Iron angle wheel brackets, as key components supporting equipment movement, are frequently exposed to humid and corrosive environments. They are highly susceptible to rust formation due to the chemical reaction of iron with oxygen and water, leading to decreased structural strength, rotational jamming, and even breakage. Therefore, enhancing rust resistance through scientific and reasonable surface treatment techniques is crucial for extending their service life and ensuring stable equipment operation. The following systematically describes rust-proofing surface treatment methods for iron angle wheel brackets from the perspectives of process principles, technical characteristics, and applicable scenarios.
Electroplating is one of the most commonly used rust-proofing processes for angle wheel brackets. Its principle is to deposit a thin metal film, such as zinc, nickel, or chromium, on the bracket surface through electrolysis. Zinc plating is the preferred choice in industrial applications due to its low cost and excellent rust-proof performance—zinc quickly forms a dense zinc oxide protective film in the air, protecting the iron substrate even if the plating is partially damaged through the "sacrificial anode" effect. Nickel plating combines corrosion resistance and wear resistance, making it suitable for high-load applications; chromium plating is known for its high hardness and chemical corrosion resistance, and is often used in precision equipment casters. The key to electroplating lies in controlling the current density and plating solution composition to ensure a uniform and dense coating, preventing rust failure due to porosity or cracks.
Powder coating uses electrostatic adsorption to evenly cover the surface of angle wheel brackets with powder coating, which is then cured at high temperature to form a tough coating. The core of this rust-prevention process lies in the physical isolation effect of the coating—the resin and pigment in the powder coating form a dense barrier, effectively blocking the contact between oxygen, water, and the iron substrate. Compared to traditional spray painting, powder coating is thicker, has stronger adhesion, and produces no solvent evaporation, making it more environmentally friendly. Furthermore, powder coating allows for customized production of various colors and surface textures to meet the aesthetic needs of different scenarios. For example, outdoor equipment casters often use gray or black powder coating, which is both dirt-resistant and coordinates with the overall style of the equipment.
Hot-dip galvanizing involves immersing angle wheel brackets in molten zinc, causing a metallurgical reaction between iron and zinc to form a composite structure of an iron-zinc alloy layer and a pure zinc layer. The rust-prevention advantage of this process lies in its dual protection mechanism: the alloy layer bonds tightly to the iron substrate, providing long-term corrosion resistance; the pure zinc layer acts as a sacrificial layer, preferentially oxidized to protect the alloy layer from corrosion. Hot-dip galvanizing offers a rust-prevention lifespan of over 20 years, making it particularly suitable for humid, salt-spray environments, such as coastal areas or chemical plants. However, this process limits the size of the brackets and results in a higher surface roughness, requiring subsequent grinding to meet the needs of precision equipment.
For high-end angle wheel brackets, stainless steel is the ultimate rust-prevention solution. By adding elements such as chromium and nickel, stainless steel forms a dense chromium oxide protective film on its surface, which can quickly self-repair even if scratched, preventing further corrosion. For example, 304 stainless steel contains 18% chromium and 8% nickel, exhibiting excellent corrosion resistance and suitable for high-cleanliness environments such as food and medical settings; 316 stainless steel, with the addition of molybdenum, has stronger resistance to chloride ion corrosion and is commonly used in marine environments. The processing of stainless steel angle wheel brackets requires precision casting or machining processes to ensure surface smoothness and prevent micro-cracks from becoming corrosion initiation points.
While anodizing is primarily used for light metals like aluminum and magnesium, improved processes can also be applied to rust prevention of iron angle wheel brackets. This process generates an iron oxide film on the iron surface through electrolysis. By adjusting the electrolyte composition and current parameters, the film thickness and porosity can be controlled. After sealing, the pores in the oxide film are filled, forming a dense protective layer with significantly improved corrosion resistance. Anodizing offers advantages such as the ability to achieve various color options and produces a film with high hardness and wear resistance, making it suitable for casters requiring frequent movement.
Rust-preventive grease coating is an economical and practical auxiliary rust prevention method. By applying a layer of grease containing rust inhibitors to the surface of angle wheel brackets, a dual physical and chemical protective film is formed. The physical film prevents oxygen and water from contacting the iron substrate; the chemical film reacts with the rust inhibitor on the iron surface to form a passivation layer, inhibiting corrosion. Rust-preventive grease is suitable for short-term storage or low-corrosion environments, such as indoor equipment casters. However, it's important to note that grease easily attracts dust, requiring regular cleaning and recoating to maintain its rust-preventive effect.
The rust-proofing surface treatment for iron angle wheel brackets needs to be selected comprehensively based on the usage scenario, cost budget, and performance requirements. Electroplating and powder coating are suitable for most industrial scenarios, balancing rust prevention and aesthetics; hot-dip galvanizing and stainless steel are suitable for highly corrosive environments, providing long-term protection; anodizing and rust-preventive grease are supplementary methods to meet specific needs. Through scientific material selection and process optimization, the rust resistance of angle wheel brackets can be significantly improved, providing a solid guarantee for the stable operation of equipment.
