Our process applies a fully fused zinc coating to the exterior surface after seam welding. This is beneficial in that the total circumference of the tube is coated with zinc. This provides an equal amount of protection over the entire surface of the tube including the weld seam. Unlike products manufactured using pre-galvanized materials with a metallized seam, the weld seam does not have the same level of protection as the body of the tube or pipe. It is widely accepted that metallization of the weld seam will fail far more rapidly than the pre-galvanized material. The following graphic illustrates typical performance of various products tested under the ASTM-117B Salt Spray Standard.
Comparison of ASTM-117B Salt Spray Zinc-Tech™ ILG vs. Pre-Galv & Hot Dip Products
The above illustrates the exceptional comparative corrosion performance of products manufactured utilizing our inline galvanizing process.
You may rightly ask, "with an equal level of zinc, how does one process so significantly out-perform the rest"? The answer lies in the process design. The Zinc-Tech™ process applies the highest percentage of "Free Zinc" weight as a percentage of overall coating weight. Fundamentally stated, other galvanizing processes have higher percentage of zinc - iron alloy layers. Our process by nature of its design applies a very thick layer of ductile pure zinc absent of iron. Up to three times greater than that of alternative galvanizing methods. The result is a galvanized coating that due to its composition will resist corrosion at a much higher rate.
(Micrograph of Hot Dip Galvanizing)
Viewing the micrograph it is easy to see the various well defined zinc-iron alloy layers. Note the total % of "free zinc" is approximately 35% of the total coating thickness.
(Micrograph of In-line Galvanizing)
Viewing the corresponding micrograph you will note the compressed zinc-iron alloy layers. Only the base layer which promotes adhesion is well defined. the total % of "free zinc" is approximately 80% of the total coating thickness.
The micrographs above demonstrate the significantly greater concentration of free or pure zinc that is characteristic of Zinc-Tech™ ILG process. This is the fundamental reason for the exceptional corrosion performance exhibited by the products manufactured utilizing our technology.
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