Electrogalvanization is a process that uses electricity to adhere a layer of zinc to steel to prevent rust and corrosion. It is commonly used in products exposed to atmospheric conditions or corrosive elements, and can be enhanced by adding chemicals to the solution. It is different from galvanizing and is more permanent.
Electrogalvanization is a process used in metalworking as a corrosion prevention. An electrolytic galvanizing process, or galvanizing process, adheres a layer of zinc to the surface of the steel to inhibit rust and corrosion. Zinc is not subject to normal corrosion, so this metallic plating protects the steel underneath the plating.
This galvanic process uses a sacrificial zinc anode suspended in a solution of zinc and saline. An electric current is introduced in this setup with the zinc anode connected to the positive side of the power source while the steel to be galvanized is connected to the negative side of the power source. By connecting the power supply in this way, the positively charged zinc ions emitted by the anode are attracted to the negatively charged steel.
This process is used as a corrosion prevention method for a variety of manufactured products. Galvanized nails, screws, wires and pipes are common examples of the products that are treated by electro-galvanizing. Additionally, the automotive industry has made extensive use of the electroplating process to protect body panels, frames, and other automobile components.
The use of electroplating as an anti-corrosion layer is common for products that are used in an environment where they would be exposed to atmospheric conditions or corrosive elements. Products made with electrogalvanized steel remain useful long after the same regular steel product would have been reduced to rust, due to electrogalvanizing’s rustproofing qualities. From metal fences and electro-galvanized steel gates to traffic signs and electrical appliances, electro-galvanizing is used almost anywhere a long-lasting metal product is desirable.
By adding chemical components to the zinc and saline solution used in the electroplating process, further benefits can be achieved. Automakers commonly use a technique called pre-phosphating to improve the surface adhesion of paint to electro-galvanized parts. By adding phosphate salts or other chemicals to the electroplating solution, various benefits, such as better paint adhesion, lubrication or coloring, can become a lasting effect because the chemicals are embedded in the electrolytic zinc layer.
Electrogalvanizing is not the same process as galvanizing. The electro-galvanizing process requires the use of electricity to create a layer of zinc on the steel conductor. This process is more permanent than galvanizing through processes such as hot dip because the zinc actually adheres to the steel at a molecular level rather than simply being a coating added to the steel. This is an important distinction, but misidentification of zinc plating as electrogalvanizing is quite common.
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