Effect of coating thickness on the corrosion behavior of galvanized steel in 3.5 % nacl solution

Corrosion behavior of three carbon steels with increasing galvanized coating thickness of 5.6, 8.4 and 19.2 μm named as T1, T2 and T3, respectively, was studied by immersion test, potentiodynamic polarization and electrochemical impedance spectroscopy in freely aerated 3.5% NaCl solution. The major phase in the corrosion product of all the samples after immersion test was found to be zincite, as determined by X-Ray Diffraction and Fourier Transform Infrared Spectroscopy techniques. The corrosion product on sample T1was well adhered and was compact in most regions. Samples T2 and T3 showed porous and non-adherent growth of corrosion product. Corrosion rates were found to increase with increasing coating thickness. The impedance provided by the coating as well as the substrate was the highest for the sample with thinnest coating (T1). The early exposure of the underlying steel in sample T1 resulted in higher corrosion resistance, which was probably due to the combined effect of zinc corrosion products and Fe-Zn alloy layer. Higher amount of protective γ-FeOOH as well as compact corrosion product could have also improved the corrosion resistance of sample T1. Although the average uniform corrosion resistance was higher for T1, the localized pitting corrosion was also observed, probably due to the thin galvanized layer