Brad nails are available in electro galvanized as well as hot dip galvanized forms.

While hot dip galvanizing provides a thicker layer of coating and hence more corrosion resistance, electroplated or electro galvanized brad nails have a better aesthetic appearance and are better suited for closed fitted parts. Both processes entail a coating of zinc on steel. Coating Thickness The average thickness of hot dip galvanized coating is about ten times more compared to electro galvanized brad nails. Thus, when it comes to outdoor exposure, the hot dip galvanized brad nails stand a better chance as opposed to electro galvanized versions. Difference in Methods There is a general misconception about the terms electro galvanized, which also refers to electroplating and hot dip galvanizations. Several times, the term galvanized might be used for electroplated brad nails, leading people to believe that this refers to the hot dip galvanization technique. The primary difference between the two finishes lie in their techniques. In the hot dip galvanizing method, the coating comprises a mix of zinc and iron. The uniform coating provides superior protection at edges and corners. With this process, there is metallurgical reaction between steel and iron, causing multiple alloy layers of iron and zinc. Both the alloy layers and pure zinc coating provide additional protection in the event of damage or scratches to the surface. In the case of mechanical electroplating or electro galvanization, there is a flash type copper coating after, which the brad nails are tumbled inside a barrel containing zinc powder and glass beads. As per ASTM standards, coating thickness should range between 0.2 and 4.3 mils. While the hot dip galvanized brad nails have density of 0.6 oz/ft square/mil, the electro galvanized brad nails have densities of 0.45 oz/ft square/mil. Thus, with a hot dip galvanized surface coating, there is approximately 30 percent extra zinc content in each unit compared to the electro galvanized coating. Since it is the zinc, which is responsible for corrosion resistance, the hot dip galvanized technique offers greater protection. Electrogalvanized Coating Structure The coating of electrogalvanization comprises round zinc particles held together loosely. The bond between zinc-zinc or zinc-steel is much weaker compared to the bond forged in hot dip galvanization. The thread, edge as well as corner coating thicknesses are much lower due to the deposition technique involved in electrogalvanization process. Coating Thinness When it comes to electrogalvanized coating, it is much thinner and has less adhesive strength as compared to hot dip galvanization of brad nails. The edges of bolts and nuts tend to have a thinner coating and hence offer lesser degree of resistance to corrosion. Due to these faults, the overall protection offered by the fastener is compromised. Hence, if you are looking for long-term protection from damage or corrosion, make sure to invest in hot dip galvanized brad nails. If you want a shiny, lustrous surface, consider electrogalvanized brad nails as these surfaces typically have a smoother, brighter appearance. In the case of hot dip galvanized brad nails,

the surface is duller owing to more quantity of zinc. Depending on where the brad nails will be located and the amount of exposure to the elements, as well as the cost allocated to the process, you can choose between the cheaper electrogavanization and hot dip galvanization, which is more expensive.

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In hot dip galvanizing components are immersed in molten zinc. As they are withdrawn, the zinc cools and forms a coating of zinc on the components. Strictly speaking, the term should be hot dip zinc coating instead. Electro-galvanizing or 'zinc electroplated' means components are immersed in an aqueous bath, and electricity is used to induce anodes of zinc to dissolve in the aqueous solution, transport the ions, and electroplate them onto the components. The principal function of both processes is corrosion resistance. Galvanized steel can last for many years if other means are maintained, such as paint coatings and additional sacrificial anodes. In spite of the protection, rusting will be inevitable, especially due to natural acidity of rain.

Differences between Hot dip zinc coatings and Electroplated zinc coatings Hot dip zinc coatings Advantage 1. Several times thicker than electroplated zinc coatings. Hence several times as corrosion resistant and durability. Will always greatly outlast zinc electroplating in any environment. 2. The thickness of hot dip zinc coating is up to 10 times as electroplated zinc coating. The thickness depends on thickness of the part and the amount of silicon in the steel so the hot dip galvanizer is not free to pick a thickness. However, you can find out what thickness you can get on a sample part. Here is an example of the thickness: about 10 um for electro galvanized and 55 um for hot dip. Disadvantage 1. Doesnt have smooth finish. May be spangled, or grey and drippy. 2. Cannot be used for bolts and nuts size M10 or smaller. Electroplated zinc coatings (zinc plating) Advantage 1. Smooth, shiny and drip-free. Electroplated steel is visually indistinguishable from stainless steel when new. So Electroplated zinc coatings are preferable for aesthetic reasons. 2. Significantly lower cost. 3. Doesnt interfere with fastener threads because Zinc electroplating is thin. 4. Can be painted easily. Disadvantage 1. Electroplating is rarely adequate for direct outdoor exposure. However, electroplating and subsequent painting is a durable combination which is used for car bodies of some premium models. 2. Less durable.