HOT DIPPING AND ION

IMPLANTATION
K. BALAJI

Hot Dipping
Hot-dip galvanizationis a form ofgalvanization.
It is the process of coatingironandsteelwith a
layer ofzincby immersing themetalin a bath of
molten zinc at a temperature of around 840F
(449C). When exposed to the atmosphere, the
pure zinc (Zn) reacts with oxygen (O2) to form zinc
oxide (ZnO), which further reacts with carbon
dioxide (CO2) to form zinc carbonate (ZnCO3), a
usually dull grey, fairly strong material that
protects the steel underneath from
furthercorrosionin many circumstances.

HISTORY OF HOT DIPPING

79 AD
Record of zinc usage in construction began, which could be considered the
origination of galvanizing.
1742
The first recorded history of galvanizing dates back to when P.J. Malouin, a
French chemist, presented to the Royal Academy of Sciences several
experiments involving coating iron with molten zinc.
1772
Luigi Galvani, galvanizing's namesake, discovered the electrochemical process
that takes place between metals during an experiment with frog legs.
1801
Alessandro Volta furthered the research on galvanizing when he discovered the
electro-potential between two metals, creating a corrosion cell.
1829
Michael Faraday discovered zinc's sacrificial action during an experiment
involving zinc, salt water, and nails.

 1837
French engineer Stanislaus TranquilleModeste Sorel took out a patent for the
early galvanizing process.
1850
The British galvanizing industry was consuming 10,000 tons of zinc annually for
the production of galvanized steel.
1870
The United States, slightly behind, had its first galvanizing plant open. At the
time, the steel was hand dipped in the zinc bath.
2000
Advancements in metallurgy and furnace technology improve process efficiency
and sustainability.
Today
Today, more than 600,000 tons of zinc is consumed annually in North America to
produce hot-dip galvanized steel 200,000 tons for after fabrication (batch)
process and 400,000 for the continuous galvanizing process. Galvanizing is found
in almost every major application and industry where iron orsteel is used. The
utilities, chemical process, pulp and paper, automotive, and transportation
industries, to name just a few, historically have made extensive use of
galvanizing for corrosion control. They continue to do so today. Hot-dip
galvanizing has a proven and growing history of success in myriadapplications
worldwide.

Hot dipping process

The galvanizing process consists of three basic
steps:
Surface preparation
Galvanizing
Inspection.

SURFACE PREPARATION
Surface preparation is the most important step in the application of any
coating. Any failures or inadequacies in surface preparation will
immediately be apparent when the steel is withdrawn from the molten
zinc because the unclean areas will remain uncoated and immediate
corrective action must be taken.
Caustic Cleaning - A hot alkali solution often is used to remove
organic contaminants such as dirt, paint markings, grease and oil from
the metal surface. Epoxies, vinyls, asphalt or welding slag must be
removed before galvanizing by grit-blasting, sand-blasting or other
mechanical means.
Pickling - Scale and rust normally are removed from the steel surface
by pickling in a dilute solution of sulfuric acid (5-15% by volume) or
ambient temperature hydrochloric acid.
Fluxing - Fluxing is the final surface preparation step in the galvanizing
process. Fluxing removes oxides and prevents further oxides from
forming on the surface of the metal prior to galvanizing.

Galvanizing
In this step, the material is
completely immersed in a bath
consisting of a minimum of 98% pure
molten zinc. The bath temperature is
maintained at about 840 F (449 C).
Fabricated items are immersed in the
bath until they reach bath
temperature. The zinc metal then
reacts with the iron on the steel
surface to form a zinc/iron

Inspection
A variety of simple physical and
laboratory tests may be performed to
determine thickness, uniformity,
adherence and appearance. Products
are galvanized according to long
established, well-accepted, and
approved standards of ASTM
A123/A123M, AS/NZS 4680, and BS
EN ISO 1461.

Advantages:
Smooth and uniform coating.
Sharp edges and corners are protected
optimally.
Stress release
The coating is very robust and can withstand
minor bumps and bruises in connection with
the mounting, transportation etc.
Disadvantages:
Limitation of the product size.
Risk of distortion due stress release
especially in forged products.

Applications

Roofing and walling

Safety barriers
Handrails
Consumer appliances
Automotive body parts
Metal pails in most heating and
cooling duct systems in buildings.

Ion implantation
Ion implantationis amaterials
engineeringprocess by whichionsof
a material are accelerated in an
electrical field and impacted into a
solid. This process is used to change
the physical, chemical, or electrical
properties of the solid. Ion
implantation is used
insemiconductor device
fabricationand in metal finishing, as

Equipment needed to perform ion

implantation
Produce a beam of ions (ion source)
n Select among beam atoms just the
chemical species we want to implant
(magnetic mass filter) n Accelerating
ions at the desired energy
(acceleration column) n Bring the ion
beam to hit the surface of the target
material (beamline: ion lenses, beam
scanner, neutral trap,...)

Schematic diagram

Working process
Nuclear collisions: Ions collide with atoms.
The positively charged ions are coulombically
repealed by the positive cores of the wafers
lattice atoms. This coulombic repulsion is
screened by the cloud of electrons
surrounding each atom.
Electronic stopping: If ions graze the lattice
atoms, they do not interact with the lattice
atoms electrons and not the positive core.
This interaction slows the ions by viscous
friction similar to a rock thrown into water.

Advantages
Precise control of dose and depth profile
Very fast (1 6" wafer can take as little as
6 seconds for a moderate dose)
Wide selection of masking materials e.g.
photoresist, oxide, poly-Si, metal
Less sensitive to surface cleaning
procedures
Excellent lateral uniformity (< 1%
variation across 12 wafer)

Disadvantages
Not all the damage can be corrected
by annealing.
Typically has higher impurity content
than does diffusion.
Often uses extremely toxic gas
sources such as arsine (AsH3), and
phosphine (PH3).
Expensive

Application
Doping
Nitrogen or other ions can be
implanted into a tool steel target
(drill bits, for example).
prosthetic devices such as artificial
joints, it is desired to have surfaces
very resistant to both chemical
corrosion and wear due to friction.
ion beam mixing, i.e. mixing up
atoms of different elements at an