{"id":14759,"date":"2021-01-09T02:46:13","date_gmt":"2021-01-09T01:46:13","guid":{"rendered":"https:\/\/verzinkshop.nl\/zinc-galvanizing-problems-and-solutions\/"},"modified":"2025-12-08T01:56:17","modified_gmt":"2025-12-08T00:56:17","slug":"zinc-galvanizing-problems-and-solutions","status":"publish","type":"post","link":"https:\/\/verzinkshop.nl\/en\/zinc-galvanizing-problems-and-solutions\/","title":{"rendered":"Zinc Galvanizing Problems and Solutions"},"content":{"rendered":"\t\t
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Here is a list of the problems that can occur during the galvanizing of objects and the corresponding solutions.<\/p>\n

Zinc galvanizing \u2013 problems and solutions<\/h2>\n\n\n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n \n
Problem<\/th>\n Solution<\/th>\n <\/tr>\n <\/thead>\n
General dullness:<\/strong><\/td>\n <\/td>\n <\/tr>\n
1. Too much or too little brightener<\/td>\n Perform a Hull-cell test (1 ampere \u2013 15 min) to determine the correct amount.<\/td>\n <\/tr>\n
2. Bad ingredients out of balance<\/td>\n Perform a Hull cell test (1 ampere \u2013 15 min) to determine the correct amount.<\/td>\n <\/tr>\n
3. Poor cleaning<\/td>\n Check the cleaning agents.<\/td>\n <\/tr>\n
4. High Temperature<\/td>\n Reduce the temperature to 27\u00b0C or add brightener to compensate (if no cooling is available).<\/td>\n <\/tr>\n
5. Insufficient agitation<\/td>\n Adjust the agitation.<\/td>\n <\/tr>\n
6. High pH<\/td>\n Lower the pH with hydrochloric acid.<\/td>\n <\/tr>\n
7. Low level ammonium chloride for the glazing agent<\/td>\n Perform an analysis to determine the correct addition (rapid increase in pH indicates low concentration of ammonium chloride agent).<\/td>\n <\/tr>\n
8. Organic Contamination or Metal Contamination<\/td>\n Treat with carbon: 0.5 to 1 gram per liter, or carbon together with 1 gram of hydrogen peroxide per liter. Treat the bath with 0.5 to 1 gram of potassium permanganate per liter. Treat with zinc dust.<\/td>\n <\/tr>\n
9. Low Chloride Content<\/td>\n Perform an analysis to determine the appropriate addition.<\/td>\n <\/tr>\n\n
High current density combustion:<\/strong><\/td>\n <\/td>\n <\/tr>\n
1. Excessive current<\/td>\n Reduce the amperage in the bath.<\/td>\n <\/tr>\n
2. Bad ingredients out of balance<\/td>\n Perform a Hull cell test (1 ampere \u2013 15 min) to determine the correct amount.<\/td>\n <\/tr>\n
3. Low zinc concentration<\/td>\n Maintain the zinc metal concentration in an optimal range by adding zinc chloride.<\/td>\n <\/tr>\n
4. Low temperature<\/td>\n Increase the temperature to 29\u00b0C.<\/td>\n <\/tr>\n
5. Low level ammonium chloride for the brightener<\/td>\n Perform an analysis to determine the correct addition (rapid increase in pH indicates low concentration of buffering agent).<\/td>\n <\/tr>\n
6. High pH<\/td>\n Lower the pH with hydrochloric acid to 5.3<\/td>\n <\/tr>\n
7. Low pH<\/td>\n Increase pH with ammonia to 5.3<\/td>\n <\/tr>\n
8. Anode and cathode too close<\/td>\n Increase the distance between anode and cathode.<\/td>\n <\/tr>\n
9. Iron Contamination<\/td>\n Perform high current density dummy galvanization.<\/td>\n <\/tr>\n
10. Current is too high in the electrocleaner<\/td>\n Reduce the current in the cleaning bath.<\/td>\n <\/tr>\n
11. Insufficient agitation<\/td>\n Adjust the agitation.<\/td>\n <\/tr>\n
12. High chloride content<\/td>\n Perform an analysis and decant the solution.<\/td>\n <\/tr>\n
13. High Cl\/Zn ratio<\/td>\n Reduce chloride additives.<\/td>\n <\/tr>\n\n
High current density dullness:<\/strong><\/td>\n <\/td>\n <\/tr>\n
1. High Temperature<\/td>\n Reduce the temperature to 27\u00b0C or add brightening agent to compensate (if no cooler is available).<\/td>\n <\/tr>\n
2. Low chloride content<\/td>\n Perform an analysis to determine the appropriate addition.<\/td>\n <\/tr>\n
3. Too much or too little brightener<\/td>\n Perform a Hull-cell test (1 ampere \u2013 15 min) to determine the correct amount.<\/td>\n <\/tr>\n
4. Bad ingredients out of balance<\/td>\n Perform a Hull cell test (1 ampere \u2013 15 min) to determine the correct amount.<\/td>\n <\/tr>\n
5. Low amperage<\/td>\n Increase the amperage.<\/td>\n <\/tr>\n
6. Metal contamination (Pb, Cd, Cu)<\/td>\n Isolate the source of the contamination from the electroplating solution. Perform an HCD dummy galvanization. Treat with zinc dust.<\/td>\n <\/tr>\n
7. High zinc metal concentration<\/td>\n Maintain zinc metal concentration in an optimal range by lowering chloride content, increasing pH, or decanting solution.<\/td>\n <\/tr>\n
8. High pH<\/td>\n Lower the pH with hydrochloric acid.<\/td>\n <\/tr>\n
9. Poor cleaning<\/td>\n Check the cleaning agents.<\/td>\n <\/tr>\n
10. Organic Contamination<\/td>\n Treat with carbon: 0.5 to 1 gram per liter, or carbon together with 1 gram of hydrogen peroxide per liter. Or treat the bath with 0.5 to 1 gram of potassium permanganate per liter.<\/td>\n <\/tr>\n\n
LCD Dustiness:<\/strong><\/td>\n <\/td>\n <\/tr>\n
1. Too much or too little brightener<\/td>\n Perform a Hull-cell test (1 ampere \u2013 15 min) to determine the correct amount.<\/td>\n <\/tr>\n
2. Current too low<\/td>\n Increase the amperage.<\/td>\n <\/tr>\n
3. Low chloride content<\/td>\n Perform an analysis to determine the appropriate addition.<\/td>\n <\/tr>\n
4. Bad ingredients out of balance<\/td>\n Perform a Hull cell test (1 ampere \u2013 15 min) to determine the correct amount.<\/td>\n <\/tr>\n
5. Metal contamination<\/td>\n Isolate the source of the contamination from the electroplating solution. Perform an LCD dummy electroplating. Treat bath with zinc dust.<\/td>\n <\/tr>\n
6. High pH value<\/td>\n Lower the pH with hydrochloric acid.<\/td>\n <\/tr>\n\n
Reduced cover:<\/strong><\/td>\n <\/td>\n <\/tr>\n
1. Low chloride content<\/td>\n Perform an analysis to determine the appropriate addition.<\/td>\n <\/tr>\n
2. High zinc metal concentration<\/td>\n Maintain the zinc metal concentration in an optimal range by lowering chloride or raising pH. Or decant the solution.<\/td>\n <\/tr>\n
3. Low pH<\/td>\n Increase the pH with ammonia.<\/td>\n <\/tr>\n
4. High pH<\/td>\n Lower the pH with hydrochloric acid.<\/td>\n <\/tr>\n
5. Too much brightener<\/td>\n Increase the temperature.<\/td>\n <\/tr>\n
6. Bad ingredients out of balance<\/td>\n Perform a Hull cell test (1 ampere \u2013 15 min) to determine the correct amount.<\/td>\n <\/tr>\n
7. Low current Increase<\/td>\n the amperage.<\/td>\n <\/tr>\n
8. Low temperature<\/td>\n Increase the temperature to 29\u00b0C.<\/td>\n <\/tr>\n
9. Metal Contamination (Pb)<\/td>\n Isolate the source of the contamination from the electroplating solution. Perform dummy electroplating. Treat bath with zinc dust.<\/td>\n <\/tr>\n
10. Chromium contamination (above 10 ppm)<\/td>\n Treat bath with 0.25 g of sodium bisulphite per 1 litre.<\/td>\n <\/tr>\n
11. Organic Contamination<\/td>\n Treat with carbon: 0.5 to 1 gram per liter, or carbon together with 1 gram of hydrogen peroxide per liter. Or treat the bath with 0.5 to 1 gram of potassium permanganate per liter.<\/td>\n <\/tr>\n
12. Anode surface area<\/td>\n too smallAdd anodes.<\/td> \n <\/tr>\n
13. Too much peroxide added<\/td>\n Solution was treated too aggressively with peroxide. Perform Hull-cell test (1 ampere \u2013 15 min) to determine the correct amount of brightener.<\/td>\n <\/tr>\n\n
Blistering:<\/strong><\/td>\n <\/td>\n <\/tr>\n
1. Poor cleaning<\/td>\n Check the cleaning agents.<\/td>\n <\/tr>\n
2. Too much brightener<\/td>\n Dummy plate. Treat the bath with 0.5 to 1 gram of potassium permanganate per liter. Increase the temperature of the bath to 43\u00b0C. Treat with carbon: 0.5 to 1 gram per liter, or carbon together with 1 gram of hydrogen peroxide per liter.<\/td>\n <\/tr>\n
3. High pH<\/td>\n Lower the pH with hydrochloric acid.<\/td>\n <\/tr>\n
4. Quality of the substrate<\/td>\n Find a suitable cleaning process for this substrate.<\/td>\n <\/tr>\n
5. Low chloride content for glazing agent<\/td>\n Perform an analysis to determine the appropriate addition (rapid increase in pH indicates low concentration of buffering agent).<\/td>\n <\/tr>\n
6. Organic or metal contamination<\/td>\n Treat with carbon: 0.5 to 1 gram per liter, or carbon along with 1 gram of hydrogen peroxide per liter. Or treat the bath with 0.5 to 1 gram of potassium permanganate per liter.<\/td>\n <\/tr>\n
7. Chromium contamination (above 10 ppm)<\/td>Treat bath with 0.25 g of sodium bisulphite per 1 litre.<\/td>\n \n <\/tr>\n
8. Copper in the acid<\/td>\n Change the acid solution.<\/td>\n <\/tr>\n
9. Electrical problems<\/td>\n Check the electrical contacts.<\/td>\n <\/tr>\n
10. Bath ingredients out of balance<\/td>\n Perform a Hull cell test (1 amp \u2013 15 min) to determine the correct amount.<\/td>\n <\/tr>\n\n
Roughness:<\/strong><\/td>\n <\/td>\n <\/tr>\n
1. Poor filtration<\/td>\n Use a filter of 1 to 5 microns.<\/td>\n <\/tr>\n
2. High pH<\/td>\n Lower the pH with hydrochloric acid.<\/td>\n <\/tr>\n
3. Anode surface area<\/td>\n too smallAdd anodes.<\/td> \n <\/tr>\n
4. Bad ingredients out of balance<\/td>\n Perform a Hull cell test (1 ampere \u2013 15 min) to determine the correct amount.<\/td>\n <\/tr>\n
5. Poor cleaning<\/td>\n Check the cleaning agents.<\/td>\n <\/tr>\n
6. Magnetized particles<\/td>\n Collect them with a magnet and filter the solution.<\/td>\n <\/tr>\n
7. Copper in the acid<\/td>\n Change the acid solution.<\/td>\n <\/tr>\n\n
Brittle deposit:<\/strong><\/td>\n <\/td>\n <\/tr>\n
1. Too much brightener<\/td>\n Dummy plate. Treat the bath with 0.5 to 1 gram of potassium permanganate per liter. Increase the bath temperature to 43\u00b0C. Or treat with carbon: 0.5 to 1 gram per liter, or carbon together with 1 gram of hydrogen peroxide per liter.<\/td>\n <\/tr>\n
2. Excess thickness of the zinc deposit<\/td>\n Reduce the electroplating time.<\/td>\n <\/tr>\n
3. Too little carrier agent<\/td>\n Perform a Hull cell test (1 ampere \u2013 15 min) to determine the correct amount.<\/td>\n <\/tr>\n
4. High pH<\/td>\n Lower the pH with hydrochloric acid.<\/td>\n <\/tr>\n\n
Pits and pinholes:<\/strong><\/td>\n <\/td>\n <\/tr>\n
1. Too much brightener<\/td>\n Dummy plate. Treat the bath with 0.5 to 1 gram of potassium permanganate per liter. Increase the bath temperature to 43\u00b0C. Treat with carbon: 0.5 to 1 gram per liter, or carbon together with 1 gram of hydrogen peroxide per liter.<\/td>\n <\/tr>\n
2. High Temperature<\/td>\n Reduce the temperature to 27\u00b0C or add brightener to compensate (if no cooler is available).<\/td>\n <\/tr>\n
3. Organic Contamination<\/td>\n Treat with carbon: 0.5 to 1 gram per liter, or carbon together with 1 gram of hydrogen peroxide per liter. Or treat the bath with 0.5 to 1 gram of potassium permanganate per liter.<\/td>\n <\/tr>\n
4. Bad ingredients out of balance<\/td>\n Perform a Hull cell test (1 ampere \u2013 15 min) to determine the correct amount.<\/td>\n <\/tr>\n
5. Low Chloride Content<\/td>\n Perform an analysis to determine the appropriate addition.<\/td>\n <\/tr>\n\n
Uneven deposit:<\/strong><\/td>\n <\/td>\n <\/tr>\n
1. Low temperature<\/td>\n Increase the temperature to 29\u00b0C.<\/td>\n <\/tr>\n
2. Too much brightener<\/td>\n Dummy plate. Treat the bath with 0.5 to 1 gram of potassium permanganate per liter. Increase the bath temperature to 43\u00b0C. Treat with carbon: 0.5 to 1 gram per liter, or carbon together with 1 gram of hydrogen peroxide per liter.<\/td>\n <\/tr>\n
3. Bad ingredients out of balance<\/td>\n Perform a Hull cell test (1 ampere \u2013 15 min) to determine the correct amount.<\/td>\n <\/tr>\n
4. Chromium contamination<\/td>\n Treat bath with 0.25 g of sodium bisulphite per 1 litre.<\/td>\n <\/tr>\n
5. Quality of the substrate<\/td>\n Find a suitable cleaning process for this substrate.<\/td>\n <\/tr>\n
6. Too much peroxide added<\/td>\n Solution was treated too aggressively with peroxide. Perform Hull-cell test (1 ampere \u2013 15 min) to determine the correct amount of brightener.<\/td>\n <\/tr>\n
7. Electrical problems<\/td>\n Check the electrical contacts.<\/td>\n <\/tr>\n
8. Metal contamination<\/td>\n Isolate the source of the contamination from the electroplating solution. Perform LCD dummy electroplating. Treat bath with zinc dust.<\/td>\n <\/tr>\n\n
Poor efficiency:<\/strong><\/td>\n <\/td>\n <\/tr>\n
1. Anode surface area<\/td>\n too smallAdd anodes.<\/td> \n <\/tr>\n
2. Low chloride content<\/td>\n Perform an analysis to determine the appropriate addition.<\/td>\n <\/tr>\n
3. Electrical problems<\/td>\n Check the electrical contacts.<\/td>\n <\/tr>\n
4. Low current Increase<\/td>\n the amperage.<\/td>\n <\/tr>\n
5. Low temperature<\/td>\n Increase the temperature to 29\u00b0C.<\/td>\n <\/tr>\n
6. Low zinc metal concentration<\/td>\n Maintain the zinc metal concentration in an optimal range by adding zinc chloride.<\/td>\n <\/tr>\n
7. Bad ingredients out of balance<\/td>\n Perform a Hull-cell test (1 ampere \u2013 15 min) to determine the correct amount.<\/td>\n <\/tr>\n
8. Too much or too little brightener<\/td>\n Perform a Hull cell test (1 ampere \u2013 15 min) to determine the correct amount.<\/td>\n <\/tr>\n
9. Low pH value<\/td>\n Increase the pH with ammonia.<\/td>\n <\/tr>\n\n
Decreasing zinc metal concentration:<\/strong><\/td>\n <\/td>\n <\/tr>\n
1. Anode surface out of balance<\/td>\n Adjust the anode surface.<\/td>\n <\/tr>\n
2. High pH<\/td>\n Lower the pH with hydrochloric acid.<\/td>\n <\/tr>\n
3. Electrical problems<\/td>\n Check the electrical contacts.<\/td>\n <\/tr>\n
4. High drag-in and drag-out<\/td>\n Overhaul rack and drum operations and equipment.<\/td>\n <\/tr>\n\n
Increasing zinc metal concentration:<\/strong><\/td>\n <\/td>\n <\/tr>\n
1. Low pH<\/td>\n Increase the pH with ammonia.<\/td>\n <\/tr>\n\n
Inappropriate use of additives:<\/strong><\/td>\n <\/td>\n <\/tr>\n
1. High Temperature<\/td>\n Reduce the temperature to 27\u00b0C or add brightener to compensate (if no cooler is available).<\/td>\n <\/tr>\n
2. High pH<\/td>\n Lower the pH with hydrochloric acid.<\/td>\n <\/tr>\n
3. Bad ingredients out of balance<\/td>\n Perform a Hull cell test (1 ampere \u2013 15 min) to determine the correct amount.<\/td>\n <\/tr>\n
4. Organic Contamination<\/td>\n Treat with carbon: 0.5 to 1 gram per liter, or carbon together with 1 gram of hydrogen peroxide per liter. Or treat the bath with 0.5 to 1 gram of potassium permanganate per liter.<\/td>\n <\/tr>\n
5. Too much peroxide added<\/td>\n Solution was treated too aggressively with peroxide. Perform Hull-cell test (1 ampere \u2013 15 min) to determine the correct amount of brightener.<\/td>\n <\/tr>\n
6. Drag-in of low pH rinse water<\/td>\n <\/td>\n <\/tr>\n\n
Rising solution pH:<\/strong><\/td>\n <\/td>\n <\/tr>\n
1. Bad ingredients out of balance<\/td>\n Perform an analysis to determine the appropriate addition (rapid increase in pH indicates low concentration of buffering agent).<\/td>\n <\/tr>\n\n
Stains after electroplating:<\/strong><\/td>\n <\/td>\n <\/tr>\n
1. Poor rinsing<\/td>\n Increase the water flow.<\/td>\n <\/tr>\n
2. Excess time between plating and<\/td>\n rinsingReduce the transfer time.<\/td> \n <\/tr>\n
3. Weak nitrogen dip<\/td>\n Change the nitrogen dip solution.<\/td>\n <\/tr>\n
4. Rinse water temperature is cold<\/td>\n Increase the temperature or rinse time.<\/td>\n <\/tr>\n
5. Contamination in rinse water<\/td>\n Turn the water into a rinse tank.<\/td>\n <\/tr>\n
6. Metal contamination<\/td>\n Isolate the source of the contamination from the electroplating solution. Perform LCD dummy electroplating. Treat bath with zinc dust.<\/td>\n <\/tr>\n\n
Blackness in HCD after clear dip:<\/strong><\/td>\n <\/td>\n <\/tr>\n
1. Iron contamination<\/td>\n Isolate the source of the contamination from the electroplating solution. Perform LCD dummy electroplating. Treat bath with zinc dust.<\/td>\n <\/tr>\n <\/tbody>\n<\/table>\n\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t","protected":false},"excerpt":{"rendered":"

Zinc Electroplating Problems and Solutions. Here is a list of the problems that can occur during the galvanizing of objects and the corresponding solutions. <\/p>\n","protected":false},"author":1,"featured_media":0,"comment_status":"closed","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"footnotes":""},"categories":[953],"tags":[976,964],"class_list":["post-14759","post","type-post","status-publish","format-standard","hentry","category-galvanize","tag-zinc-electroplating","tag-zinc-plating"],"acf":[],"_links":{"self":[{"href":"https:\/\/verzinkshop.nl\/en\/wp-json\/wp\/v2\/posts\/14759","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/verzinkshop.nl\/en\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/verzinkshop.nl\/en\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/verzinkshop.nl\/en\/wp-json\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/verzinkshop.nl\/en\/wp-json\/wp\/v2\/comments?post=14759"}],"version-history":[{"count":0,"href":"https:\/\/verzinkshop.nl\/en\/wp-json\/wp\/v2\/posts\/14759\/revisions"}],"wp:attachment":[{"href":"https:\/\/verzinkshop.nl\/en\/wp-json\/wp\/v2\/media?parent=14759"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/verzinkshop.nl\/en\/wp-json\/wp\/v2\/categories?post=14759"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/verzinkshop.nl\/en\/wp-json\/wp\/v2\/tags?post=14759"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}