Abstract
The characterization of the FeAl intermetallic layer formed at the FeZn interface of a Zn-5 wt.% Al coating is presented in this paper. The interfacial layer was solely composed of Fe4Al13-xZnx crystals, but it exhibited different morphologies. The layer formed on α-Fe grains, having orientations of <100>//ND or <110>//ND, was smooth with a uniform thickness of 50–100 nm. The composing crystals were columnar in shape with their (010) plane parallel to a common {011}α plane. Five possible orientation relationships between α-Fe and Fe4Al13-xZnx were proposed, and three of them were verified. The layer formed on the <111>//ND grains was rough with thicknesses varying from 30 to 200 nm. The Fe4Al13-xZnx crystals in the rough region formed flower-like aggregates, in which five Fe4Al13-xZnx variants co-existed.
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