Hardness and corrosion resistance of Zn coatings on mild steel obtained by electrodeposition and hot-dip galvanization

The purpose of this work is a comparative study of the characteristics of the layers of Zn on a substrate of mild steel from two different processes (electrodeposition and galvanizing), and to review the progress that has been made in understanding the intermetallics phases’ effect on the corrosion behavior. The obtained Zn-containing film was investigated using diverse instrumental methodologies such as microhardness, X-ray diffraction, and potentiodynamic polarization measurements. This study allows the conclusion that the layers of Zn developed have: a homogeneous structure and good hardness. The corrosion test results showed an improvement in corrosion resistance for electrodeposition coatings compared with galvanizing coatings. XRD results identify that the electrodeposition and the galvanizing coatings have similar phases and the maximum hardness is obtained for the galvanizing process. Intermetallic phases were found to influence the corrosion behavior of mild steel. The results show that the size of Fe–Zn particles gradually decreases with the immersion time.