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Effects of Heat Treatment and Plating Sequence on Microstructure Evolution and Corrosion Properties of Mechanically Plated Zinc-Tin Coatings

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Abstract

Steel fasteners were mechanically plated with different deposition sequence of Zn and Sn and heat treated at 340 °C for 30 min. After heat treatment and irrespective of the plating sequence, a dense iron-zinc (Fe-Zn)-rich interfacial layer was formed adjacent to the substrate while the outer coating layer was Sn-rich and appeared more porous. Energy-dispersive x-ray spectroscopy (EDS) and x-ray diffractometry (XRD) analyses confirmed the presence of ζ-FeZn13, δ1p-FeZn10, δ1k-FeZn7, and Γ-Fe3Zn10 phases within the interfacial layer. Post-mechanical plating heat treatment was diffusion controlled, with Fe and Zn atoms diffusing in opposite direction, but the process was dominated by the diffusion of Zn toward the steel substrate, and this was facilitated by Sn. Microhardness test indicated that the hardness of steel substrate was not affected by post-mechanical plating heat treatment. Cyclic salt spray testing showed that the heat-treated coatings exhibited better corrosion resistance (in terms of red rust appearance) despite the presence of porosity. In the early stage of corrosion, Zn at the Sn-rich outer layer dissolved preferentially, followed by the dissolution of Sn. When the anodic reaction at the outer layer approached the Fe-Zn intermetallic layer, the anodic site changed to the Fe-Zn layer. The Fe-Zn intermetallic layer acted as an effective barrier to the corrosion of underlying steel substrate because Zn from Fe-Zn layer dissolved slower than pure Zn.

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Acknowledgments

This work was financially supported by Swinburne University Postgraduate Research Award (SUPRA) scholarship program, and a Higher Degree Research Publications Award from the Faculty of Science, Engineering and Technology. We are grateful to Mr. Peter Cook and Kwik-Coat (Aust) Pty Ltd for the access to materials, coating facilities, and testing equipment. This research did not receive any specific grant from funding agencies in the public, commercial, or not-for-profit sectors.

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  1. Department of Mechanical Engineering and Product Design Engineering, School of Engineering, Swinburne University of Technology, Hawthorn, VIC, 3122, Australia

    P. P. Chung, J. Wang & Y. Durandet

  2. School of Engineering and Science, Faculty of Engineering, Computing and Science, Swinburne University of Technology Sarawak Campus, 93350, Kuching, Malaysia

    P. P. Chung

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Chung, P.P., Wang, J. & Durandet, Y. Effects of Heat Treatment and Plating Sequence on Microstructure Evolution and Corrosion Properties of Mechanically Plated Zinc-Tin Coatings. Metall Mater Trans A 54, 791–807 (2023). https://doi.org/10.1007/s11661-022-06920-x

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