Steel galvanizing

Therefore, this type of coating is not sensitive to defects, pinlroles or mechanical damage during service. A typical example is galvanized steel (Zn layer on steel). 

Materials of Construction Suitable materials of constmction are steel, stainless steel, and aluminum 3003. Galvanized steel should not be used. Plastic tanks and lines are not recommended. 

Galvanized steel Cooling tower components, fan blades and shrouds, transfer pipes, plumbing fixtures... 

On galvanized steel, tubercles may develop rapidly at breaches in the zinc layer. Attack is frequently highly localized if aggressive ions such as chloride or sulfate concentrate beneath deposits (Fig. 4.9). 

Oxygen corrosion only occurs on metal surfaces exposed to oxygenated waters. Many commonly used industrial alloys react with dissolved oxygen in water, forming a variety of oxides and hydroxides. However, alloys most seriously affected are cast irons, galvanized steel, and non-stainless steels. Attack occurs in locations where tuberculation also occurs (see Chap. 3). Often, oxygen corrosion is a precursor to tubercle development. 

Carbon steel heat exchangers, cast iron water boxes, screens, pump components, service water system piping, standpipes, fire protection systems, galvanized steel, engine components, and virtually all non-stainless ferrous components are subject to significant corrosion in oxygenated water. 

Figure 5.12 Severely corroded galvanized steel pipe supplying water to a cooling tower fan-bearing system. Where the galvanized metal has been consumed, only a brown rust patch is visible.

The galvanic potential of metals can vary in response to environmental changes such as changes in fluid chemistry, fluid-flow rate, and fluid temperature. For example, at ambient temperatures steel is noble to zinc (as in galvanized steel). In waters of certain chemistries, however, a potential reversal may occur at temperatures above 140°F (60°C), and the zinc becomes noble to the steel. 

With hot-dipped galvanized steel, hydrogen absorption with the formation of blisters can be observed in cathodic protection [38]. 

The assessment for nonalloyed ferrous materials (e.g., mild steel, cast iron) can also be applied generally to hot-dipped galvanized steel. Surface films of corrosion products act favorably in limiting corrosion of the zinc. This strongly retards the development of anodic areas. Surface film formation can also be assessed from the sum of rating numbers [3, 14]. 

Cell formation can easily be detected by measuring potential if coated surfaces with no pores have a more positive potential than uncoated material. Usually this is the case with coated steel in solutions containing oxygen. More negative potentials can only arise with galvanized steel surfaces. Figure 5-4 shows examples of measured cell currents [9,10,16]. 

Fig. 5-4 Cell currents between a coated specimen (5 = 300 cm ) and uncoated steel electrode (5 =1.2 cm ) in NaCl solutions at 25°C. Left shot-peened steel sheet, 150 pva EP-tar. Right hot-dipped galvanized steel sheet, 150 jim EP-tar.

Fig. 13-6 Potential variation of a galvanized steel easing pipe ehannel eathodi-cally protected with a flexible polymer cable anode.

Fig. 13-7 Potential of a cathodically protected special cable with galvanized steel armoring (zinc coating already eorroded).

Materials for metal tanks and installations include plain carbon steel, hot-dipped galvanized steel, stainless steel [e.g., steel No. 1.4571 (AISI 316Ti)], copper and its alloys. The corrosion resistance of these materials in water is very variable and can... 

The electrolysis protection process using impressed current aluminum anodes allows uncoated and hot-dipped galvanized ferrous materials in domestic installations to be protected from corrosion. If impressed current aluminum anodes are installed in water tanks, the pipework is protected by the formation of a film without affecting the potability of the water. With domestic galvanized steel pipes, a marked retardation of the cathodic partial reaction occurs [15]. Electrolytic treatment alters the electrolytic characteristics of the water, as well as internal cathodic protection of the tank and its inserts (e.g., heating elements). The pipe protection relies on colloidal chemical processes and is applied only to new installations and not to old ones already attacked by corrosion. 

Fitzpatrick et al. [41] used small-spot XPS to determine the failure mechanism of adhesively bonded, phosphated hot-dipped galvanized steel (HDGS) upon exposure to a humid environment. Substrates were prepared by applying a phosphate conversion coating and then a chromate rinse to HDGS. Lap joints were prepared from substrates having dimensions of 110 x 20 x 1.2 mm using a polybutadiene (PBD) adhesive with a bond line thickness of 250 p,m. The Joints were exposed to 95% RH at 35 C for 12 months and then pulled to failure. 

Fig.. 24. Schematic drawing of the visual appearance of the failure surfaces of lap joints prepared from hot-dipped galvanized steel substrates. Reproduced by permission of John Wiley and Sons from Ref. [41].

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