Why is coating thickness easier to control in electrogalvanizing?

In electrogalvanizing, controlling the coating thickness is more straightforward than in the hot-dip galvanizing process due to the precise, predictable relationship between the electric current applied and the amount of zinc deposited on the steel strip.1

Because the process relies on electrolytic deposition, the quantity of zinc formed is directly proportional to the current used; for example, a specific amount of current over a set time will theoretically yield a consistent, calculable mass of zinc. In contrast, hot-dip galvanizing relies on mechanical methods, such as gas-knives, to wipe away excess molten zinc, making thickness control dependent on adjusting gas pressure and knife positioning. Consequently, electrogalvanizing is the preferred method when thinner, highly controlled coatings are required for specific applications.12