For over a century, hot-dip galvanizing has been the primary method for industrial anti-corrosion. However, cold-spray zinc has emerged in less than a decade and is already becoming mainstream in heavy-duty anti-corrosion coatings. What’s behind this shift? Today, Mengneng Coating experts will break it down from four key perspectives:

1. Lower surface preparation requirements

Cold-spray zinc requires a lower degree of surface treatment — meeting the Sa2.5 cleanliness standard is sufficient.

Hot-dip galvanizing, on the other hand, demands extensive preparation: alkali degreasing, water rinsing, acid pickling, neutralization, and more. Each step must be strictly controlled and monitored.

2. Comparable corrosion protection performance

Cold-spray zinc combines organic and metallic coatings. It achieves Grade 0 in adhesion testing, indicating excellent bonding between the zinc-chromium layer and steel substrate, with a service life of 15–20 years.

Hot-dip galvanizing also provides a 15–20 year lifespan, but the process is complex. If parameters are not well controlled, defects such as uneven coating and peeling may occur.

3. Easier and more flexible applicationCold-spray zinc can be applied via spraying or brushing — it's user-friendly, unrestricted by location, workpiece size, or shape. It’s also highly efficient, easy to recoat, and can even be used to repair hot-dip galvanized surfaces.

Hot-dip galvanizing must be done in specialized facilities, with relatively low efficiency. Poor control of process parameters can severely impact anti-corrosion results and make repairs difficult.

4. More eco-friendly and saferCold-spray zinc contains no heavy metals such as lead or chromium. The solvent is free of harmful organics like benzene, toluene, or MEK. It meets the UK BS6920 standard and is safe for contact with drinking water.

Hot-dip galvanizing produces wastewater that poses significant environmental hazards. Environmental compliance costs are high, and many developed countries have already banned non-eco-friendly hot-dip galvanizing, outsourcing it instead to developing countries.

That’s the key comparison between cold-spray zinc and hot-dip galvanizing. If you're looking to purchase coatings or need technical support, feel free to contact us!

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