The corrosion behaviour of nine Zn–Al alloys, pure zinc and pure aluminium was examined in a 2 mass%HCl solution. Furthermore, the behaviour of Zn-50 mass%Al and Zn-60 mass%Al alloys cooled to room temperature by eight methods was also examined in 2 mass%HCl and 3 mass%NaCl solutions. To obtain the information on the effect of cooling conditions after coating on the corrosion behaviour of hot dip Zn–Al alloy coated steel sheet, the results obtained were discussed from the standing point of matrix structure.
Up to 60 mass%Al, a sample surface is corroded extensively, while at and above 70 mass%Al, a part of original sample surface remains uncorroded. At 10 mass%Al, a dendrite is corroded preferentially, on the contrary, an interdendritic portion is corroded at and above 30 mass%Al. The mass loss of Zn–Al alloy by corrosion decreases generally with increasing Al content of alloy, except Zn-50 mass%Al, Zn-60 mass%Al and Zn-90 mass%Al alloys. The mass loss of Zn-60 mass%Al alloy is greater than that of pure zinc.
Independent of the cooling condition and the alloy type, the mass of sample decreases in a HCl solution, while it increases in a NaCl solution. The mass loss of Zn-50 mass%Al alloy in a HCl solution decreases with decreasing cooling rate, while the mass gain in a NaCl solution increases. The mass loss of Zn-60 mass%Al alloy in a HCl solution is greater when the alloy is cooled to room temperature in 54 ks, and is smallest when the alloy is held in an alpha region and then water-quenched. In each solution, a Zn-rich portion is corroded prior to an Al-rich one.
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