Tuning of WO3 nanoparticles integration into Fe–Zn intermetallic layers of hot-dip zinc coating to control corrosion

•Tuning of the intermetallic layers of hot-dip zinc galvanic coatings.•Layer-wise microstructural modification for improved corrosion resistance.•Tuning of WO3 incorporation in each layer of hot-dip zinc coating.•Exploring SKP technique to characterize the intermetallic layers. The paper reports about an in-depth analysis on the dissolution study of ɳ, ζ and δ phases of composite zinc coating developed by integrating WO3 nanoparticles, and assessment of their anti-corrosion characteristics. The composite coating with WO3 nanoparticles effectively integrated into the ɳ phase than the mixed ζ &δ phases or γ phase offers the best corrosion protection characteristics. The superior anti-corrosion performance of composite zinc coating with distinct amount of nanoparticles integration into the ɳ phase than the other intermetallic phases is due to the formation of compact and crack free Fe–Zn intermetallic layer with strong W–Zn bonds. The work is proposed as a cost-effective and simple method for the evaluation of high-temperature coatings, where the performance is influenced by the formation and stability of interior intermetallics.