modern industrial equipment allows hot-dip galvanizing of power lines, scaffolding, etc.

Cold galvanizing method

Cold galvanizing of metal is becoming the most popular galvanizing method. The technological process involves coating the iron with paint containing powdered zinc.

The surface of a galvanized product contains 89-93% Zn. The technology is simpler compared to the previous hot-dip galvanizing method.

The metal surface of the product is coated with sprayed zinc in the same way as conventional paint is applied, that is, using a roller or brush.

If you use sprayers, you can not only save time on processing the product, but also paint hard-to-reach places.

Cold zinc paint of metal surfaces is convenient in cases where it is difficult or impossible to apply other processing methods; special equipment is not used for this.

This method of processing metal with zinc is also used for previously galvanized products. This technology can be carried out at different temperatures.

Gas thermal spraying

This technology is used in cases where the dimensions of the structures being processed do not make it possible to paint using equipment in the form of baths, as with the methods described above.

The types of zinc used are wire or powder.

Zinc is first melted, after which it is sprayed onto the surface to be treated using a gas flow.

The surface of galvanized material takes on a scaly, porous appearance. Due to the resulting structure, the material must be additionally painted to fill the resulting pores.

IMPORTANT TO KNOW: Methods of metal oxidation

Gas-thermal spraying of zinc has a high degree of protection of the material even in such conditions as in water (fresh and sea), as well as in various atmospheric conditions.

Galvanic galvanizing at home

Do-it-yourself galvanizing of a material requires a car battery or charger that meets the following requirements: 2-6A, 6-12V.

The electrolyte can be made from any salt, but it is better to use a solution of zinc salt.

To make it, you will need zinc sulphate (200g), ammonium or magnesium sulphate (50g), sodium acetate (15g), water (1l).

You can also use battery electrolyte (diluted sulfuric acid) in which zinc is placed for galvanizing yourself.

As a result of the reaction, zinc remains on the surface of the product, and the acid is converted into salt.

If sediment forms at the bottom, this indicates a high concentration of the acid solution. In this case, the solution is diluted with a small amount of water.

A glass jar is used as a container if the part being processed is small, or vinyl plastic or any other glass container.

The container must be selected so that the electrode with the part can be attached to it.

The process of coating metal with zinc yourself must begin with cleaning and degreasing the part.

After this, it is placed in a solution of sulfuric acid for several seconds (up to 10 seconds), thus the metal part is activated.

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Then it must be rinsed with plain water. Next, the material is anodized.

The electrode is made from a small piece of zinc, in which a hole is drilled and copper wire is threaded through it.

At the same time, a self-made electrode must be comparable in area to the material being processed; it is better to take a flat shape for ease of placement in a container.

The available equipment is connected with a minus to the material, and a plus to the zinc. The process will take place for 40 minutes, as a result of which the zinc will dissolve and settle on the surface of the product.

It should be noted that do-it-yourself galvanizing should be carried out in a ventilated area, as well as wearing gloves and special clothing. The price of the home method remains low.

Cold galvanizing at home

At home, you can cold galvanize the metal for which paint is used. It should be noted that this is not just paint with zinc added, but rather zinc in this form.

To create a galvanized product, special materials are used (sold in stores) with two components: zinc powder and a binder in liquid form.

The paint in the form of two substances is in separate containers. They are mixed according to the instructions on the packages.

The proportions in which they are mixed with each other can be 1:1 or 3:1 (zinc and binder component, respectively).

The paint is applied at a positive temperature (5-40 degrees) in a ventilated area.

Galvanol paint is considered a good way to paint a metal product. It is easy to use even at home, can be applied to rust, dries quickly, and the price remains affordable for ordinary people.

Home galvanizing methods are distinguished by their simplicity, accessibility and effectiveness of the appearance of galvanized material.

It should also be noted that there is no need to use special equipment for this process at home.

Source: https://rezhemmetall.ru/cinkovanie-metalla-svoimi-rukami.html

Metal galvanizing

Steel products are used in all areas of human life. Durable and reliable, they bring benefit and convenience for a long time. But steel products have a dangerous enemy - rust, which can render them unusable. There are many ways to protect against it. One of the popular ones is galvanizing the metal.

Metal galvanizing

Features of the galvanizing procedure and the main methods of metal protection

Metal corrosion, or the process of its oxidation, is especially intensified in conditions of high humidity. To prevent corrosion of metal products, protective coatings are applied to them. Galvanizing of metal is considered one of the most reliable, since zinc takes on the effects of aggressive environments. Galvanizing provides not only barrier, but also electrochemical protection of the metal. During the reaction, an oxide layer appears on the surface of the part, which provides additional protection.

After mechanical destruction of the coating, the effect of the protective layer ceases. There are various types of metal galvanizing, many of them require complex and expensive equipment, but some can also be used at home.

Galvanized pipes

Galvanizing technology was first mastered in France in the 18th century and further developed in England. Domestic scientists Jacobi and Mendeleev made a great contribution to improving the process. Today, galvanizing metal is one of the most affordable ways to protect against corrosion.

Galvanizing methods

Metalworking specialists distinguish the following methods for applying zinc coatings to metals:

• hot;
• cold;
• electrochemical, or galvanic;
• gas-thermal;
• thermal diffusion.

The application method is selected based on the following criteria:

• conditions for using the part;
• thickness of the protective layer;
• durability;
• special protection requirements.

The thickness of the layer is determined by the time the part is in the working environment and the temperature in the working area. When designing a technological process, it should be borne in mind that mechanical processing after coating the part with zinc will destroy the protective layer.

Cold galvanizing

This method is technologically much simpler. It can be reproduced at home. A layer of zinc-containing substance is applied to the workpiece using a brush or roller. To protect workpieces of particularly complex shapes and topography, spray guns are used. Compositions for cold galvanizing of metal are polymer solutions based on fine-grained zinc powder. The most commonly used is zinconol, which creates a corrosion-protecting layer on the surface with a 90% Zn content.

Cold galvanizing is also used in industry to protect already assembled parts and structures - for example, power line supports.

Cold galvanizing

The method is also used to restore partially damaged anti-corrosion coatings, for example, as a result of wear or repair work.

The disadvantage of this method of coating metal with zinc is the low mechanical strength of the coating.

Galvanic method

The electrochemical method allows you to obtain a durable and smooth layer. During the process, you can control the thickness of the applied metal layer. The quality very much depends on the degree of degreasing of the workpiece.

Galvanization of parts occurs as follows. Protected workpieces and zinc plates - donors are lowered into a bath of electrolyte, and voltage is applied to them. The current flowing in the resulting circuit, using the phenomenon of electrochemical metal transfer, pulls zinc atoms from the plates and deposits them on the workpieces.

Galvanic galvanizing

The disadvantages of the method are the high cost, which consists of the cost of plates, electrolyte and electricity. In addition, you will have to incur high costs for decontamination of the spent electrolyte.

Gas thermal spraying of zinc

The method is used for processing large-sized products, steel sheets, etc. Zinc is transferred to the prepared surface of the workpiece by a jet of burning gas. A zinc wire is placed in the flame of a gas burner, it melts and droplets of metal fall on the workpiece, forming a scale-like layer on it.

Gas thermal galvanizing

The method is used in combination with the application of anti-corrosion paints and varnishes and is very effective for protecting the hulls of sea vessels and coastal structures.

How to perform the procedure at home

Galvanizing at home is most often carried out using the galvanic or cold method. First of all, you need to degrease the workpieces, pickle them with an acid solution and rinse thoroughly with water.

A galvanizing installation will require the following materials and equipment:

• Battery 6-12 V, 2-6 A (any car or motorcycle). Instead of a battery, you can use a charger of sufficient power.
• Bath made of non-conductive material (plexiglass, textolite, etc.)
• Suspension system: conductive rods and hooks.
• Switching devices and wires.
• Ammeter and rheostat.
• Electrolyte - any zinc-containing salt. You can take a car electrolyte and dissolve zinc powder in it.
• Zinc plates.

The rods are placed across the bathtub, the plate parts are suspended from them, after which the wires from the battery are connected through an ammeter and a rheostat. When carrying out galvanizing with your own hands, keep in mind that the thickness of the layer is determined by such parameters as:

• current strength;
• electrolyte temperature;
• electrolyte density

Affects the thickness and total surface area of ​​the workpiece.

Source: https://stankiexpert.ru/spravochnik/materialovedenie/cinkovanie-metalla.html

Do-it-yourself metal galvanizing, galvanizing at home

Galvanizing metal in a modern car is an opportunity to protect the body surface from corrosion. Galvanizing metal with your own hands at home is a completely feasible task.

There are certain types of metal that, when in contact with air, form a protective film on the surface. It protects the material from environmental influences and prevents corrosion. On metal, which is used to produce cars, the film is weak, so it is not able to protect the product from destruction.

Industrial processing methods

You can create additional protection against corrosion in several ways, for example, by coating products with tin or zinc. Galvanizing a material is a fairly simple task and can be easily done with your own hands. Treatment of parts, for example for a car, will protect the surface of the products from direct contact with air, which prevents oxidation of the surface. Metal processing with zinc is possible in several ways:

• Hot and cold galvanizing.
• Galvanic.
• Gas-thermal.
• Thermal diffusion.

When processing a material using one of these methods, the duration and temperature of the process affect the thickness of the protective surface layer formed.

Hot-dip galvanizing technology

This method of metal processing is one of the most effective. Zinc remains on the surface for a long time and reliably protects against corrosion. The disadvantage of this treatment is that this technology is harmful to the environment since the material is processed chemically. Hot galvanizing of metal consists of several subsequent processes:

• Preparation. The surface of the parts must be degreased, and then the metal must be etched.
• Treatment. After preparation, the machine part must be washed and dried.
• Galvanizing. The product is lowered into a tank containing molten zinc.

This processing method, despite its effectiveness, has significant disadvantages:

• Galvanizing metal requires special equipment and containers.
• Impossibility of processing large-sized products, for example, car bodies.

Cold galvanizing technology

Galvanizing car parts using this method is quite simple. Surface treatment is carried out using a special paint containing zinc. The metal surface is painted with zinc paint using the usual painting method: with a brush, roller or spray gun.

Using zinc-containing powder paint and a spray gun makes galvanizing a vehicle easier. The spray gun allows you to completely treat the entire surface of the body, including hard-to-reach places. This method is most often used to apply a protective coating to products that are difficult to hot process. The car body is just such a case. This method is also used for processing previously galvanized metal.

Galvanizing technology

Galvanic deposition of zinc involves processing the metal using electrochemical action. Processing with this method allows you to achieve a smooth and thin protective layer on the surface of the product.

In order for the zinc to adhere to the surface, for example, of a car body, the products are placed in a special container in which a zinc plate is located.

After this, electricity is supplied to the container, as a result of which the zinc from the surface of the plate is transferred to the machine body, forming a protective layer.

The disadvantages of this method include its high cost compared to other methods of applying a protective layer. In addition, such treatment is dirty and wastewater treatment also requires high costs.

Gas-thermal galvanizing method

This method of applying protective coating is excellent for the body of large vehicles that cannot be treated using conventional methods.

Zinc is applied to the surface of the car body using a strong gas stream. The use of this method requires subsequent application of paint, since the zinc does not spread evenly on the surface and does not fill the entire surface of the car. But despite this, this method of creating protection provides reliable coverage. It protects the car both from air exposure and provides reliable protection against corrosion in wet conditions.

Thermal diffusion galvanizing method

Galvanizing a car body using this method involves the use of high temperatures. At a temperature of approximately 2.6 thousand degrees, zinc breaks down into atoms, which are deposited on machine parts. The advantage of this method is that it can be used to achieve a thick protective layer.

The process of applying protective material to the car body is carried out in a special closed chamber. Powdered zinc is applied to the product, after which the entire chamber is heated. This can only be done in an industrial environment, so you won’t be able to apply zinc yourself at home.

The use of this method is safe for the environment and allows for galvanizing of excellent quality. Zinc is applied to the surface of the machine in a thick layer, which will reliably protect metal products from corrosion. The method has only one drawback - its high price.

Galvanizing a car body at home

If noticeable pockets of corrosion have formed on the body of your truck or car, but they are still not through, you need to take immediate action. As practice shows, if you do not stop body corrosion in time, the cost of subsequent repairs to your car will be many times higher. For this reason, you can’t hesitate!

In recent years, many motorists have noticed: even in large densely populated cities, road services mercilessly use salt. As a result, the bodies rot to holes in literally two to three years.

To resist the rusting process and the aggressive effects of road reagents, there is a very simple but effective way - do-it-yourself galvanizing of the body.

Galvanizing a car is carried out in order to protect the body once and for all from the formation of annoying “saffron caps”, as well as to prevent the further spread of corrosion throughout the body.

The zinc “crust” on the surface of the metal creates a kind of barrier that protects the steel from negative factors and the destructive effects of an aggressive environment. The zinc-based coating effectively resists the effects of salts, chemicals and moisture.

Please note that you can galvanize both a part of the car body (fender, trunk, hood, etc.) and any individual part. And this will require direct hands, certain knowledge, a specific set of materials and tools, as well as the desire to give your car additional strength.

How to galvanize a body yourself

The “home” method of galvanizing metal allows you to prevent the formation of corrosion on the car body and thereby reduce service costs. Liquid galvanizing can also be used for various metal products to further protect them from rust.

It must be said right away that this method is very simple and does not require large financial costs. In fact, this is the well-known Zinkor car, but with your own hands. This miracle remedy will be written in detail below, as the article progresses.

Preparatory work

This method involves the use of phosphoric acid with zinc dissolved in it, and will also require zinc (salt) batteries. You can use both small finger batteries and large batteries - in this case it all depends on the amount of work being done.

If you need to galvanize a large surface area on your car, then it is better to take large zinc batteries. First, you need to “print” them all and remove all the excess braiding.

If you wish, you can also use only the casing of a salt battery, after removing the graphite core and soot, but in principle you can leave all the “internals” in place.

On the body of the “bare” galvanized battery, on one side you need to secure a cotton pad with an elastic band, and on the other side (also using a regular rubber band) - the power wire. You can use a car battery or a suitable power supply as a power source.

How does galvanizing of a surface occur?

If you don't know how to galvanize correctly, read the short instructions first.

The “minus” from the car battery must be connected directly to the part of the body (or part) that you are going to galvanize with the battery - that is, using the battery.

We connect the wire that goes to the zinc body of the battery to the positive terminal of the battery. Please note that the negative terminal should never be disconnected, because the desired effect will not be obtained.

Before starting galvanizing, it is advisable to clean the surface to be treated from traces of rust, if any. You need to take orthophosphoric acid with zinc dissolved in it into a syringe and soak a cotton pad that is placed on the body of the salt battery. After this, you just need to move the “nozzle” over the entire area of ​​the surface being treated.

The most important thing is not to stop. If you keep the battery in one place for a long time, then burns appear, and if you move continuously over the surface, you get a neat and even layer of zinc. You will see the result almost from the first seconds.

Although some people call this method of galvanizing a car “artisanal,” it is truly a proven, simplest and, most importantly, effective way to combat corrosion. And, as an option, you can use a ready-made camping kit - a car kit for galvanizing Zinkor auto.

Using this product, you can quickly localize particularly advanced areas of rust, as well as remove all traces of corrosion on the car body. Galvanic galvanization allows you to reliably protect the metal surface from the reappearance of “saffron caps”.

Method of galvanizing metal using “white powder”

Typically, for galvanizing small areas of metal surfaces, phosphoric acid and a galvanized battery casing are most often used. However, for better processing, it is better to use soldering acid instead of phosphoric acid. It is hydrochloric acid in which zinc is dissolved. It is believed that the galvanization of the body in this case will be deeper and more durable.

You can purchase soldering acid at almost any radio electronics store. But it’s not entirely convenient that soldering acid for soldering at home is sold only in small bottles.

Therefore, if you need large volumes of soldering acid for galvanizing, it can be made at home from “white powder” - zinc chloride, which is sold by weight.

Main stages of work

Pour zinc chloride into a suitable container, then add distilled water and mix until a clear liquid consistency is formed (note that you need to wear rubber gloves when working with chemicals). From 1 kg of zinc chloride, approximately 3.5 liters of finished soldering acid are obtained.

The result is a galvanic bath, in which, if necessary, pieces of sheet steel and entire metal parts can be galvanized.

For further work, you will need a galvanized battery case and an iron bolt, at the ends of which cotton fabric must be secured with rubber bands.

The part that needs to be galvanized must first be thoroughly cleaned of rust with a grinder, using a cleaning disc with a metal brush. Before galvanizing, the metal must be “activated” - the oxide film must be removed from the surface using electricity.

How to activate metal

To do this, the positive terminal from the charger must be connected directly to the workpiece, and the negative terminal through a 20-watt light bulb to the electrode. A bolt with a cotton cloth at the end is used as an electrode, which must be moistened in soldering acid or electrolyte.

After applying current, we treat the surface of the part; as a result, the product is better cleaned of oxides. Only after this procedure can you begin directly processing the car - galvanizing the car body.

Galvanizing a car body with a battery in a garage

According to the good old tradition, pockets of corrosion on the body appear after the winter period, when the roads are sprinkled with reagent. To stop rust and prevent through corrosion, you need to stop this process as quickly as possible. And galvanizing the car will help in this situation.

For self-galvanizing you will need salt batteries, the body of which is made of zinc, a wire and a battery. A small piece of rag moistened with soldering acid is placed on the battery, and it is connected through a wire to the positive terminal of the battery. The made device must be pressed against the source of corrosion and moved carefully from side to side.

As a result of all manipulations, a film of silver coating appears on the metal surface instead of rust. An important addition to the work done will be the neutralization of the remaining acid, which can be extinguished with a solution of baking soda and water.

These are the simple “folk” methods used to perform the technology of galvanizing a car body with your own hands using the galvanic method. By the way, we forgot to mention another good product with which you can easily and quickly galvanize a metal surface - Tsinkar for cars.

For more information on how to stop rust on a car body with your own hands, you can watch a video tutorial that talks about all the nuances of galvanizing a car body at home using a battery and other methods accessible to the common driver.

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Source: https://sdelairukami.ru/samyj-prostoj-i-effektivnyj-metod-tsinkovaniya-avtomobilya/

The purpose of galvanized metal and methods of galvanizing it, organizing the process with your own hands

Galvanizing metal is one of the most common ways to protect it from the appearance and development of corrosion, increasing its performance qualities and significantly increasing its service life.

Galvanizing refers to the application of a coating consisting of 95 percent zinc to the surface of a metal. Galvanizing is performed in various ways, each technology has its own advantages and disadvantages.

Steel products are susceptible to corrosion, especially when used in conditions of high humidity. The galvanized steel part is reliably protected from corrosion. The coating together with the metal forms a galvanic couple, where zinc has a higher degree of electronegative charge compared to steel. Accordingly, zinc undergoes corrosion, and steel reacts practically without any reaction. The anti-corrosion protection of the metal will last until the zinc coating is destroyed.

There are several galvanizing technologies. Some technologies allow do-it-yourself galvanizing with obtaining an acceptable result.

Metal galvanizing methods

There are the following methods of galvanizing metal:

• cold;
• hot;
• galvanic;
• thermal diffusion;
• gas-thermal.

You need to choose one or another method for galvanizing steel parts or structures depending on the conditions of use and the characteristics of the protective layer. Regardless of the galvanizing technology used, it is necessary to determine the thickness of the protective layer. It depends on parameters such as the period of exposure of the working environment to the metal and the processing temperature.

When using steel structures on the surface of which a layer of zinc is applied, you must remember that they cannot be subjected to strong mechanical stress, since the protective metal coating is highly brittle and can be destroyed.

Let's look at different types of metal galvanizing.

Hot galvanizing method

Hot galvanizing of metal allows us to achieve maximum quality of products and ensure their durability. This method has a key drawback - its implementation involves the use of chemical reagents to treat the surface, and the procedure is performed in molten zinc.

The hot galvanizing method of steel includes preparing the surface of the product and the actual procedure of coating the metal with zinc.

Steps to prepare the surface to be treated:

• cleansing;
• degreasing;
• application of acid solutions;
• washing and fluxing;
• drying the surface.

When the surface goes through all the stages of preparation and dries, the product is placed in a special bath with molten zinc. A thin layer of zinc and iron is formed on the surface of the steel, which reliably provides anti-corrosion protection. When the product is removed from the bath, it is blown with compressed air to dry it and remove excess zinc from the surface.

The disadvantage of this method is that the dimensions of the products are limited by the dimensions of the bath with molten zinc. This method is practiced at large production facilities when working with power transmission poles, scaffolding or lighting masts.

The method involves a lot of labor and the use of complex equipment, so it is not suitable for home use.

Cold galvanizing of steel

This method of processing metal with zinc has gained wide popularity in recent years. The reason is the high manufacturability and simplicity of the method, coupled with the high protective properties of the layer on the metal surface. The option is suitable for galvanizing metal with your own hands, since no special equipment is required for the work.

Cold galvanizing technology involves applying a zinc-containing mixture, for example, zinconol, to the surface of the product. It must be applied with a roller or brush. If you need to cover structures of complex shapes or hard-to-reach places, you can use a spray gun. Thanks to special compounds, a protective layer is formed on the surface, consisting of more than 90 percent zinc.

This galvanizing method is the only one acceptable for providing anti-corrosion protection to structures that cannot be galvanized in any other way. For example:

• installed pipes;
• elements of railway tracks;
• power line supports and other structures in a stationary or mounted version.

Zinconol and other cold galvanizing compounds are used during repairs if there is a need to restore the damaged zinc layer on metal structures. For example, this is relevant for the purpose of restoring the galvanization of a car body.

Cold galvanizing of steel products is carried out over a wide temperature range; the resulting coating has high protection, elasticity, and resistance to mechanical stress and temperature changes.

Cold galvanizing has its disadvantages. For example, the formed coating does not have high enough resistance to mechanical stress; safety precautions must also be strictly observed if the procedure involves the use of organic solvents.

Galvanic galvanizing method

During galvanic galvanizing, an electrochemical effect is applied to the surface of the product. The resulting coatings have high thickness accuracy and exceptional smoothness. Also, a protective layer with a thickness of about 20–30 microns is formed on the metal surface.

With the help of such galvanizing, the thickness of the protective layer can be adjusted, while the layer is uniform and has high decorative qualities. Metal and zinc are combined at the molecular level during galvanizing; the coating has high adhesion to the base material. The degree of adhesion is affected by the presence of oxide and fatty films on the surface, which are almost impossible to remove.

Galvanic galvanizing is carried out as follows:

• the structure and zinc plates are placed in an electrolytic solution, then the positive and negative contacts of the current source are connected to the wall of the bath and the plates;
• due to the potential difference, the plates dissolve in the electrolyte, and zinc molecules settle on the surface of the product and form a uniform protective layer.

The key advantage of this method is that in this way a protective layer is formed on the surface, which has special decorative characteristics. The thickness of the layer can be adjusted. But the method also has its drawbacks. In particular, this is a high cost.

Thermal diffusion galvanizing technology

This technology is also called sherardization. It was developed in the 20s of the last century, but for a long time it was not widely used. It was only in the 90s that the method gained popularity.

The essence of the method is that the part, together with a dry zinc-based mixture, is placed in a sealed container, where a temperature of about 2600 degrees is created. At this temperature, zinc goes into a gaseous state, and accordingly, the process of diffuse penetration of zinc atoms into the surface layer of the product is accelerated. This galvanizing technology is used in cases where it is necessary to form a protective layer with a thickness of 15 microns on the metal surface.

The preparation of metal products for thermal diffusion coating with zinc does not differ from the hot method. Advantages of this method:

• the process takes place in a sealed container, therefore, it is environmentally friendly;
• there are almost completely no pores on the protective coating, which has high adhesion to the surface;
• the coating receives a high degree of protection;
• complex geometric shapes and parameters of zinc-coated products are preserved;
• the resulting waste does not require special disposal.

Disadvantages of the thermal diffusion method:

• the finished coating does not have a metallic sheen and has a dirty gray tint;
• low productivity;
• zinc dust in the air during work can harm the body;
• The zinc coating is not uniform in thickness.

Thermal spraying

The gas-thermal galvanizing method is suitable for coating a three-dimensional part or sheet of metal with zinc. Its essence is that zinc, in the form of a dry mixture or wire, is sprayed in a gaseous environment onto the surface of the workpiece. The technology is used to apply a layer of zinc to large-sized products that cannot be processed otherwise.

Zinc plating process:

• particles of molten metal are applied to the surface to be treated, forming a thin layer with a scaly structure;
• Paints and varnishes are applied to the porous coating. The layer created by combining protects the product and allows it to be used for a long time in conditions of high humidity, constant exposure to fresh or sea water and other aggressive environments.

The parameters of zinc coatings applied by the methods listed above are established by the relevant GOST.

https://www.youtube.com/watch?v=jHFJ_Nn5QPs

As already mentioned, some types of galvanizing can be done independently at home. This applies to cold galvanizing technology or the electrochemical method.

To perform galvanizing yourself using an electrical method, you need to carefully prepare the surface of the workpiece. Preparation includes:

• cleaning;
• degreasing;
• acid pickling;
• rinsing under running water.

You can make an apparatus for galvanic galvanizing yourself based on a direct current source with a voltage of 6-12 V at a current strength of 2-6 A and a capacitance based on a dielectric device and a device for fixing the product and electrode. Any salt solution containing zinc acts as an electrolyte. To prepare the solution, zinc is placed in a battery electrolyzer and dissolved in it. Before use, the composition is filtered.

When performing galvanizing with your own hands, you need to take into account that the following factors influence the quality and thickness of the coating:

• current density per unit area of ​​the product;
• temperature of the electrolytic solution;
• electrolyte temperature;
• geometry and complexity of the product shape.

Galvanizing metals allows you to slow down the process of corrosion of products. Galvanizing methods depend on the operating conditions of the products. You can galvanize materials at home.

Source: https://tokar.guru/metally/cinkovanie-metalla-svoimi-rukami-i-tehnologii-ocinkovki.html

Galvanizing metal at home

Any metal product, no matter how high-quality steel it is made of, sooner or later dies, poisoned by corrosion.

There are many ways to combat corrosion, including chemical, mechanical, and electrochemical methods of protection. Each of them is effective in its own way, each of them, however, has its own profitability.

The most optimal method of protecting steel from rust in terms of price/effectiveness ratio has become galvanizing. We'll talk about this process today.

:

• Painting and galvanizing of metal, as necessary
• Hot galvanizing of metal
• Gas-thermal galvanizing method
• Thermo-diffuse and galvanic galvanization
• Cold galvanizing

Painting and galvanizing of metal, as necessary

A strong and stable metal that can withstand crazy loads and is used everywhere, is absolutely helpless against corrosion if the appropriate treatment is not carried out.

Galvanization is one type of protection of metal surfaces from rust, and its main advantage is efficiency and reasonable price. The same can be said about most methods used for galvanizing.

Zinc itself is valuable because, as a result of interaction with oxygen, it forms a fairly strong and stable film, an oxide coating, which protects steel from environmental influences.

Metal can be galvanized in several ways:

1.  Thermal diffusion method.
2.  Cold galvanized.
3. Galvanic galvanization.
4.  Hot galvanizing.
5. Gas thermal spraying.

Galvanizing metal at home can be carried out either using one method or in a complex manner. It all depends on the conditions in which the surface operates and on the qualities of the protective layer that need to be achieved. When choosing a galvanizing method, the desired thickness of the zinc is taken into account, and this already affects the temperature and duration of the process. However, galvanized surfaces have some limitations in use, and the most important of them is the lack of direct mechanical impact.

Hot galvanizing of metal

In terms of general industrial volumes of metal galvanizing, hot galvanizing takes almost the first place. This is due to the very high durability of the coating obtained in this way. Its use only at home is hardly possible, since the process is quite complex, costly and unfavorable from the point of view of environmental safety. Equipment for hot-dip galvanizing is expensive and inaccessible.

Hot galvanizing occurs by immersing the part in a container with liquid zinc, molten at a temperature of 500 to 4500 ° C. Naturally, in a simple household, it is quite difficult to obtain such a coating. In addition, the preparation of the metal surface requires certain exposure to chemical processes, which can be harmful to health if strict protective measures are not taken.

Gas-thermal galvanizing method

Galvanizing using this algorithm is carried out by spraying. This method is good only in cases where it is necessary to process large surfaces and in large batches. Otherwise, the profitability of this method will be questionable. Galvanization using the gas-thermal method is carried out by spraying powdered zinc or zinc in the form of a thin wire. Zinc is supplied to the metal in molten and sprayed form.

It is used in cases where the dimensions of the product do not allow it to be placed in a bath of liquid zinc, most often these are large-sized metal structures. After galvanizing, the metal surface is a porous coating, and the pores are most often filled with paint and varnish material.

Due to its strength properties and resistance to aggressive environments, this combined coating is considered one of the most durable and can preserve metal even in salt water for 25-35 years.

Thermo-diffuse and galvanic galvanization

During thermal-diffuse galvanizing of metals, a protective coating is obtained on the basis of atomic bonds between zinc and iron atoms, resulting in the formation of a durable zinc alloy with a complex structure. This effect can only be achieved when the zinc enters the evaporation phase, and this is possible only at a temperature of at least 2500 ° C. The peculiarity of the process is that it takes place in a closed volume, is completely safe for health, and the zinc layer can be up to 100 microns.

Galvanic galvanizing allows you to obtain a smooth and uniform coating with a precisely maintained layer thickness. As a rule, the thickness of the coating does not exceed 40 microns, but from an aesthetic point of view, this coating is one of the most successful. The galvanizing process is no different from other electrochemical processes in which positively charged particles move from the surface of the zinc to the surface of the workpiece.

Cold galvanizing

This is the most affordable type of galvanizing, since from the point of view of application technology it is no different from conventional painting. The part is painted with a special zinc-containing primer material, which contains up to 90% zinc in its structure.

Firstly, it is good because it can be used in any conditions, including garages and small workshops, and secondly, galvanizing metal, the price of which is tens of times lower than the above methods, can be used in cases where the use of other methods is impossible for various reasons reasons.

Its durability, however, is rather mediocre when compared with other galvanizing methods.

Of the above methods, only the last two can be used at home, however, they help fight corrosion quite effectively. So, not all is lost and any metal structure can be provided with a long life and practical appearance.

Source: https://www.spets-stroy-portal.ru/doma-i-dachi/cinkovanie-metalla-v-domashnih-uslovijah.html