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<p>This study investigated the effect of zinc (Zn) with alloy elements applied via the hot-dip galvanized method on the corrosion protection of carbon steel substrates. The alloy layers consisted of Zn plus nickel (Ni) and aluminum (Al) incorporated at varying weight percentages (wt.%) under a constant temperature of 450&#xa0;°C. The influence of alloying elements on the Zn alloys was assessed through electrochemical and microstructural analyses, and fog chamber characterization. Electrochemical characterization conducted after 40&#xa0;days indicated that, among the Zn-Al samples, 0.0045 wt.% Al composition exhibited the highest resistance, at 10 kΩ-cm<sup>2</sup>, whereas for the Zn-Ni samples, a 0.0065 wt.% Ni composition demonstrated the highest resistance, at 16 kΩ-cm<sup>2</sup>. Notably, the resistance of the Zn alloy galvanized samples was almost four times higher than that of the conventional Zn galvanized samples, and reached a maximum resistance of 4 kΩ-cm<sup>2</sup>. The effects of corrosion resistance were further observed in a salt fog chamber. Addition of Al and Ni was found to increase the corrosion resistance of the Zn galvanized layer because of the barrier effect and the distribution of corrosion products.</p>

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Electrochemical Characterization of Hot-Dip Galvanized (HDG) Coatings of Zinc-Aluminum and Zinc-Nickel Alloys

  • 期刊论文

  • 发表日期：

    2025年4月30日

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  • A. C. Ferrel-Alvarez,
  • Yi Lu,
  • A. Ashok,
  • V. Subramaniam,
  • H. Castaneda

摘要

This study investigated the effect of zinc (Zn) with alloy elements applied via the hot-dip galvanized method on the corrosion protection of carbon steel substrates. The alloy layers consisted of Zn plus nickel (Ni) and aluminum (Al) incorporated at varying weight percentages (wt.%) under a constant temperature of 450 °C. The influence of alloying elements on the Zn alloys was assessed through electrochemical and microstructural analyses, and fog chamber characterization. Electrochemical characterization conducted after 40 days indicated that, among the Zn-Al samples, 0.0045 wt.% Al composition exhibited the highest resistance, at 10 kΩ-cm2, whereas for the Zn-Ni samples, a 0.0065 wt.% Ni composition demonstrated the highest resistance, at 16 kΩ-cm2. Notably, the resistance of the Zn alloy galvanized samples was almost four times higher than that of the conventional Zn galvanized samples, and reached a maximum resistance of 4 kΩ-cm2. The effects of corrosion resistance were further observed in a salt fog chamber. Addition of Al and Ni was found to increase the corrosion resistance of the Zn galvanized layer because of the barrier effect and the distribution of corrosion products.