Locating a the thinnest spot in a zinc coated steel

Abstract:

This Report covers the procedure for locating, by the use of a solution of copper sulfate, the
thinnest spot in a zinc coating (hot dipped, electroplated, or sprayed) on iron or steel
articles that are coated after the shape is produced by casting, drawing, pressing, or other
forming methods.

:Significance and Use

This practice is designed to locate the thinnest portions of the zinc coating on newly coated
items.
Variations in coating thickness can be due to the process by which the zinc is applied (hot
dipped, electroplated, or sprayed) or by the geometry of the part that is coated.

Material and Tools:

Ser. Item
1 Specimen
2 Copper Sulfate (CUSo4.5H2O)
3 Beaker from poly ethylene or glass or chemically Nonreactive material
4 Distilled Water
5 Copper Hydroxide (CU (OH)2)
6 Filter
7 Hydrometer
8 PH meter
9 Volatile Organic Solvent
10 Gloves

Procedures

A- Solution preparation:

A solution of copper sulfate for this test shall be made from distilled water and a reagent grade
of cupric sulfate (CuSO4). In a copper container or in a glass, polyethylene, or other chemically
nonreactive container.

A quantity of the cupric sulfate shall be dissolved in hot distilled water.

Measure specific gravity of the solution using hydrometer.

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The purpose is to obtain a solution that has a specific gravity slightly higher than 1.186 after the
solution is cooled to a temperature of 18.3°C (65.0°F).

Measure PH level of the solution using PH meter. If it is not within range *(3~4), approximately 1
gram of cupric hydroxide (Cu (OH) 2) per liter of solution shall be added to neutralize solution.

(1) Repeat measuring PH level of the solution. Check it’s within (3~4) range.

(2) The neutralized solution shall be allowed to stand for 24 h and then filtered or decanted.

Measure specific gravity of the solution using hydrometer.

The purpose is to obtain a solution that has a specific gravity slightly higher than 1.186 after the
solution is cooled to a temperature of 18.3°C (65.0°F). If this is not achieved, and gravity is
higher than the mentioned value, solution shall be diluted with distilled water to obtain a specific
gravity of exactly 1.186 at a temperature of 18.3°C (65.0°F).
If the gravity is lower than the mentioned value, CuSO4 shall be added to obtain a specific
gravity of exactly 1.186 at a temperature of 18.3°C (65.0°F).

B- Specimen preparation:

- Several 15-cm specimens shall be cut from a sample length of the finished zinc-coated
Tubing.
- Specimens shall be cleaned with a suitable volatile organic solvent (Acetone).
- Half of the specimens shall be cut longitudinally.
- The selected specimens shall be rinsed in water, and all surfaces shall be dried with clean
cheesecloth. As much of the water as possible shall be removed in the drying operation
The surface of the zinc shall be dry, clean and temperature between (15-21 Celsius) before
specimen is immersed in the solution of copper sulfate.

Steps:

- A glass, polyethylene, or other chemically nonreactive beaker having a diameter equal to

Approximately twice the diameter measured over the specimen shall be filled with the
solution of copper sulfate to a depth of not less than 76 mm (3 in). The temperature of
the solution shall be maintained at18.3 ±1.1°C (65.0 ±2.0°F).
- The specimen shall be immersed in the solution and supported on end in the center of the
beaker so that not less than 64 mm (2-1/2 in) of its length is immersed. The specimen shall
remain in the solution for 60 s, during which time it shall not be moved nor shall the solution

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 be stirred at the end of the 60 s period, the specimen shall be removed from the beaker,
rinsed immediately in running tap water, rubbed with clean cheesecloth until any loosely
adhering deposits of copper are removed, and then dried with clean cheesecloth. Again,
hands and other damaging and contaminating objects and substances shall not touch the
surfaces that were immersed.

Result:

- The part of the specimen that was immersed shall be examined, considering each broad
surface separately and disregarding the portions of the specimen within 13 mm (1/2 in) of
the cut ends on sizes 12 – 53 (3/8 – 2) and 25 mm (1 in) for sizes 63 – 103 (2-1/2 – 4) and
within 3 mm (1/8 in) of any longitudinal edges cut in the process of preparing the specimen.
record shall be made when the immersed part of the specimen has any deposit of bright,
firmly adhering copper exclusive of the 13 mm (1/2 in) cut-end portions and any 3 mm (1/8
in) longitudinal cut edge portions.
- When bright adhering copper is not found, the process of immersing, washing, rubbing,
drying, examining, and recording shall be repeated up to the required number of
immersions, or until the presence of copper is noted, whichever comes first, using the same
specimen and beaker of solution.
- After the dips are completed on any one specimen, the portion of the solution of copper
sulfate used shall be discarded. A fresh portion of the solution shall be employed for each of
any succeeding specimens.
- A protective zinc coating that provides the sole means of primary corrosion resistance on
the exterior of the tubing shall be such that a specimen of the finished tubing does not show
a bright, adherent deposit of copper after four 60-s immersions in a copper sulfate solution.
- Protective zinc coating that provides the sole means of primary corrosion resistance on the
interior of the tubing shall be such that a specimen of the finished tubing does not show a
bright, adherent deposit of copper after one 60-s immersion in a copper sulfate solution.

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Summary

- Mix copper sulfate with distilled water.

- Check temperature ,specific gravity and PH of Solution
- Prepare the selected specimens (cut, rinse, clean , dry and maintain temperature)
- Immerse specimen.
- Examine specimen visually and compare it to acceptance criteria.

Acceptance criteria:

In case of presence of bright copper on above mentioned considered areas of the tubes before
the required number of immersions, specimen is defected and test fails.

References:

(1) The neutralized solution shall be allowed to stand for 24 h and then filtered or decanted
(according to ASTM A 239 – mentioned in UL 797)

(2) Solution PH value between 3.0 and 4.0 (as mentioned in “acquiring copper Sulfate

solution- UL”) copper

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