Advancements in Zr-based conversion coatings on galvanized steel

Zirconium-based conversion coatings have emerged as a promising alternative to traditional chromate and phosphate treatments for galvanized steel, offering comparable corrosion resistance, environmental sustainability, and strong adhesion properties. This review discusses recent advancements in Zr-based coatings, focusing on their formation mechanisms, the role of metal ion additives, and the influence of organic modifiers on coating structure and performance. The impact of different substrates, including zinc, aluminum, and magnesium, on deposition behavior and adhesion strength is examined, highlighting the necessity of substrate optimization. By addressing key factors influencing Zr-based coatings, this study provides insights into improving their application for industrial corrosion protection, and expanding their commercial viability as an environmentally friendly coating technology.