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Galvanization is one of the most widely used to methods for protecting metal from corrosion. It involves applying a thin coating of zinc to a thicker base metal, helping to shield it from the surrounding environment. The next time you are in your car, take a look at the street signs and lamp posts you pass. A large number of them will have a mute, silver color on them. That “silver” is actually the coating of zinc.
As the name implies, this method involves dipping the base metal into a molten pool of zinc. First, the base metal must be cleaned either mechanically, chemically, or both to assure a quality bond can be made between the base metal and the zinc coating. Once cleaned, the base metal is then fluxed to rid it of any residual oxides that might remain after the cleaning process. The base metal is then dipped into a liquid bath of heated zinc and a metallurgical bond is formed.
The advantages of this method are that it is economical; it can be performed quickly and to complex shapes. However, the final coating can be inconsistent relative to other Galvanization processes.