JUN 2022

Difference Between Hot Dip Galvanizing And Electro-Galvanization

In recent years, the requirement of the Galvanization process has been increasing. Most of the industrial sector relies on the galvanization process to get the best-finished products. Besides, enhancing the visual aesthetics of the objects, the galvanization process is also known for offering immense strength and protection, which makes the metal objects durable and long-lasting.

What Do We Mean By Galvanization Process?

The galvanization process is a scientific method used for developing a layer of protective zinc coat on iron and steel objects. With the help of the galvanization process, you can ensure that the iron and steel objects do not lead to corrosion. Even if the objects are coming in contact with water or moisture, the zinc layer on the material will prevent rusting.

If the iron and steel objects are protected with the zinc coat, the rusting process will eat up the material and damage its internal structure. If you want to maintain the strength and efficiency of the objects, it is essential to embrace the galvanization process. This process is in high demand in the manufacturing units. Their end products are perfectly galvanized and also have a sleek look.

When it comes to galvanizing, there are two different techniques.

  • Hot Dip Galvanization
  • Electro-Galvanization

The aim of both the processes is the same – to develop a protective layer on the surface of the iron/steel objects. Apart from that, the procedures have different characteristics that make them unique. Due to the differences in the features of the processes, their applications are varied. While performing the galvanization process, you should maintain proper care and safety. If not, you will end up damaging the material, and the galvanization process will not achieve the best results.

What Is The Difference Between Electro-Galvanization Process And Hot-Dip Galvanization Process?

#1 How Both The Galvanization Process Are Different In The Application Of Zinc Layer

If you consider the hot-dip galvanization process, the layer of zinc is applied to prevent rusting. The iron/steel (or any other metallic object) gets immersed in the pool of melted zinc. The material is left in the bath for a while. It is because the zinc layer bond with the metal surface.

The temperature used during the application of the zinc coat on the metal surface is around – 850 to 900 degrees. It should not be more than that. It is the ideal temperature that will develop a perfect layered coating. The electro-galvanized process achieves the same thing, but with a different approach. In the electro-galvanization process, the layer of zinc is formed but with the support of electricity.

#2 Understanding The Different Between The Formation Of The Zinc Layer

electro-galvanizationThe zinc layer formed with the electro-galvanization process is thinner and sleeker than the layer formed with hot-dip galvanization. Considering the precision value, the thickness of the zinc coat over the metallic surface is about 4 to 7 microns. This value is correct if you employ the electro-galvanization process for metallic objects. In case you are using hot-dip galvanization, the thickness of the zinc coat is about 8 to 9 microns. It shows that the zinc layer in the hot-dip galvanization process is thicker than the electro-galvanization process. Sometimes, the thickness of the zinc layer in the hot-dip process reaches up to 100 microns.

#3 Understanding The Difference In The Cleaning Process

The cleaning process for the electro-galvanization and hot-dip process is different. When you are employing the hot-dip procedure, it is essential to keep the cleaning process rigid. There should be around 7 to 9 baths where the objects get cleaned. All the dirt, debris, and grease are removed. These baths include cleaning, rinsing, using pickling water, align with an alkaline solution. Whereas, if you are using the electro-galvanization process, there is no need for rigid cleaning techniques.

#4 The Difference In The Average Life Expectancy Of The Metallic Objects

hot-dip galvanizingWhen you are using the electro-galvanization process, the layer is thin. Therefore, the average life expectancy is low. Whereas the layer of zinc coat, in the hot-dip process, is thick. This increases the average life expectancy of metallic objects. The service life is about 20 to 40 years on average.

#5 The Final Touch On The Process

There is a difference in the final finish of both the processes. If you want the metallic surfaces to have a proper finish and the best appearance, choose the electro-galvanized process. The layer formed is uniform and makes the objects appear shiny.


Are you looking for the best service provider for the galvanization process? Consult Noble Metals. They have the best staff in the industry. The staff is highly professional and ensures that you get the best services in return for your money. You can visit their website and check out the services right now!

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