HOT-DIP GALVANIZING OF STEEL WIRE:
AN EFFECTIVE BARRIER AGAINST CORROSION
Hot-dip galvanizing is an industrial process by which a zinc coating is applied to steel products to protect them from corrosion.
The galvanizing process can take place using various methods, but hot dip galvanizing is the most suitable method for protecting steel rope wire from external aggression and thus improving both its performance and durability.
Hot-dip galvanized steel wire
THE PROCESS OF HOT DIP GALVANISING STEEL WIRE IS CARRIED OUT THROUGH A SERIES OF MAIN STEPS THAT OCCUR IN LINE IN THE FOLLOWING ORDER:
- Surface preparation: The steel wire is thoroughly cleaned to remove all traces of dirt, grease, rust or other contaminants that could hinder zinc adhesion. This process is generally carried out by degreasing, acid pickling and fluxing.
- Immersion in molten zinc: the steel wire is immersed in a bath of molten zinc at a temperature of approximately 450°C. The molten zinc reacts with the steel surface to form an iron-zinc alloy.
- Removal of excess zinc: Once removed from the zinc bath, the wire is drained to remove excess zinc.
- Cooling: The wire is cooled in air or water.
- Quality control: The galvanized wire is finally checked for thickness and uniformity of the zinc coating.
The advantages of hot-dip galvanizing steel wire are numerous:
- High corrosion resistance: Zinc offers excellent protection against rust and other corrosive agents, extending the life of the steel wire.
- Strength: The iron-zinc alloy gives the wire greater strength and hardness.
- Excellent adhesion: The zinc coating adheres very well to the steel surface, creating a durable protective barrier.
- Versatility: Hot-dip galvanizing is suitable for a wide range of applications, both internal and external.
- Competitive costs: Compared to other corrosion protection methods, hot dip galvanizing offers good value for money.
Much of the above-mentioned advantages are attributable to the fact that « the metallic zinc layer that coats the steel is not a simple covering film. During immersion in molten zinc, a actual iron-zinc alloy is formed which, as such, clings tenaciously to the steel and can only be removed by strong mechanical action or strong acid solutions. »1
Our ropes are produced with normal or high galvanized wire (class B or class A) depending on the amount of zinc required for their final application.
Galvanized wire ropes are used in various sectors. In some of them, such as fishing, agriculture or earthing systems, it is necessary for the wire to have a thicker zinc coating, the one provided by rich galvanizing.
APPLICATIONS OF HOT-DIP GALVANISED STEEL WIRE:
- Telecommunications: telephone lines, telephone communication systems and data networks.
- Power lines: aerial overhead and underground power lines.
- Fences: galvanized wire is widely used for the construction of fences, gates and barriers.
- Construction: galvanized wire is used in various construction applications, such as reinforcing concrete and making reinforcement.
- Earthing installations: electrical earthing and grounding systems.
- Agriculture: agricultural fencing, protection and anti-hail installations for vineyards and orchards, barbed wire.
- Fishing: steel wire ropes and combination ropes made with steel and fiber.
Hot-dip galvanization is therefore, of all the alternatives, the choice of choice to guarantee the steel wire, and therefore the rope, the greatest resistance to corrosion in critical and hostile environments such as the maritime environment and all those where the rope is exposed to the aggressions of atmospheric agents.
The careful choice of selected and reliable suppliers, capable of guaranteeing top-quality hot-dip galvanized steel wire consistently over time, is an essential prerequisite for producing well-made and high-performance wire ropes.