Coil Joining Process For Galvanizing Lines - Welding Galvanized Steel

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Galvanizing Lines

Coil Joining Process For Galvanizing Lines - Welding Galvanized Steel

Galvanizing lines can consist of machinery for coil joining before the galvanizing procedure. While steel can be welded after galvanizing, it requires special precautions such as ventilation due to fumes. Galvanizing is the process of coating steel with zinc. "Coating" is somewhat of a misnomer, however, because the zinc indeed becomes part of the steel. The presume steel is galvanized is to forestall rust and corrosion. When steel is dipped in zinc and exposed to air, the pure zinc undergoes a reaction with oxygen to make zinc oxide. The zinc oxide reacts with carbon dioxide to form zinc carbonate. Zinc carbonate is a dull gray, strong material that commonly stops further corrosion.

Welding galvanized steel not only causes fumes, but any time you weld coated metals, the coating melts and can contaminate the base metal and filler metal. If zinc gets into the weld, it will cause cracks referred to as "zinc penetration cracking" that makes the weld as a whole less strong. This can be avoided by using welds that consist of less than 0.2% silicon in the welds. But with galvanizing lines, it is thorough to do any coil joining before the galvanizing process.

Applications for galvanized steel consist of use in protection barriers, appliances, car body parts, handrails, walling, and roofing. Metal buckets are often galvanized, and galvanized steel is used in ductwork for heating and cooling systems. Also hot dip galvanizing, metal can be galvanized by electroplating, which deposits a layer of zinc from an aqueous electrolyte. This forms a very thin, strong bond.

Thermal diffusion galvanizing creates a zinc coating similar to that produced by hot dip galvanizing. With thermal diffusion galvanizing, zinc is applied in the form of a powder combined with accelerator chemicals. The metal and zinc aggregate are sealed up in a drum, and the drum is rotated in an oven. The accelerator chemicals cause the iron-zinc diffusion, or alloying, takes place at a lower climatic characteristic than does hot dip type galvanizing. Thermal diffusion galvanizing results in a more uniform coating that is more wear-resistant. The process also eliminates need for caustic, acid, and flux baths to prepare the parts for hot dipping.

Since hot dip galvanizing lines use coiled steel, the efficiency of the lines can be improved by using larger coils or by inserting a step to join the end of one coil to the starting of the next, therefore providing the engine with a continuous feed that cuts downtime significantly.

A sequence of machinery that includes a coil joining doing before hot dip galvanizing might go like this:

• pay-off reel
• leveller
• cropping shear
• welding machine
• entry loop accumulator

Typically a welding machine, whether transported or fixed, will consist of a Tig end welder. Tig stands for tungsten inert gas. This type of welder generates heat with an arc of electricity going from a tungsten electrode to the metal welding surface. A sheath of argon gas mixed with carbon dioxide surrounding the electrode keeps the weld as clean and free from debris as possible. The trailing coil end is first sheared and positioned inside the weld station. Then the foremost end of the next coil is sheared and positioned. The welding is automatic.

Tig welding is great for coil joining but it can be dangerous done by hand. There are Tig machines for coil joining where the coil ends to be joined are fed in, automatically welded by the machine, and the newly continuous line of steel then flows onto an entry accumulator.

Processing plants like those with galvanizing lines that use cold rolled steel can feel productivity drops of 20 to 30% when they have to stop yield lines so that a new coil of steel can be threaded in when the old coil runs out. A coil joining engine included in the yield process can cut productivity losses drastically by allowing continuous feeding of coiled steel into the yield machinery.

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