Abstract
Abstract Aluminium and magnesium are known for their ability to improve corrosion performance of zinc coatings used for steel protection in automotive applications. To investigate the inhibiting properties of other elements, series of model Zn X, Zn Al X, Zn Mg X and Zn Al Mg X alloys containing 0.2–2 wt% of titanium, mischmetal (mixture of cerium and other lanthanides), zirconium, molybdenum, chromium, boron, gallium, indium, copper, nickel, calcium, manganese and silicon were prepared and their corrosion performance in a cyclic accelerated test and at a marine field site and the ability to provide galvanic protection to steel in defects were characterized. On openly exposed surfaces, none of the investigated elements showed stronger inhibiting effect on atmospheric corrosion than Al and Mg. When exposed to marine climate, it was beneficial to combine Al and Mg. The corrosion stability of Zn Al Mg was further improved by addition of a fourth element. Quaternary Zn Al Mg X alloys outperformed binary Zn X and ternary Zn Al X and Zn Mg X alloys. In average, mass loss was 4-fold higher in confined zones simulating hem flanges. Strong inhibition with Mg and detrimental effects of Al on corrosion in confined zones was found. Several quaternary Zn Al Mg X alloys with improved corrosion stability in both open and confined configurations were identified.
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