Hot Dip Galvanizing
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About
- Kettles - copper causes premature kettle failure.
- Kettle manufacturer - [1]
- Materials engineered for use in galvanizing operations - the specific property required is? Low in C and Si. It is flange or firebox quality steel. [2]
- Wikipedia - [3]
- Zinc Ammonium Chloride - used as flux - [4]. Zaclon in Ohio makes it. [5]
- Coating thickness for 1/4" and above steel is 85 microns minimum. [6]
- Kettle inspections - tests wall thickness - apparently for wear and complete loss of metal. Wall thickness is measured ultrasonically in situ o a working kettle with molten metal. [7]
- Melting zinc - you can even melt on stovetop, here is a tiny wad of zinc melted into a mini-ingot [8]
Process
From [9]
Howto
- Sand blast
- Base bath - 10 minutes min
- Base bath - 7 minutes min
- Flux - ammonium
- Actual dip - 3.5 minutes (until base metal reaches melt temp of 835F)
- Water - trapped water explodes, and is dangerous, so first dip is dangerous and venting must be assured.
- Zinc - 2400 lb blocks are the feedstock for hot dip baths. This is only 0.1 cubic meter - or 4 cubic feet.
https://www.aisc.org/globalassets/modern-steel/archives/2014/08/2014v08_galvanizing.pdf
More about surface preparation: [10]
Sourcing
- Acid -
- Base - KOH pr NaOH for grease - [11], NaOH doesn't require hot water.
- Ammonium chloride - $2/lb [12]
Zinc Ingots
See Zinc#Sourcing
- [13]
- Carter Alloys, 2" zinc balls [14]
- ACI - [15]
- Ney - [16]
- Industrial Metal Supply - [17]. Do they have ingot?
- Victory - [18]
- Milward - [19]
- Umicore - [20]
- Belmont Brooklyn - [21]
- AEM says zinc - [22]
- Ingots on Thomas Register - [23]
- Zinc Ingot on Thomas Register - [24]
- Zinc on Thomas Register - [25]