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Abstract

The paper presents the results of investigations of the growth of protective coating on the surface of ductile iron casting during the hot-dip

galvanizing treatment. Ductile iron of the EN-GJS-600-3 grade was melted and two moulds made by different technologies were poured to

obtain castings with different surface roughness parameters. After the determination of surface roughness, the hot-dip galvanizing

treatment was carried out. Based on the results of investigations, the effect of casting surface roughness on the kinetics of the zinc coating

growth was evaluated. It was found that surface roughness exerts an important effect on the thickness of produced zinc coating

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Authors and Affiliations

D. Kopyciński
E. Guzik
A. Szczęsny
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Abstract

The article presents the method to assess the diffusion coefficient D in the sub-layer of intermetallic phases formed during hot-dip

galvanizing “Armco” iron and ductile cast iron EN-GJS-500-7. Hot-dip galvanizing is one of the most popular forms of long-term

protection of Fe-C alloys against corrosion. The process for producing a protective layer of sufficient quality is closely related to diffusion

of atoms of zinc and iron. The simulation consist in performed a hot-dip galvanizing in laboratory condition above Fe-C alloys, in the

Department of Engineering of Cast Alloys and Composites. Galvanizing time ranged from 15 to 300 seconds. Then metallographic

specimens were prepared, intermetallic layers were measured and diffusion coefficient (D) were calculated. It was found that the diffusion

coefficient obtained during hot-dip galvanizing “Armco” iron and zinc is about two orders of magnitude less than the coefficient obtained

on ductile cast iron EN-GJS-500-7.

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Authors and Affiliations

D. Kopyciński
E. Guzik
A. Szczęsny
D. Siekaniec
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Abstract

This paper presents the effect of the addition of Ti to the zinc bath. Hot-Dip Galvanizing was carried out on a machined ductile cast iron substrate. The process was carried out at 550°C. Experimental baths A, B and C contained 0.01%, 0.05% and 0.1%Ti, respectively. Metallographic samples were prepared to reveal the microstructure of the coatings. Thickness measurements of the obtained coatings were carried out, and graphs of the approximate crystallization kinetics of the zinc coating were prepared. High-temperature galvanization carried out on the treated surface led to the release of graphite beads from the metal matrix and their diffusion into the coating. This phenomenon can have an adverse effect on the continuity of the coating and its adhesion to the substrate. Crystallization of the δ phase was observed in the coating, and at longer immersion times – a mixture of two-phase δ1 and η phases. With increasing Ti content in the bath, a deterioration in the casting properties of the bath was observed.
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Bibliography

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[3] Kopyciński, D., Guzik, E. & Szczęsny, A. (2014). The effect of the number of eutectic grains on coating growth during hot dip galvanising of ductile iron castings. Archives of Foundry Engineering. 14(1), 67-70. ISSN (1897-3310).
[4] Kania, H. & Liberski, P. (2014). The structure and growth kinetics of zinc coatings on link chains produced of the 23MnNiCrMo5-2 steel. Solid State Phenomena. 212, 145- 150. DOI:10.4028/www.scientific.net/SSP.212.145.
[5] Kopyciński, D., Guzik, E., Szczęsny, A. & Siekaniec, D. (2015). Growth kinetics of the protective coating during high- and low- temperature process of hot dip galvanizing of ductile iron castings. Archives of Foundry Engineering. 15(spec.2), 47-50. ISSN (1897-3310). (in Polish).
[6] Kopyciński, D. (2015). Sequence of formation of intermetallic phases in a zinc coating. Inżynieria Materiałowa. 5(207), 251-255 DOI 10.15199/28.2015.5.10. (in Polish).
[7] Di Cocco, V. (2012). Sn and Ti influences on intermetallic phases damage in hot dip galvanizing. Frattura ed Integrità Strutturale. 22, 31-38. DOI: 10.3221/IGF-ESIS.22.05.
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[37] Jędrzejczyk, D. & Hajduga, M. (2011). Effect of the surface oxidation on the hot-dip zinc galvanizing of cast iron. Archives of Metallurgy and Materials. 56(3), 839-849. https://doi.org/10.2478/v10172-011-0093-x.
[38] Jędrzejczyk. D. (2010). The influence of high-temperature treatment of cast iron on the structure of the surface layer formed as a result of hot-dip galvanizing. Ochrona przed Korozją. 2, 46-48.
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Authors and Affiliations

Karolina Bracka-Kęsek
1
ORCID: ORCID
Andrzej Szczęsny
1
ORCID: ORCID
Dariusz Kopyciński
1
ORCID: ORCID
Edward Guzik
1
ORCID: ORCID

  1. AGH University of Science and Technology, Department of Foundry Engineering, Al. Mickiewicza 30, 30-059 Kraków, Poland
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Abstract

The purpose of this scientific paper is to follow the influence of thermal galvanizing, as a technological process on the quality of the galvanized surface. The galvanizing technology used and studied involves at the end of the process, the removal of excess zinc from the surface by centrifugation. The zinc layer will be lower than that of simple immersion galvanizing. The measurements were performed following the roughness of the machined surface on a five-Section specimen – each Section being processed with a different cutting regime. The results were analyzed after each operation. The first measurements were made after the turning operation, followed by measurements made after pickling and fluxing and then after thermal galvanizing. Based on the results obtained, the aim was to set up a range of best roughness at which the galvanized part should have a commercial appearance and be made with a cost-effective cutting regime in terms of costs.
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Authors and Affiliations

Sandor Ravai-Nagy
1
ORCID: ORCID
Alina Bianca Pop
1
ORCID: ORCID
Marcin Nabiałek
2
ORCID: ORCID
Costin Alexandru
3
ORCID: ORCID
Mihail Aurel Țîțu
4
ORCID: ORCID

  1. Technical University of Cluj-Napoca, Northern Un iversity Cent re of Baia Mare, Faculty of Engineering – Department of Engineering and Technology Management , 62A, Vict or Babes Street, 430083, Baia Mare, Maramures, Romania
  2. Częstochowa University of Technology, Department of Physics , Armii Krajowej 19 Av., 42-200 Częstochowa
  3. Electro Sistem, 4B, 8 Martie Street, 430406, Baia Mare, Maramures, Romania
  4. ”Lucian Blaga” University of Sibiu, Faculty of Engineering, Industrial Engineering and Management Department , 10 Victoriei Street, 550024, Sibiu, Romania
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Abstract

The paper discusses experimental studies to determine the effect of the die working portion angle on the lubrication conditions, zinc coating thickness and the mechanical properties of medium-carbon steel wires. The test material was 5.5 mm-diameter wire rod which was drawn into 2.2 mm-diameter wire in seven draws at a drawing speed of v = 10 m/s. Conventional drawing dies of a working portion angle of α = 3, 4, 5, 6, 7°, respectively, were used for the drawing process. After the drawing process, the quantity of the lubricant on the wire surface and the thickness of the zinc coating were determined in individual draws. Testing the finished 2.2 mm-diameter wires for mechanical properties, on the other hand, determined the effect of the die working portion on the yield point, tensile strength, uniform and total elongation, reduction in area, the number of twists and the number of bends.

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Authors and Affiliations

M. Suliga
R. Wartacz
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Abstract

A Si-Fe-Al ternary oxide-based micropowder coating was used to prevent the formation of a Zn coating on steel during the hot-dip Zn galvanizing process to reduce the welding fume and defects generated during the welding of Zn-galvanized steel. The composition ratio of the oxide powder was optimized and its microstructure and weldability were evaluated. The optimized oxide coating was stable in the hot-dip galvanizing bath at 470°C and effectively inhibited the formation of Zn coating. The Zn residue could be easily removed with simple mechanical impact. The proposed coating reduced Zn fume and prevented the residual Zn from melting in the weld bead during high-temperature welding, thus reducing the number of welding defects. The results indicated that this pretreatment can simplify the manufacturing process and shorten the process time cost-effectively.
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Authors and Affiliations

Seong-Min So
1
Ki-Yeon Kim
1
Il-Song Park
1
ORCID: ORCID
Seok-Jae Lee
1
ORCID: ORCID
Dong-Jin Yoo
2
Yeon-Won Kim
3
ORCID: ORCID
Min-Suk Oh
1
ORCID: ORCID

  1. Jeonbuk National University, Division of Advanced Materials Engineering, Jeonju, Republic of Korea
  2. Jeonbuk National University, Department of Energy Storage/Conversion Engineering Of Graduate School, Department of Life Science, Hydrogen and Fuel Cell Research Center, Jeonju, Republic of Korea
  3. Mokpo National Maritime University, Division of Marine Mechatronics, Mokpo, Republic of Korea
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Abstract

The growth kinetics of the zinc coating formed on the surface of casting made from ductile iron grade EN-GJS-500-3 was investigated. To produce homogenous metal matrix in test samples, the normalising and ferritising annealing was carried out. Studies showed a heterogeneous structure of cast iron with varying content of the phases formed. This was followed by hot dip galvanising treatment at 450°C to capture the growth kinetics of the zinc coating (the time of the treatment ranged from 60 to 600 seconds). Nonlinear estimation of the determined growth kinetics of the alloyed layer of a zinc coating was made and an equation of the zinc coating growth was derived. Based on the results of the investigations it was concluded that thickness of the zinc coating formed on the surface of casting with a 100% pearlitic matrix makes 55% of the thickness of coating formed on the surface in 100% ferritic.

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Authors and Affiliations

D. Kopyciński
A. Szczęsny
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Abstract

In this study, the surface roughness of galvannealed low carbon Al-killed and Ti-Nb stabilized interstitial free steels was investigated using the industrial galvannealing process parameters. The iron content of the coatings was also analysed to establish a relationship with the surface roughness and coating composition. The surface roughness displayed an exponential behaviour with increasing of annealing time at each annealing temperature in both steel coatings, which was in an increasing order in the galvannealed low carbon Al-killed steel coating, whereas it was a reverse order in the galvannealed Ti-Nb stabilized interstitial free steel coating. The craters were observed on the galvannealed coatings resulting in high surface roughness. Increasing the iron content of the coatings leads to a reduction in the surface roughness with δ1k phase.
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Bibliography

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Authors and Affiliations

Candan Sen Elkoca
1
ORCID: ORCID
Bulent Ekmekci
2
ORCID: ORCID
Oktay Elkoca
3
ORCID: ORCID

  1. Bulent Ecevit University, Alapli Vocational High School, Zonguldak 67850, Turkey
  2. Bulent Ecevit University, Department of Mechanical Engineering, Zonguldak 67100, Turkey
  3. Duzce University, Department of Mechanical Engineering, Duzce 81620, Turkey

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