Galvanized iron wire is widely used in agricultural fencing, construction binding wire, bundling and packaging, and industrial mesh due to its low cost, good corrosion resistance, and ease of processing. However, in actual use, a series of common problems still arise, affecting construction efficiency and service life.

        Ⅰ. What are the most common malfunctions of galvanized iron wire during use?

        • White rust or localized rust: White or dark spots appear on the galvanized layer in humid or corrosive gas environments.

        • Coating peeling/flaking: The coating is prone to cracking or peeling when bent, stretched or welded.

        • Tear breakage or wire breakage: Sudden breakage during use, often seen in scenarios with uneven mass or excessive stretching.

        • Poor compatibility between welding and coating: weld pool contamination, insufficient strength, or easy corrosion after welding.

        • Packaging and storage damage: Improper transportation and stacking lead to surface scratches, indentations, or deformation, affecting aesthetics and corrosion resistance.

        Ⅱ. Cause analysis and detailed explanation

        Environmental factors: Salt spray, high humidity, high temperature, or industrial pollutants (such as sulfides) can accelerate zinc layer corrosion, forming white rust or progressive corrosion.

        Zinc plating process and thickness: Hot-dip galvanizing and electroplating have different coating structures and thicknesses. Hot-dip galvanizing is usually thicker and has a stronger bond, while electroplating is thinner but has a brighter surface. Insufficient or uneven coating can lead to localized failure.

        Mechanical stress concentration: Bending, twisting, and sudden pulling can create microcracks, damaging the coating and forming stress concentration points. Long-term vibration or friction can cause wire breakage.

        Chemical compatibility issues: Incomplete cleaning or improper handling during welding, plating, or chemical treatment can damage the plating or introduce harmful residues.

        Improper storage and transportation: High humidity, large temperature differences, or contact with corrosive substances, or inadequate packaging, can easily lead to secondary contamination or surface scratches.

        Ⅲ. Prevention and optimization suggestions

        1. Construction Operation: During bending or tightening operations, avoid repeated sharp bends and excessive stretching. Use wire of appropriate diameter and strength grade to reduce the risk of wire breakage.

        2. Welding or Heat Treatment: Choose compatible processes or perform secondary plating/rust prevention treatment on the welded area to reduce post-weld corrosion risks.

        3. Surface Protection and Post-treatment: For outdoor or highly corrosive environments, prioritize hot-dip galvanized products with thicker coatings, or apply an organic coating to the surface to extend service life.

        4. Storage and Transportation: Maintain a dry and well-ventilated warehouse environment. Avoid stacking with acidic or sulfur-containing materials. Coiled products should be firmly padded and secured to prevent mutual friction damage.

        Although galvanized iron wire appears to be a simple material, its performance largely depends on the coating process, the usage environment, and the details of on-site operation. Sunny Metal offers a variety of hot-dip galvanized and electro-galvanized products, inspection reports, and technical support. Please contact us for customized advice and sample testing services.