Dross has been one of the major defects occurred in continuous hot-dip galvanizing process when molten zinc, iron and aluminum atoms reacting with each other in zinc bath at a high temperature of 460°C. How to minimize the formation of dross played an important role in the manufacture of high surface quality products. In this paper, we studied characteristics and mechanism of formation of dross that included control of chemical compositions and temperature in zinc bath, controllable fabrication process, and optimization of production schedule. It has revealed that aluminum content in zinc bath has a significant effect on dross formation and the quality of galvanized surface. Therefore, it comes as no surprise a continuous on-line monitor of aluminum content is suggested.
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