No, aluminum does not rust. Rust is a corrosion product associated with iron and iron-rich alloys (such as steel). When exposed to oxygen, it forms a thin, tightly adhering film of aluminum oxide, which slows further corrosion rather than peeling off and exposing new metal. This oxide film is a key reason why aluminum is widely considered a naturally corrosion-resistant metal. It protects the aluminum inside from further corrosion, hence the common saying "aluminum doesn't rust."

The rust formed when iron rusts is loose and porous, and it will continue to corrode inwards; the oxide film of aluminum is dense, and its properties are different.

However, under conditions such as strong acid, strong alkali, seawater/chloride ion environment, mercury salt, etc., the oxide film of aluminum will be destroyed, and aluminum will also be corroded, resulting in phenomena such as whitening, powdering, and pitting, sometimes called "white rust" or aluminum corrosion.

Aluminum does not rust like iron, but it can oxidize and corrode under certain conditions.

Yes, but it depends on the specific application. For general mechanical structural purposes, it may suffice to simply meet the relevant delivery condition and dimensional requirements; however, if the part requires higher strength, hardness, or wear resistance, appropriate heat treatment and machining will typically also be necessary.

Process

Hot-dip galvanizing: The steel grating is immersed in molten zinc at about 450°C. The zinc reacts with the iron in a metallurgical process to form an alloy layer.

Cold galvanizing (electro-galvanizing): Zinc ions are deposited on the surface of steel grating through electrolysis, which is a physical adhesion process.

Corrosion resistance and lifespan

Hot-dip galvanizing: Extremely strong. Outdoor corrosion protection can last for 20 to 50 years, which is dozens of times longer than electroplated zinc.

Cold galvanizing: Relatively weak. In humid outdoor environments, its lifespan is typically only 2 to 5 years, and they are prone to rusting.

Zinc coating thickness

Hot-dip galvanizing: Very thick, usually between 50 and 150 μm, with a high zinc coating.

Cold galvanizing: very thin, usually only 5~30μm, using very little zinc.

Bonding strength and appearance

Hot-dip galvanizing: Zinc and iron are metallurgically bonded, resulting in extremely strong adhesion and making it difficult to peel off. The surface is silvery-white, possibly with zinc spangles, and is relatively rough.

Cold galvanizing: physical adhesion, weak bonding force, easily scratched and peeled off. The surface is smooth and uniform, resulting in a more delicate and glossy appearance.

In terms of process, hot-dip galvanizing involves immersing the entire steel grating in molten zinc at a temperature above 450°C. The zinc reacts with the iron in a metallurgical process, forming a zinc-iron alloy layer and a pure zinc layer on the surface. This bonding is at the chemical level; the zinc layer is integrated with the substrate, resulting in extremely strong adhesion.

Cold galvanizing (electro-galvanizing) takes a different approach: at room temperature, zinc ions are deposited on the surface of the steel grating through an electrolytic reaction. The zinc layer and the substrate are physically adsorbed together; there is no alloying process. This means that the zinc layer itself is very thin and has weak adhesion, making it easy to peel off under mechanical damage.

Differences in manufacturing processes directly determine the direction of all subsequent performance parameters.

The thickness of the zinc coating is the most reliable indicator and the most direct basis for judgment during on-site inspection.

According to GB/T 13912, the zinc layer thickness of hot-dip galvanized steel gratings, which are commonly used in 3- 5 mm flat steel, should have an average thickness of not less than 70μm, and a minimum thickness of not less than 55μm in some areas. The actual control in the industry is usually higher, with many manufacturers achieving an average of 85-100μm, and the requirements for outdoor heavy corrosion environments are even higher. The zinc layer thickness of cold galvanizing is generally only 5-15μm, which is only one-tenth or even less of that of hot galvanizing.

The amplification effect of this thickness difference on corrosion protection lifespan is very significant. Hot-dip galvanizing has a corrosion resistance life of 20-50 years in outdoor environments, while cold galvanizing usually rusts within 1-3 years in humid outdoor environments, and is also not considered durable under dry indoor conditions. Hot-dip galvanizing is like "wearing armor," while cold galvanizing is like "wearing cling film."

There are also identifiable differences in appearance. Hot-dip galvanized surfaces are silver-gray or dark gray, and may have a small number of zinc nodules or patterns, with a matte finish; cold-dip galvanized surfaces are exceptionally bright and smooth, almost like a mirror. If you see so-called hot-dip galvanized steel that is "so shiny it reflects light" at the procurement site, you should be more cautious.

Another easily overlooked but crucial engineering difference is the coverage of weld points and cuts. Hot-dip galvanizing involves immersing the entire finished product in zinc, with welds, cuts, and inner corners all covered by the zinc layer, leaving no dead corners. Cold galvanizing, on the other hand, often involves processing before electroplating, resulting in an incomplete zinc layer at the weld joints, making corrosion most likely to spread from the weld point.

The unit price of cold-dip galvanized steel grating is indeed lower. Cold-galvanized components often require replacement within about three years. Although the unit price of hot-dip galvanizing is high, it does not need to be changed for 20 years, and the average annual cost is only about one-third of that of cold galvanizing. This does not yet take into account the disruption to production and operation caused by repeated maintenance, as well as the safety risks caused by the reduced load-bearing capacity of the steel grating after corrosion.

For scenarios with high corrosion loads and difficult maintenance, such as sewage treatment plants, chemical platforms, coastal facilities, and power plant trestle bridges, hot-dip galvanizing is almost the only reasonable option. The price difference "saved" by using cold galvanizing in these areas is usually recovered many times over by maintenance costs and downtime losses within the first major overhaul cycle.