Galfan Wire Hot Dip Galvanizing Process
Galfan wire is a type of steel wire galvanized through the hot dipping process. It is a zinc-coated wire made using one of two different processes of galvanizing. Hot dipping is the process of submerging steel wire into a molten zinc solution, which forms a protective shield, providing an extra layer of protection against rust and corrosion.
Hot dip galvanizing is the most common process used to produce Galfan wire, as it has been discovered to provide superior resistance to corrosion, rust, and other damage compared to other types of metallic coatings. Galfan hot dip galvanizing requires certain steps in order to create a finished product that is reliable and long lasting.
The first step of the hot dip galvanizing process involves the cleaning of the steel wire. Removing any dirt, grease, or other contaminants on the surface of the steel helps promote an optimal reaction between the two metals during the galvanizing process. The hot dip galvanizing line includes an alkaline cleaning system, usually a batch arrangement, which cleans the wire at a temperature of around 50 to 80 °C, using a detergent such as Caustic soda, Phosphoric acid or Sulfuric acid. After the cleaning step, the wire is rinsed with water and then dried.
The next step in the Galfan hot dip galvanizing process is the immersion of the wire into a molten zinc bath. The zinc is heated to a temperature of about 450 to 460 °C, which is high enough for the zinc to melt and form a thin coating on the surface of the wire. In the molten zinc bath, the zinc molecules react with the molecules in the steel, forming an inseparable combination of both elements.
After the wire has been immersed, the galvanized wire is subjected to a cooling process. This allows the zinc coating to solidify and become an integral part of the wire structure. This provides an extra layer of protection against corrosion and rust, as zinc is a more reactive element than steel and takes much longer to degrade in harsh environments. The cooling process also removes any excess zinc that did not join to the steel and is preventing it from forming clogs or voids.
Since Galfan wire is a zinc-coated steel wire, it is very important to ensure that no zinc is removed from the wire during the galvanizing process. To ensure this, a post-galvanizing operation known as passivation is used. This involves the exposure of the wire to a solution of chromium, which forms an extra thin layer of protection on the surface of the wire that prevents any oxidation from taking place. The amount of the chromium added is usually controlled in order to ensure a consistent protective layer without compromising the structural integrity of the wire.
In conclusion, the Galfan hot dip galvanizing process provides a reliable and long-lasting protective coating that enhances the reliability of the steel wire and provides extra protection against rust and corrosion. The process also allows for a consistent bond between the zinc and steel, ensuring a tight protective layer. The addition of the passivation step reinforces this layer by providing an extra layer of protection that prevents any oxidation from taking place.
