Relation between microstructure and adhesion of hot dip galvanized zinc coatings on dual phase steel

The microstructure of hot dip galvanized zinc coatings on dual phase steel was investigated by electron microscopy and the coating adhesion characterized by tensile testing. The zinc coating consists of a zinc layer and columnar zeta-FeZn13 particles on top of a thin inhibition layer adjacent to the steel substrate. The inhibition layer is a thin compact and continuous layer that consists of eta-Fe2Al5-xZnx fine and coarse particles. The coarse faceted particles are on top and fine faceted particles are at the bottom. The steel surface is covered with small fraction manganese oxides, which may impair adhesion of the zinc coating. The adhesion at various interfaces that exist in zinc-coated steel was quantitatively estimated using a so-called "macroscopic atom" model. In addition, the adhesion at the interfaces in zinc-coated steel was qualitatively assessed by examining the fracture and delamination behavior upon tensile testing. In accordance with this model, fracture along zinc grain boundaries preceded fracture along the zinc layer/inhibition layer and zeta-FeZn13 particle/inhibition layer interfaces. (C) 2012 Acta Materialia Inc. Published by Elsevier Ltd. All rights reserved.