Industry News

Specification Analysis and Application Scenario of Intermediate Zinc Layer of Galvanized Steel Wire

December 20, 2024

Zinc Layer Thickness

Hot - dipped Galvanized Steel Wire:

The thickness of the zinc layer in hot - dipped galvanized wire is relatively thick. It usually ranges from about 45 microns to several hundred microns. The minimum allowable thickness in the market is often around 45 microns. The actual thickness depends on various factors such as the composition of the steel base material, the temperature and composition of the zinc - melting bath, and the immersion time. For example, if the steel contains elements that have a strong reaction with zinc (such as silicon), the zinc layer may grow thicker. The growth of the zinc layer is a process of a series of chemical reactions between the steel and the zinc liquid. When the steel is immersed in the zinc - melting bath, a zinc - iron alloy layer is first formed at the interface between the steel and the zinc due to the diffusion of iron and zinc atoms. Then, pure zinc is deposited on the alloy layer.

Electro - Galvanized Steel Wire:

The zinc layer of electro - galvanized wire is much thinner than that of hot - dipped galvanized wire, generally in the range of 3 - 15 microns. The thickness is mainly controlled by electroplating parameters such as current density and electroplating time. In the electroplating process, the wire is used as the cathode, and the zinc plate is used as the anode. Under the action of an electric field, zinc ions in the electroplating solution are reduced and deposited on the surface of the wire to form a zinc layer. A higher current density or a longer electroplating time can increase the thickness of the zinc layer to a certain extent, but if it is too thick, it may lead to problems such as poor adhesion of the zinc layer and an uneven surface.

Adhesion Strength of the Zinc Layer

For both hot - dipped and electro - galvanized wires, the adhesion strength of the zinc layer to the wire substrate is an important specification. In the case of hot - dipped galvanized wire, a good zinc - iron alloy layer can ensure strong adhesion. The formation of the alloy layer is related to the temperature and composition of the zinc bath. If the process is not properly controlled, problems such as peeling of the zinc layer may occur. For electro - galvanized wire, surface pretreatment of the wire (such as pickling, degreasing) before electroplating is crucial to improve the adhesion of the zinc layer. Poor adhesion can lead to the zinc layer falling off during use, reducing the corrosion - resistance performance of the wire.

Surface Quality of the Zinc Layer

The surface of the zinc layer should be smooth and free of obvious defects such as pores, cracks, and unevenness. In hot - dipped galvanized wire, surface defects may be caused by factors such as the presence of impurities in the zinc bath and improper cooling after galvanizing. For electro - galvanized wire, the quality of the electroplating solution and the uniformity of the electric field during electroplating affect the surface quality of the zinc layer. A high - quality zinc layer surface can not only provide better corrosion - resistance performance but also has a better appearance, which is beneficial to applications that require a certain aesthetic.

Application Scenarios of the Intermediate Zinc Layer of Galvanized Wire

Construction Industry:

Building Structures: Galvanized wire is widely used in building structures such as the framework of industrial plants and high - rise buildings. The zinc layer can effectively prevent the steel wire from rusting due to exposure to air and moisture, thereby ensuring the structural integrity and safety of the building. For example, in a coastal area where the air contains a lot of salt, the use of galvanized wire can significantly extend the service life of building structures.

Fencing and Railings: Galvanized wire is used to make fences around residential areas, schools, and industrial parks, as well as railings on balconies and stairs. The corrosion - resistance of the zinc layer can maintain the appearance and function of the fence and railing for a long time. It also provides security and decoration functions.

Wall Reinforcement Mesh: In the construction of masonry structures, galvanized wire mesh is used for wall reinforcement. The zinc layer can prevent the wire from rusting and ensure the long - term effectiveness of the reinforcement.

Automotive Industry:

Vehicle Body Components: Many components of the vehicle body, such as the frame and chassis parts, use galvanized wire. The zinc layer can protect these components from corrosion caused by rain, snow, and road salt, which is very important for ensuring the safety and durability of the vehicle. For example, in a cold area where snow - melting agents are often used on the road, the anti - corrosion performance of the galvanized wire can prevent the vehicle body components from being damaged by corrosion.

Automotive Interior Parts: Some interior parts of the car, such as the seat frame and the support structure of the instrument panel, also use galvanized wire. The corrosion - resistance of the zinc layer can ensure the quality and service life of these parts, and at the same time, it also meets the requirements of interior decoration to a certain extent.

Agriculture and Animal Husbandry:

Fencing for Livestock: Galvanized wire is used to make fences for livestock farms. It can withstand the harsh outdoor environment such as sunlight, rain, and snow, and prevent rusting. This ensures the safety of livestock and the durability of the fence. For example, in a pasture, the galvanized wire fence can be used for a long time without frequent replacement.

Agricultural Tools: Some agricultural tools such as rake handles and hoe frames use galvanized wire. The zinc layer can prevent the tools from rusting due to contact with soil and moisture, which is beneficial to the storage and long - term use of agricultural tools.

Packaging Industry

Galvanized wire is often used for bundling products such as wooden products, paper boxes, and metal pipes. The zinc layer can prevent the wire from rusting during storage and transportation, which is beneficial to protecting the bundled products from being contaminated by rust. At the same time, the strength of the galvanized wire can ensure the firmness of the bundling.