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<p>Hot-dip galvanizing is critical for steel corrosion protection, but abnormal growth of the brittle <i>ζ</i>–FeZn<sub>13</sub> phase in Sandelin steel galvanizing degrades coating structure and adhesion. This work investigates the effect of 0 to 0.8 wt pct Cu addition in zinc bath at 450&#xa0;°C on the microstructure, <i>ζ</i>-phase growth kinetics, and corrosion resistance of hot-dip galvanized coatings on Sandelin steel. Results show that Cu addition thins the total alloy layer, thickens the <i>δ</i><sub>1</sub>–FeZn<sub>10</sub> phase, and inhibits abnormal <i>ζ</i>-phase growth. The <i>ζ</i>-phase growth exponent n decreases from 0.90&#xa0;±&#xa0;0.08 to 0.51&#xa0;±&#xa0;0.15, with the growth mechanism switching from interface reaction to solid-state diffusion control. The Zn-0.8Cu coating achieves refined <i>η</i>-Zn grains (36.6 <i>μ</i>m) and improved corrosion resistance: for the <i>η</i> layer, <i>R</i><sub><i>p</i></sub> increases from 674.2&#xa0;±&#xa0;6.7 to 1538.0&#xa0;±&#xa0;7.1 Ω·cm<sup>2</sup>; for the (<i>η</i>&#xa0;+&#xa0;<i>ζ</i>) layer,<i> R</i><sub><i>p</i></sub> increases from 1333.4&#xa0;±&#xa0;5.2 to 2400.5&#xa0;±&#xa0;5.4 Ω·cm<sup>2</sup> and <i>I</i><sub>corr</sub> decreases from 6.80&#xa0;±&#xa0;0.582&#xa0;×&#xa0;10<sup>−5</sup> to 3.55&#xa0;±&#xa0;0.299&#xa0;×&#xa0;10<sup>−5</sup> A/cm<sup>2</sup>. After 125 hours salt spray, red rust area is 39.1&#xa0;±&#xa0;5.2 pct vs. 97.8&#xa0;±&#xa0;7.5 pct for pure Zn.</p>

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Microstructure and Corrosion Resistance of Zn–Cu Hot-Dip Galvanized Coatings on Sandelin Steel

  • 期刊论文

  • 发表日期：

    2026年7月17日

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  • Zhenkun Yu,
  • Gang Kong,
  • Guowei Liang,
  • Delin Lai,
  • Chunshan Che

摘要

Hot-dip galvanizing is critical for steel corrosion protection, but abnormal growth of the brittle ζ–FeZn13 phase in Sandelin steel galvanizing degrades coating structure and adhesion. This work investigates the effect of 0 to 0.8 wt pct Cu addition in zinc bath at 450 °C on the microstructure, ζ-phase growth kinetics, and corrosion resistance of hot-dip galvanized coatings on Sandelin steel. Results show that Cu addition thins the total alloy layer, thickens the δ1–FeZn10 phase, and inhibits abnormal ζ-phase growth. The ζ-phase growth exponent n decreases from 0.90 ± 0.08 to 0.51 ± 0.15, with the growth mechanism switching from interface reaction to solid-state diffusion control. The Zn-0.8Cu coating achieves refined η-Zn grains (36.6 μm) and improved corrosion resistance: for the η layer, Rp increases from 674.2 ± 6.7 to 1538.0 ± 7.1 Ω·cm2; for the (η + ζ) layer, Rp increases from 1333.4 ± 5.2 to 2400.5 ± 5.4 Ω·cm2 and Icorr decreases from 6.80 ± 0.582 × 10−5 to 3.55 ± 0.299 × 10−5 A/cm2. After 125 hours salt spray, red rust area is 39.1 ± 5.2 pct vs. 97.8 ± 7.5 pct for pure Zn.