Hot Dip Galvanizing
- Process, Properties and Applications (3 day)

Course Overview                                                                     (Online Registration)

This short course systematically and thoroughly covers every aspect of hot dip galvanizing from the process to the properties and applications of galvanized coatings. The course covers design, specification, painting of galvanic steel surfaces, fabrication methods including bolting and welding, inspection, coating life prediction, maintenance and repair of galvanized products. The course will help designers, specifiers, materials engineers, consultants, and fabricators to protect and  improve their steel products.

This corrosion short course can be taken as in-house training course, online course and distance learning course worldwide. It can also be customized to meet the specific needs of your organization.

Download PDF course brochure

1 Corrosion & The Need for Galvanizing

   1.1 The economic, social, political and environmental impacts
   1.2 Liabilities due to corrosion
   1.3 History of galvanizing
   1.4 Basic concepts in corrosion
   1.5 Terminologies and conventions
   1.6 Why do metals corrode
   1.7 How do metals corrode
   1.9 Corrosion prevention methods
   1.10 Galvanic corrosion and properties of zinc and steel
   1.11 Cathodic protection
   1.12 The need for galvanizing

2 Process, Properties and Applications

   2.1   Galvanizing fundamentals
           2.1.1 The different galvanizing processes
           2.1.2 Galvanized coating characteristics
   2.2   Principles of venting
   2.3   Basic venting rules
   2.4   Principles of draining
   2.5   Basic draining rules
   2.6   Principles of avoiding distortion
   2.7   Galvanizing rules to avoid distortion
   2.8   Basic rules - design for galvanizing
   2.9   Metallurgy of the galvanizing process
   2.10 Factors affecting galvanizing quality and service
           2.10.1 Steel surface condition
           2.10.2 Steel metallurgy
           2.10.3 Weld quality
   2.11 Mechanical properties of galvanized coatings
           2.11.1 Strength and ductility
           2.11.2 Embrittlement
           2.11.3 Fatigue strength
   2.12 Other metallic zinc coatings for steel
   2.13 Continuous galvanizing processes
   2.14 Protective life of zinc coatings
           2.14.1 Performance in various environments
           2.14.2 Compatibility of galvanized coatings with various media
           2.14.3 Transport and storage of galvanized products
           2.14.4 Surface (iron) contamination of galvanized products
           2.14.5 Protection of cut edges and damaged areas
           2.14.6 Corrosion rate of galvanized coatings
   2.15 Reliability of coatings for steel
   2.16 Galvanized coatings for buildings and structural steel
   2.17 Galvanizing of fasteners and small components
   2.20 Marking for identification

3 Design, Specification and Inspection of Galvanized Products

   3.1 Size and shape of articles to be galvanized
   3.2 Materials suitable for galvanizing
   3.3 Design and fabrication of components for galvanizing
   3.4 Dimensional stability
   3.5 Galvanized coatings on threaded parts
   3.6 Galvanized coatings on moving parts
   3.7 Design for maximum corrosion protection
   3.8 Metallurgical aspect of design
   3.9 Inspection of work before dispatch to galvanizer
   3.10 Standard specification for hot dip galvanized coatings
   3.11 Standards for galvanized products
   3.12 Inspection of galvanized products
           3.12.1 Hot dip galvanized coating defects: causes and remedies
           3.12.2 Steel defects and their effects on galvanized coatings
           3.12.3 Defects in paint coatings
   3.13 Variations in appearance and their relationship to coating quality
   3.14 Non-destructive testing for coating thickness
   3.15 Reconditioning damaged galvanized surfaces

4 Bolting Galvanized Steel
 
   4.1 Zinc coating for fasteners
   4.2 Influence of galvanized coatings on design
   4.3 Slip factors
   4.4 Structural bolts and bolting technique
   4.5 Design for bolted structural joints
   4.6 Applications of high strength bolts
   4.7 Tightening procedures for high strength bolts
   4.8 Inspection of high strength bolted joints

5 Welding Galvanized Steel

   5.1 GMA welding
         5.1.1 Effect of welding position
         5.1.2 GMA braze welding
         5.1.3 GMA spot welding
   5.2 Manual metal arc welding
   5.3 GTA welding
   5.4 Carbon arc welding
   5.5 Torch welding
   5.6 Reconditioning weld-damaged surfaces
   5.7 Welding fumes

6 Painting Galvanized Steel

   6.1 Painting galvanized steel - duplex coatings
   6.2 Economics of painting galvanized steel
   6.3 Synergistic effect of duplex systems
   6.4 Painting procedures
   6.5 Adhesion
   6.6 Preparation of galvanized surfaces for painitng
   6.7 Pretreatment systems
   6.8 Specilised primers
   6.9 Finish coats
   6.10 Painting recommednations

7 Glossary of galvanizing terms
 

Back to Top

All corrosion courses can be conducted at any time for you as in-house training courses or distance-learning courses. There is no minimum or maximum number of participants required for each course. Public corrosion short courses, seminars and workshops are also conducted regularly. If you are concerned with corrosion in your business, in-house training is a great solution to train a group of employees from Production, Quality Assurance, Inspection & Maintenance, and Technical Sales & Support on corrosion control & corrosion prevention technology. Contents of all corrosion courses can be customized to fit your organization's needs. Requests for in-house training courses, online courses & distance learning courses from overseas countries are also welcome. Click here for course registration online.
 

All corrosion courses can be conducted through online or distance learning. A master hard copy of corrosion course notes can be mailed to your organization or a password may be issued to course participants for accessing the online course materials. Instructions, course assignments, discussions and questions related to the corrosion courses are posted to the website or exchanged through email for a period up to 12 months. Click here for course registration online.

If you are involved in teaching corrosion courses, you may wish to purchase a complete set of the PowerPoint slides and the computerized test banks (in MicroTest format) with solutions. These presentations are suitable for teaching corrosion courses at different levels (from undergraduate to postgraduate) and durations (from 6 hrs to 40 hrs). The PowerPoint slides can be easily edited and customized to your own styles. The test bank contains over 1,000 questions for your use in tutorials, quizzes, tests or examinations. These questions are conveniently grouped into 4 categories in the test bank: (1) true or false, (2) multiple choice, (3) calculation, and (4) reasoning & open-ended discussions).  If you need more information, please contact Corrosion Clinic.

 Copyright © 1995-2009. All rights reserved.