Steel is a strong, durable metal used to fabricate products for all kinds of industries, from construction to automotive to aerospace. The problem with steel is that it’s made of mostly iron, which rusts and corrodes when exposed to moisture.
The galvanization process takes steel to the next level by adding extra resistance to corrosion and rust, extending the metal’s lifespan, and ensuring ease of maintenance.
Keep reading to learn more about the benefits of using galvanized steel in your fabrication endeavors, common applications of this versatile material, and tips for successful machining.
What is Galvanized Steel?
First, let’s go over what exactly galvanized steel is and how it’s created. Essentially, it’s steel with a protective zinc coating. It’s commonly created by dipping steel into molten zinc in a process known as hot-dipping, which creates a chemical bond between the two metals.
Electro-galvanizing is another way to create galvanized steel. It involves electroplating, which involves submerging steel in a zinc salt solution. When an electric current is applied, it creates a reaction that bonds the zinc salt to the surface of the steel, creating a thin layer of zinc.
Galvannealing is a combination of hot-dipping and annealing. After hot-dipping the steel, it’s heated in an annealing oven to create an alloy between the steel and zinc. This process produces a specialized coating with a matte finish ideal for painting.
No matter what process is used to create it, the purpose of galvanized steel is to enhance corrosion resistance, defend against rust, extend the material’s lifespan, and make visual inspections and stress tests easier.
Benefits of Using Galvanized Steel in Metal Fabrication
While steel is a powerful metal on its own, galvanized steel provides many advantages, including:
- Corrosion resistance and longevity: When you opt for galvanized steel, you don’t have to worry about corrosion over time. Under normal conditions, your product can remain in good condition for 50 years or more.
- Cost-effectiveness: Compared to stainless steel, galvanized steel is more affordable, making it a better choice for budget-conscious fabricators.
- Low maintenance requirements: With this material’s enhanced strength and durability, there’s a reduced need for repairs and replacements.
- Strength and durability: Galvanized steel’s strength and durability make it ideal for a wide range of applications in various industries.
- Environmentally friendly: Galvanized steel scraps can be recycled into refined zinc, enhancing the sustainability of your workshop. However, the recycling process can create toxic fumes, so be aware of the potential environmental risks as you choose a recycling partner.
Common Applications in Metal Fabrication
Thanks to its versatility, galvanized steel has a wide range of applications. Because it’s corrosion-resistant, it’s commonly used in outdoor spaces that are exposed to water. Industries that take advantage of this durable metal include:
- Construction and infrastructure (beams, building frames, bridges, roofing materials, balconies, staircases)
- Automotive industry (car frames, body panels)
- Aerospace
- Industrial machinery and equipment
- HVAC and ductwork systems
- Outdoor and agricultural structures (fences, guardrails, irrigation systems, waste management, grain storage)
- Telecommunications (phone wires, outlet boxes, and equipment boxes)
- Energy (solar racking and ground mounts)
- Electronics (computer cases and electronic devices)
Challenges of Working with Galvanized Steel
However, despite all the advantages of galvanized steel, it can sometimes be challenging to work with. As you work with galvanized steel, avoid excessive force, which can crack the zinc layer. You should also keep in mind that this material tends to return slightly to its original shape, so it’s important to account for springback.
When welding this material, you must take extra safety precautions because of the zinc oxide fumes released. Inhaling these fumes can cause lung damage, cancer, and a flu-like illness known as metal fume fever. Use fume exhaust hoods, air cleaners, and source extractors to protect yourself from adverse effects.
Additionally, if it was not galvanized using galvannealing, the metal might require surface preparation if you plan to paint it or add additional coatings. Without careful preparation, the coatings may not adhere properly.
Fabrication Equipment for Galvanized Steel
Cutting galvanized steel requires the right equipment to avoid damaging the zinc coating. Plasma cutters, shears, saws, and laser cutters can all get the job done. For forming and bending, opt for press brakes or roll forming machines, which minimize stress on the metal.
Metal Fabrication Machinery for Every Application
No matter what type of metal you’re working with, Sanson Machinery has the reliable equipment you need to create high-quality products. Explore our new and used machinery online and contact us to request a quote.