Steel is still the main construction material for automobiles, general equipment and
industrial machinery. Hot dipping has been proven to be an excellent method of corrosion protection
of steels for a wide range of applications worldwide. Coatings of Zn-Al alloys on steel sheet have
high corrosion resistance due to the corrosion prevention ability from Zn and the passivation of Al
Bath composition, immersion velocity/time and substrate composition are the hot dipping
parameters that more influence on the thickness and corrosion resistance of the deposited coating. In
order to study their influence small amounts of magnesium were added.
Experiments were performed in a hot dipping simulator using different substrates, bath
compositions and hot dipping parameters. Surface layers were characterised by: Scanning Electron
Microscopy (SEM) and Energy dispersive X-Ray spectroscopy (EDX or EDS). Cyclic corrosion
tests were performed in order to observe the corrosion resistance for different Zn-Al-Mg coatings.
Results show that the microstructure and composition of the substrate strongly affect the desired
coating properties. Nevertheless, the influence of the magnesium on coating thickness is relevant,
increasing when added in small quantities in a molten bath of Zn-5wt %Al. The quality and
microstructure of the coating is affected by the amount of Mg in the bath. Cyclic corrosion tests
results show that the quality of the coating is affected by the amount of Mg in the bath.