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Evaluation of the corrosion protection of organic-coated zinc-alloy galvanised steels using novel, environmentally-friendly corrosion inhibitor pigments

Gwynfor Callaghan, Sonny Ngo, Geraint Williams

Progress in Organic Coatings, Volume: 210, Start page: 109646

Swansea University Authors: Gwynfor Callaghan, Geraint Williams

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DOI (Published version): 10.1016/j.porgcoat.2025.109646

Abstract

The corrosion behaviour of steel coated with either: a primarily zinc coating comprised of 0.15 wt% Al (HDG) or a zinc-aluminium-magnesium coating, 1.6 wt% Mg, 1.6 wt% Al, and 96.8 wt% Zn (ZAM) are investigated in the presence of industry standard and emerging, environmentally-friendly corrosion inh...

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Published in: Progress in Organic Coatings
ISSN: 0300-9440 1873-331X
Published: Elsevier BV 2026
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URI: https://cronfa.swan.ac.uk/Record/cronfa70311
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spelling 2025-09-05T11:13:58.1578004 v2 70311 2025-09-05 Evaluation of the corrosion protection of organic-coated zinc-alloy galvanised steels using novel, environmentally-friendly corrosion inhibitor pigments 22dc96e0dcaa88650bde2c5ab671b2a6 Gwynfor Callaghan Gwynfor Callaghan true false 0d8fc8d44e2a3c88ce61832f66f20d82 Geraint Williams Geraint Williams true false 2025-09-05 The corrosion behaviour of steel coated with either: a primarily zinc coating comprised of 0.15 wt% Al (HDG) or a zinc-aluminium-magnesium coating, 1.6 wt% Mg, 1.6 wt% Al, and 96.8 wt% Zn (ZAM) are investigated in the presence of industry standard and emerging, environmentally-friendly corrosion inhibitor technologies. With this paper evaluating the inhibitory performance of a functionalised oxy-amino-phosphate-salt of magnesium (OPMG), a hydrotalcite carbonate clay loaded with 4-aminobenzoic acid (HT-PABA), a calcium ion exchange pigment (Ca-Ex), and an inhibitor based on 2-(1,3-benzothiazol-2-ylithio) succinic acid (BTSA) dispersed in model poly-vinyl-butyral (PVB) coatings and 3.5 wt% NaCl (aq) solutions. With their inhibitory performance evaluated against two corrosion-driven coating failure mechanisms: cathodic disbondment (CD), and filiform corrosion (FFC) as a function of inhibitor loading. In the case of CD, an inhibitor ranking order of BTSA > HT-PABA > OPMG > Ca-Ex is observed, while OPMG and HT-PABA are the most effective at slowing rates of FFC. Potentiodynamic and scanning vibrating electrode (SVET) experiments were conducted to evaluate the efficiency of the most promising inhibitors at slowing rates of corrosion on the bare ZAM alloy surface and the exposed cut edges immersed in chloride solutions. With OPMG and BTSA both shown to act as net anodic inhibitors, resulting in an increase in the polarisation resistance by over an order of magnitude. Both inhibitors produced a derived 67 % reduction in total (zinc) metal loss at the exposed ZAM cut-edges over a 24 h immersion period against the control. Journal Article Progress in Organic Coatings 210 109646 Elsevier BV 0300-9440 1873-331X Galvanised steel; Cathodic disbondment; Filiform corrosion; Corrosion inhibitive pigments; Scanning vibrational electrode technique; ZMA 1 1 2026 2026-01-01 10.1016/j.porgcoat.2025.109646 COLLEGE NANME COLLEGE CODE Swansea University SU Library paid the OA fee (TA Institutional Deal) This work was sponsored by: Beckers Industrial Coatings, the EPSRC as part of the centre for Doctoral training in Functional Industrial Coatings (COATED) grant reference (EP/S02252X/1). The author would like to thank Beckers Industrial Coatings, the EPSRC, Swansea University, Tata steel and COATED M2A for the funding, materials and support during the EngD studentship. 2025-09-05T11:13:58.1578004 2025-09-05T11:06:26.3808885 Faculty of Science and Engineering School of Engineering and Applied Sciences - Materials Science and Engineering Gwynfor Callaghan 1 Sonny Ngo 2 Geraint Williams 3 70311__35063__5761310a7dcc4b5f88457417ebf84497.pdf 70311.VOR.pdf 2025-09-05T11:11:56.0200314 Output 7954637 application/pdf Version of Record true © 2025 The Authors. This is an open access article distributed under the terms of the Creative Commons CC-BY license. true eng http://creativecommons.org/licenses/by/4.0/
title Evaluation of the corrosion protection of organic-coated zinc-alloy galvanised steels using novel, environmentally-friendly corrosion inhibitor pigments
spellingShingle Evaluation of the corrosion protection of organic-coated zinc-alloy galvanised steels using novel, environmentally-friendly corrosion inhibitor pigments
Gwynfor Callaghan
Geraint Williams
title_short Evaluation of the corrosion protection of organic-coated zinc-alloy galvanised steels using novel, environmentally-friendly corrosion inhibitor pigments
title_full Evaluation of the corrosion protection of organic-coated zinc-alloy galvanised steels using novel, environmentally-friendly corrosion inhibitor pigments
title_fullStr Evaluation of the corrosion protection of organic-coated zinc-alloy galvanised steels using novel, environmentally-friendly corrosion inhibitor pigments
title_full_unstemmed Evaluation of the corrosion protection of organic-coated zinc-alloy galvanised steels using novel, environmentally-friendly corrosion inhibitor pigments
title_sort Evaluation of the corrosion protection of organic-coated zinc-alloy galvanised steels using novel, environmentally-friendly corrosion inhibitor pigments
author_id_str_mv 22dc96e0dcaa88650bde2c5ab671b2a6
0d8fc8d44e2a3c88ce61832f66f20d82
author_id_fullname_str_mv 22dc96e0dcaa88650bde2c5ab671b2a6_***_Gwynfor Callaghan
0d8fc8d44e2a3c88ce61832f66f20d82_***_Geraint Williams
author Gwynfor Callaghan
Geraint Williams
author2 Gwynfor Callaghan
Sonny Ngo
Geraint Williams
format Journal article
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container_volume 210
container_start_page 109646
publishDate 2026
institution Swansea University
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publisher Elsevier BV
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hierarchy_top_title Faculty of Science and Engineering
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department_str School of Engineering and Applied Sciences - Materials Science and Engineering{{{_:::_}}}Faculty of Science and Engineering{{{_:::_}}}School of Engineering and Applied Sciences - Materials Science and Engineering
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description The corrosion behaviour of steel coated with either: a primarily zinc coating comprised of 0.15 wt% Al (HDG) or a zinc-aluminium-magnesium coating, 1.6 wt% Mg, 1.6 wt% Al, and 96.8 wt% Zn (ZAM) are investigated in the presence of industry standard and emerging, environmentally-friendly corrosion inhibitor technologies. With this paper evaluating the inhibitory performance of a functionalised oxy-amino-phosphate-salt of magnesium (OPMG), a hydrotalcite carbonate clay loaded with 4-aminobenzoic acid (HT-PABA), a calcium ion exchange pigment (Ca-Ex), and an inhibitor based on 2-(1,3-benzothiazol-2-ylithio) succinic acid (BTSA) dispersed in model poly-vinyl-butyral (PVB) coatings and 3.5 wt% NaCl (aq) solutions. With their inhibitory performance evaluated against two corrosion-driven coating failure mechanisms: cathodic disbondment (CD), and filiform corrosion (FFC) as a function of inhibitor loading. In the case of CD, an inhibitor ranking order of BTSA > HT-PABA > OPMG > Ca-Ex is observed, while OPMG and HT-PABA are the most effective at slowing rates of FFC. Potentiodynamic and scanning vibrating electrode (SVET) experiments were conducted to evaluate the efficiency of the most promising inhibitors at slowing rates of corrosion on the bare ZAM alloy surface and the exposed cut edges immersed in chloride solutions. With OPMG and BTSA both shown to act as net anodic inhibitors, resulting in an increase in the polarisation resistance by over an order of magnitude. Both inhibitors produced a derived 67 % reduction in total (zinc) metal loss at the exposed ZAM cut-edges over a 24 h immersion period against the control.
published_date 2026-01-01T05:30:33Z
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