Electro galvanizing is the process of forming a zinc layer on the surface of steel using electrochemical principles. The zinc ingot is used as the anode. The zinc atoms lose electrons and become ions that dissolve into the electrolyte, while the steel strip is used as the cathode. The zinc ions gain electrons on the steel strip and are reduced to zinc atoms that are deposited on the surface of the steel strip to form a coating. The process is simple, environmentally friendly and low-cost, but the coating is thin, the adhesion between the zinc layer and the steel substrate is poor, and the scope of application is narrow. The electroplated zinc is very thin, about 3-5 μm; the hot-dip surface is rough and bright, and in severe cases, there are zinc flowers, while the electroplated surface is smooth and gray (dirty).

Hot-dip galvanizing is a process that forms a zinc-iron alloy layer on the surface of steel. The process is relatively complicated and uses the alloying reaction of metallic zinc and iron at high temperature to form a zinc-iron alloy layer on the surface of steel. The process is relatively complicated and has certain requirements for steel, but the coating is stronger, more corrosion-resistant, and has a wider range of applications. Hot dip galvanized sheet generally has a thicker zinc layer, about 10μm or more, and has a stronger anti-corrosion ability. Therefore, it is a commonly used galvanizing process.

1. Thickness Differences: The hot-dip galvanized zinc layer itself is relatively thick, generally over 10µm thick, which provides excellent corrosion resistance. While the surface is bright, it is slightly rough and may show zinc spangles.
Electro-galvanized steel, on the other hand, has a thinner zinc layer, approximately 3-5µm thick. While smooth, it can appear dull and smudged. While workability is good, corrosion resistance is limited.

2. The surface of hot-dip galvanized steel is a pure zinc coating, which is uniform and has no pores. However, there is a layer of relatively brittle compound between the coating and the substrate.
The electro-galvanized coating is composed of only zinc atoms, which are deposited on the surface of the steel strip. It is a physical adhesion effect and has many pores on the surface, so it is more susceptible to corrosion.

3. Hot-dip galvanizing uses the alloying reaction of metallic zinc and iron at high temperature to form a zinc-iron alloy layer on the surface of steel. The process is relatively complex and has certain requirements for steel, but the coating is stronger, more corrosion-resistant, and has a wider range of applications.
Electrogalvanizing is the process of forming a zinc layer on the surface of steel using electrochemical principles. The process is simple, environmentally friendly and low-cost, but the coating is thin, the adhesion between the zinc layer and the steel substrate is poor, and its scope of application is narrow.

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