Corrosion behaviors of the eutectic structure in zn-al-mg alloy coated steel in chloride containing aqueous environment

To clearly understand the effect of the eutectic structure in the Zn-Al-Mg alloy coating on the corrosion behaviors in chloride containing aqueous environments, a bulk Zn-MgZn₂ sample was fabricated by diffusion bonding process, and a variety of experiments, such as electrochemical polarization and galvanic corrosion measurements, salt spray tests, and cyclic corrosion tests, were carried out. This study revealed that the corrosion potential values of MgZn₂ and Zn samples exposed to a 5 wt.% of NaCl solution were approximately -1.5 and -1 V_SCE, respectively, and the MgZn₂ showed a higher corrosion current density than Zn at the early stage of corrosion. The continued dissolution of MgZn₂ phase from the eutectic structure in the coating layer provides not only sacrificial protection, but also environmental conditions for the co-formation of two types of corrosion products (simonkoleite (Zn₅(OH)₈Cl₂·H₂O) and hydrotalcite (ZnAl₂(OH)₆Cl₂· H₂O)) which have an inhibiting effect on the outer surface. The formation areas and kinetics of the two products on the coating surface were different, and they were greatly dependent upon the types of eutectic structures in the coating layer. Based on the results, a modified anti-corrosion mechanism of Zn-Al-Mg alloy coated steel sheet in chloride containing aqueous environment was proposed.