Abstract

The present study aims at to study the effect of Mg variation on corrosion behavior of Zn-5Al-xMg (where x = 1.5 and 4.5 wt.%) hot-dip coating. The hot-dip Zn-5Al-xMg coating on steel substrate was carried out using Hot-dip process simulator (HDPS). Microstructure of the Zn-5Al-xMg coating was characterized using scanning electron microscope and x-ray diffraction. Micro-harness of the Zn-5Al-4.5Mg coating has been found to be ~ 3 times higher than that of galvanized coating. The corrosion behavior of the coatings was studied using dynamic polarization and electrochemical impedance spectroscopy (EIS) techniques in 3.5% NaCl solution as well as salt spray test (SST) in 5% NaCl solution. Zn-5Al-4.5Mg coating has exhibited two times higher corrosion resistance as compared to that of Zn-5Al-1.5Mg coating and 10 times higher corrosion resistance than conventional galvanized coating. Mechanism of corrosion has been analysed and discussed. The spot weldability of Zn-5Al-xMg coated steels has been found to be comparable to that of conventional galvanized (GI) steel sheets.

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