Mechanistic interpretation of electrochemical behaviour of galvannealing coating in saline environment

Abstract A comparative study on galvannealed (GA) and galvanised plain-skin passed (GP-SP) coatings was carried out to evaluate coating microstructures, the corrosion resistance and electrochemical behaviour in 3.5% NaCl solution. The corrosion resistance behaviour of GA coating was found to be superior compared to GP-SP coating. The Fe–Zn intermetallic phases formed in GA coating provided galvanic protection i.e., a cell reaction between Fe and Zn within a single phase. This gives rise to protective potential plateau and are believed to be responsible for the electrochemical polarisation resulting in sluggish corrosion reaction kinetics, thereby reducing the corrosion rate significantly after prolonged exposure in saline environment. It was also observed from the electrochemical impedance spectroscopy (EIS) study that the coating capacitance (Cc) decreased and polarisation resistance (Rp) increased with exposure time indicating a continuous charge transfer reaction across the coating and electrolyte interface. Although the corrosion potential of both coatings increased towards more noble direction with exposure time, it was observed that the potential for GA coatings was always nobler than GP-SP coating as Ecorr shifted towards more positive potential corresponding to a flat potential band of −850 ± 20 mV.