The influence of Si addition in 55AlZn bath on the coating structures obtained in the batch hot-dip metallization

One of the methods of increasing the corrosion resistance of zinc coatings is the application of zinc and aluminium alloy baths in the metallization process. The coatings obtained are characterized by much better corrosion resistance thanks to the combination of aluminium properties, i.e. the barrier protection provided by naturally created aluminium oxides, with the capacity to protect the steel substrate, which is characteristic of zinc coatings. Zinc coatings with 55 wt. % Al and an addition of Si have gained industrial importance. The introduction of a third alloying component into the metallization bath is a technological addition, the aim of which is to reduce and possibly inhibit the aluminium diffusion towards the substrate. The article presents the results of the examination of coatings obtained in a 55AlZn bath at varied parameters of the technological process, as well as the specification of silicon addition influence on the structure and chemical composition of the coatings, and on the kinetics of growth. The coatings were obtained in three temperatures: 620, 640 and 660°C, and the process was conducted in a 55 wt. % Al bath with Si content of 0, 0.8 and 1.6 wt. % respectively, the remaining content was Zn. For the purposes of evaluating the microstructure and thickness of the coatings obtained, examinations on a light microscope were conducted. In order to determine the chemical composition of the coatings obtained, an EDS analysis was conducted. Quantitative examination of the chemical composition was carried out on the selected cross-sections of samples with coatings considered to be representative ones, using a SEM with a microanalysis system. Moreover, the linear distribution of elements on the cross-sections of the chosen coatings was determined. It is possible to state that the addition of silicon to 55AlZn baths allows reducing the uncontrolled growth of a layer. The layers obtained are more uniform, continuous and they show good adhesion to the substrate.