Galfan® Systems

Galfan® Systems (Zn, 5% Al Alloy)

Galfan SystemsQED is proud to be on the leading edge of Galfan® equipment technology, having designed and commissioned many of the wire Galfan® lines operating in the world today. Our customers are based in Malaysia, USA, China, Turkey and Italy. This hot-dip process uses our ceramic lined furnaces with either Immersion Burner or Top Heated combustion technologies. The process includes; heat-treating, pickling, hot-dipping and pad wiping zinc, pre-Galfan flux, Galfan® bath and Nitrogen Wiping.

Our Galfan® Furnace, heated with QED’s patented “Pressure Feedback Signal” control system, combines exceptionally stable performance with enhanced operations. Each Galfan system is custom designed to suit your production requirements.

Galfan LogoQED Wire is an approved Galfan® Equipment Supplier providing Galfan® Technology for the coating of steel wire. The Associate license was granted by the Galfan Technology Center.

Features

Excellent in Coating
The superior zinc – aluminum (95%-5%) coating offers 3 to 5 times more corrosion resistance than zinc alone. With perfect adhesion to the wire the coating has no hard intermediate layer. The presents of aluminum in the alloy provides excellent ductility and malleability.

Proven Double Dip System
Although other Zn-Al processes have been tried the double-dip method has proven to be the most reliable for consistent high quality production. The wire is first hot dip galvanized and pad or nitrogen wiped on exit. An optional pre-Galfan flux of zinc chloride can then be applied. The second dip in the Galfan bath (95% Zn, 5% Al) is followed by wiping through our nitrogen nozzles.

Optional Pre-Galfan Flux
The process is made more forgiving to exposed iron (causing mis-galfan) by the addition of our special fluxing system. The Pre-Galfan Flux tank operates in much the same way as a standard galvanizing flux tank – but with a different flux fluid.

Galvanizing Line with Pickling

Galvanizing & Galfan® Line with Annealing and Pickling

Galfan® Line 25 Year Refractory LifeQED’s furnaces are solidly built from rolled steel and structural sections. Our special “freeze plane” multiple layer refractory design is nearly fail-safe and will last over 25 years. This robustness was proven is a spectacular fashion when one QED galvanizer survived complete immersion underwater and was successfully put back into operation. Our furnaces are all supplied to international combustion and safety standards. Our control systems incorporate state of the art Siemens PLC hardware and are programmed for user friendliness in any language.

QED provides the installation of the refractory as part of the equipment price.

Immersion Burners Type

Immersion Burner Galvanizer with Mark 4 ART BurnersOur immersion burner furnaces are provided with our latest generation burner, the Mark 4 ART. This Advanced Recuperative Technology burner offers unparalleled heat recovery from an extended double-pass integral recuperator that pre-heats incoming combustion air. The finite element analysis design optimizes energy efficiency and delivers with cooler burner skin temperature. Building on the strength of the Mark 3 burner, this unit also delivers air spin dynamics for excellent flame retention, smooth starting and reliable operation.

Top Heated Type

Our immersion burner furnaces are provided with our latest generation burner, the Mark 4 ART. This Advanced Recuperative Technology burner offers unparalleled heat recovery from an extended double-pass integral recuperator that pre-heats incoming combustion air. The finite element analysis design optimizes energy efficiency and delivers with cooler burner skin temperature. Building on the strength of the Mark 3 burner, this unit also delivers air spin dynamics for excellent flame retention, smooth starting and reliable operation.

Optional Pre-Galfan Flux

Galfan Systems Double dip processOur flux tank is contrasted of FRP (Fiberglass) for exceptional strength and corrosion resistance. The tanks are heated with titanium electric immersion heaters and a latest generation PLC controls the temperature. An ultrasonic level sensor provides accurate fluid level indication and high and low level alarms. Flux fluid is circulated from the lower tank to the upper process tray by means of a low maintenance vertical pump and heavy duty CPVC piping.

High Efficiency Air Wipe

The wires exit the tank into individual high efficiency air wipes. Air from a high volume blower is feed to the header from below the wire field. An integrated drain tray returns the excess fluid back to the tank.