Hot dip Galvanising of radiator for a transformer may not be advisible considering the thickness of the radaitor sheet which may deform during hot dipping. But some client may prevail on this?. Why.
Clients usually the radiator fins are prone to atmospheric corrossion, and more so in the Indian Climate.Besides, atmos[heris corrossion , the fins are welded making them more corrossion prone.The corrosion of fins , lead to porosity and hence leakage of transformer oil.
It is difficult to plug these leaks as they originate from difficult to access, or from the weld joints that could practically be inaccessible.
It is observed that the if the corrosion can be avoided / or atleast delayed, the trouble free working time can be increased.
Hence clients desire Hot Dip Galvansing on radiator fins.
However, the process can through up problems as mentioned by you.
You may consider Cold Galvanising , a process where you can deposit about 90% Zn by as a coating , either bu brushing or spraying.Sme such coatings are tested for salt mist condidionts that may be help you evaluate the suitabvility for your application.I recollect some products claiming sustainability for over 180 empirical hours, but you may please check afresh.
You may check with good industrial coatings manufacturer, metal care products.Accesing ITW devcon, Nicco websites could be of help.