Abstract
A new hot dip Zn–7Al alloy coating was performed on a structural steel by double coating of fine Zn and Zn–7 wt.% Al alloy, to prevent severe corrosion in coastal area. The alloy-coated steels were exposed to seaside, quasi-industrial, and rural districts to compare with conventional Zn coating. Double coating was significantly effective in preventing corrosion, particularly in a seaside. It was estimated from the exposure test for 10 years that the life of the Zn–7Al alloy-coated steel would be almost four times that of the Zn-coated steel in the seaside. A bending test showed that no exfoliation occurred at the interface between the coated alloy and substrate steel. TEM observation revealed that the excellent adhesiveness of the doubly coated fine Zn and Zn–7Al alloy to the steel substrate was due to formation of the interface region consisting of heterogeneous fine phase mixture of zinc, aluminium and iron.
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