Optimizing corrosion protection: Performance comparison of Zn and Zn-Al-Mg alloys Hot-Dip galvanized coatings

The corrosion resistance of galvanized coatings is essential for improving the performance of steel structures. Coating quality is strongly influenced by several parameters, including the addition of chemical elements to the zinc bath, such as aluminum and magnesium, which can improve the limitations of zinc coatings, particularly in aggressive environments. In this study, zinc (Zn) and zinc-aluminum-magnesium (ZAM) coatings were compared by assessing their effectiveness against corrosion and its evolution through a series of microstructural and tribological properties. The presence of binary and ternary eutectic phases in the ZAM coating enhances the corrosion resistance and the self-healing capacity through their preferential corrosion, unlike the zinc coating, which is formed by a single zinc phase. This study highlights the potential of Zn-Al-Mg alloys as a viable alternative to traditional zinc-based coatings, and paves the way for the development of more durable and effective protective coatings for industrial applications. •Comparative analysis of Zn-0.2 %Al and Zn-4 %Al-5 %Mg coatings in hot-dip galvanizing.•Improved mechanical strength and corrosion resistance of Zn-4 %Al-5 %Mg alloy coatings.•Performance evaluation under accelerated and natural corrosion conditions.•Prospects for optimizing hot-dip galvanizing processes for industrial applications.•Significant contributions to the advancement of surface treatment techniques in various industries.