Effect of Zn-Mg interlayer on the corrosion resistance of multilayer Zn-based coating fabricated by physical vapor deposition process

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A novel Zn/Zn-Mg/Zn multilayer coating is prepared on steel plate by PVD. The effect of the multilayer structure comprising Zn-Mg interlayer on the corrosion resistance is discussed. The corrosion resistance is evaluated by the salt spray test, and the corrosion progression is analyzed by electrochemical impedance spectroscopy and corrosion products observation. Eluted Mg ions from the Zn-Mg interlayer form a porous Mg corrosion product layer that permeates chlorine ions, assists the coating transform to Zn5(OH)8Cl2·H2O phase. Improved corrosion resistance of the coating can be explained by the rapid increasement of the impedance by the formation of the protective Zn5(OH)8Cl2·H2O phase.

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