Research and Innovative Application of "Zinc Flower" Control Technology for Galvanized Coils

Galvanized coils, as important deep - processed steel products, are widely used in various industries such as construction, household appliances, and automobiles. The morphology of the "zinc flower" on their surface not only affects the appearance quality of the products but also has a close relationship with the corrosion resistance of the galvanized layer. Therefore, the research and innovative application of "zinc flower" control technology for galvanized coils are of great practical significance.

During the hot - dip galvanizing process, the zinc liquid solidifies and crystallizes on the surface of the steel to form a zinc layer. The formation of zinc flowers is the external manifestation of zinc crystallization during the solidification process. When the zinc liquid cools down from a high temperature, zinc atoms begin to arrange regularly to form crystals. If there are some specific elements in the zinc liquid, such as lead, antimony, bismuth, etc., they will affect the crystallization process of zinc, thus forming zinc flowers of different shapes and sizes. For example, lead elements can act as crystal nuclei for zinc crystallization, promoting zinc to crystallize and grow around them, thereby forming larger zinc flowers.

Traditional "zinc flower" control technologies mainly include adjusting the composition of the zinc liquid and controlling the cooling rate. In terms of adjusting the zinc liquid composition, appropriate alloying elements are added to control the size and morphology of zinc flowers. For example, adding lead can obtain large zinc flowers, but due to the toxicity of lead, its application has been greatly restricted in the context of increasingly strict environmental protection requirements. In terms of cooling rate control, different cooling methods such as air cooling and water cooling are used. However, traditional cooling methods have limited ability to precisely control zinc flowers, making it difficult to meet the increasingly high requirements for the surface quality of galvanized coils in modern high - end manufacturing industries. Moreover, in large - scale production, the stability of product quality also has certain fluctuations.

In recent years, researchers have been constantly exploring new alloy elements or element combinations to replace traditional harmful elements. For example, by adding rare earth elements such as cerium and lanthanum, it has been found that they can play a unique regulatory role in the formation and growth of zinc flowers without affecting the corrosion resistance of the galvanized layer. Rare earth elements can refine the grains of zinc, thus obtaining more uniform and finer zinc flowers, and improving the surface quality of galvanized coils. In addition, the composite addition technology of some micro - alloying elements is also constantly developing. By precisely controlling the proportion of multiple elements, the precise regulation of the morphology of zinc flowers can be achieved.

Advanced cooling technologies such as atomized air cooling and spray cooling are gradually being applied to the production of galvanized coils. Atomized air cooling combines the advantages of gas cooling and liquid cooling, enabling more precise control of the cooling rate and cooling uniformity. By accurately controlling parameters such as the flow rate, temperature, and spray angle of the cooling medium, the effective intervention in the growth process of zinc flowers can be realized. For example, using different cooling intensities at specific cooling stages can guide zinc atoms to crystallize in the expected way and form the desired zinc flower morphology. At the same time, intelligent cooling control systems are also constantly evolving. By real - time monitoring the temperature and surface condition of galvanized coils, the cooling parameters are automatically adjusted, further improving the accuracy of "zinc flower" control.

In household appliance manufacturing, the appearance quality of galvanized coils is of crucial importance. Through innovative "zinc flower" control technologies, galvanized coils with ultra - small zinc flowers or no zinc flowers can be produced, which can meet the requirements for a beautiful and flat surface of household appliance casings. Galvanized coils without zinc flowers have a mirror - smooth surface, and after painting, they can present a high - end and fashionable appearance effect, enhancing the market competitiveness of household appliance products. At the same time, the precisely controlled zinc flower morphology also helps to improve the adhesion between the galvanized layer and the coating, prolonging the service life of household appliance casings.

Automobile bodies use galvanized coils to improve corrosion resistance. Innovative "zinc flower" control technologies can produce galvanized coils with special zinc flower structures, which can meet the requirements of processes such as stamping and welding in automobile manufacturing while ensuring good corrosion resistance. For example, by controlling the size and distribution of zinc flowers, the galvanized layer can better adapt to the deformation of the steel during the stamping process, avoiding problems such as zinc layer spalling. In addition, the uniformly fine zinc flower structure helps to improve the electrophoretic coating quality of automobile bodies, making the appearance of the body more beautiful and the corrosion resistance more excellent.

In the construction field, galvanized coils are often used in structures such as roofs and walls. Galvanized coils produced by using innovative "zinc flower" control technologies have significantly improved corrosion resistance and appearance quality. For some high - end construction projects, customized zinc flower morphologies can add a unique aesthetic feeling to the building appearance. At the same time, by optimizing the zinc flower structure, the atmospheric corrosion resistance of the galvanized layer is improved, the service life of building components is extended, and the maintenance cost is reduced.

The research and innovative application of "zinc flower" control technology for galvanized coils is a continuous development process. From the in - depth understanding of the formation principle of "zinc flowers", to the improvement of traditional technologies and the exploration of new technologies, each step promotes the improvement of the quality of galvanized coils. With the continuous development and improvement of new alloy element addition technologies and advanced cooling technologies, as well as their innovative applications in various industries, galvanized coils will play an important role in more high - end fields, meeting the constantly upgrading market demands and providing strong support for the development of related industries. In the future, with the continuous progress of science and technology, the "zinc flower" control technology for galvanized coils is expected to achieve greater breakthroughs, bringing new development opportunities for the galvanized coil industry.