The difference between cold-dip galvanizing and hot-dip galvanizing in steel pipe processing
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- May 28,2025
Summary
Hot-dip galvanizing and cold-dip galvanizing are both methods of applying zinc to steel to prevent corrosion, but they vary greatly in process, durability, and cost.
Hot Dip VS Cold Dip Galvanizing
Hot-dip galvanizing and cold galvanizing are both methods for coating steel with zinc to prevent corrosion, but they differ significantly in process, durability, and cost. Hot-dip galvanizing involves dipping steel into a molten bath of zinc, creating a durable, chemically bonded zinc layer. Cold galvanizing, on the other hand, is a process where a zinc-rich coating is applied, often by spraying or painting.
In steel pipe processing, galvanizing is a key process to improve corrosion resistance, which is mainly divided into two methods: hot-dip galvanizing (HDG) and cold galvanizing (Electro-Galvanizing, EG). There are significant differences between the two in terms of processing principles, coating characteristics, and applicable scenarios. The following is a detailed analysis from the dimensions of processing methods, principles, performance comparison, and application fields:
1. Comparison of processing methods and principles
1. Hot-dip galvanizing (HDG)
Processing process: The steel pipe is immersed in molten zinc liquid, and zinc and iron react to form an alloy layer.
Coating formation principle:
Metallurgical bonding: Molten zinc reacts with the steel pipe matrix to form a Fe-Zn layer (Γ phase Fe₃Zn₁₀, δ phase FeZn₇, etc.), and the outer layer is a pure zinc layer.
2. Cold galvanizing (electrogalvanizing, EG)
Processing process: The steel pipe is immersed in an electrolyte containing zinc ions as a cathode, and a zinc layer is deposited by direct current.
Coating formation principle:
Electrochemical deposition: Zinc ions (Zn²⁺) are reduced to zinc atoms by electrons on the cathode (steel pipe) surface to form a uniform coating (without alloy layer).
2. Process Difference Analysis
1. Coating structure
Hot-dip galvanizing:
Layered structure: substrate → Fe-Zn alloy layer → pure zinc layer. The alloy layer has high hardness and provides additional protection.
Cold galvanizing:
Single zinc layer, no alloy transition, easy to cause corrosion spread due to mechanical damage.
2. Adhesion test
Hot-dip galvanizing: After bending test or hammer test, the coating is not easy to peel off (the alloy layer is tightly bonded to the substrate).
Cold galvanizing: The coating may fall off due to external force (such as "peeling" phenomenon after scratching).
3. Corrosion resistance mechanism
Hot-dip galvanizing:
Sacrificial anode + barrier protection: The zinc layer corrodes first, and the alloy layer delays the spread of rust to the substrate.
Cold galvanizing:
Mainly relies on barrier protection, and the substrate is prone to corrosion after the coating is damaged.
3. Application scenario selection
3. Application scenario selection
Applicable scenarios for hot-dip galvanized steel pipes
Harsh environments: outdoor structures (transmission towers, bridges), underground pipelines, marine facilities.
High durability requirements: building scaffolding, highway guardrails.
Applicable scenarios for cold-dip galvanized steel pipes
Mild corrosion environment: indoor electrical conduit, furniture frame, automotive parts.
High appearance requirements: home appliance housing, decorative pipes (smooth surface and uniform color are required).
Cost-sensitive projects: temporary facilities, low-budget projects.