In the case of hot dip coating, the intermediate alloying layer which is formed between coating and base metal has an effect on the characteristics of the coated metal. When steel is aluminium-coated the intermediate alloying layer of iron-aluminium causes cracking and peeling of the coating because of its hardness and brittleness.
The effect of copper addition up to 10 pct. in the aluminium bath has been determined to lighten the intermediate layer. This attempt to lighten the intermediate layer was for the purpose of improving the repeated bending property of the coated metals. The repeated bending test has been done on the dipped metals in aluninium-copper baths of different conditions, and a limit of fracture has been plotted for a copper content of each bath. The copper addition is effective on lightening the intermediate layer, but has little effect on improving the bending property of the coated metals in comparison to the aluminium bath without copper addition.