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The effect of deformation-induced cracks on the corrosion behaviour of HDG Zn-Mg-Al coatings

Amar Malla Orcid Logo, David Penney Orcid Logo, Geraint Williams, F. E. Goodwin, Ana P. Domingos Cardoso, MATTHEW BROOKS, James Sullivan Orcid Logo

npj Materials Degradation, Volume: 10, Issue: 1, Start page: 81

Swansea University Authors: Amar Malla Orcid Logo, David Penney Orcid Logo, Geraint Williams, MATTHEW BROOKS, James Sullivan Orcid Logo

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DOI (Published version): 10.1038/s41529-026-00800-0

Abstract

Zn-Mg-Al coatings (ZMA) on steel can provide enhanced corrosion resistance compared to zinc coating (GI) and are often used in applications that require shaping processes. This study investigates the effect of deformation-induced cracking on the corrosion of ZMA coatings of different weights (310 an...

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Published in: npj Materials Degradation
ISSN: 2397-2106
Published: Springer Nature 2026
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URI: https://cronfa.swan.ac.uk/Record/cronfa72179
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This study investigates the effect of deformation-induced cracking on the corrosion of ZMA coatings of different weights (310 and 80 g m-2) benchmarked against GI. Cracks were more prevalent and of greater depth in ZMA coatings due to the presence of MgZn2 in the eutectic. ZMA with 310 g m-2 weight (ZMA310), exhibited a ~ 3 times greater crack area than 80 g m-2 weight (ZMA80) through an increased eutectic volume fraction. This caused an increase in corrosion rate of 3.8 times for ZMA310 relative to its undeformed condition over 24 h, with increases between 1.5 and 1.7 times for ZMA80 and GI. 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spelling 2026-06-26T16:21:15.5269799 v2 72179 2026-06-26 The effect of deformation-induced cracks on the corrosion behaviour of HDG Zn-Mg-Al coatings 51d0d611e98814e99679d9bb21836e3d 0000-0002-9133-7615 Amar Malla Amar Malla true false 869becc35438853f2bca0044df467631 0000-0002-8942-8067 David Penney David Penney true false 0d8fc8d44e2a3c88ce61832f66f20d82 Geraint Williams Geraint Williams true false fa6725c93f5cac4415c60ad1a6ace0dc MATTHEW BROOKS MATTHEW BROOKS true false 40e32d66748ab74184a31207ab145708 0000-0003-1018-773X James Sullivan James Sullivan true false 2026-06-26 EAAS Zn-Mg-Al coatings (ZMA) on steel can provide enhanced corrosion resistance compared to zinc coating (GI) and are often used in applications that require shaping processes. This study investigates the effect of deformation-induced cracking on the corrosion of ZMA coatings of different weights (310 and 80 g m-2) benchmarked against GI. Cracks were more prevalent and of greater depth in ZMA coatings due to the presence of MgZn2 in the eutectic. ZMA with 310 g m-2 weight (ZMA310), exhibited a ~ 3 times greater crack area than 80 g m-2 weight (ZMA80) through an increased eutectic volume fraction. This caused an increase in corrosion rate of 3.8 times for ZMA310 relative to its undeformed condition over 24 h, with increases between 1.5 and 1.7 times for ZMA80 and GI. Two phenomena cause this increase: deformation-accelerated corrosion due to differential aeration-induced anodic activation in non-through-coating cracks, and cathodic activation in through-coating cracks resulting from galvanic coupling with the steel. Journal Article npj Materials Degradation 10 1 81 Springer Nature 2397-2106 4 5 2026 2026-05-04 10.1038/s41529-026-00800-0 COLLEGE NANME Engineering and Applied Sciences School COLLEGE CODE EAAS Swansea University Other International Zinc Association and Swansea University via the Galvanised Autobody Partnership program. 2026-06-26T16:21:15.5269799 2026-06-26T16:12:12.8273871 Faculty of Science and Engineering School of Engineering and Applied Sciences - Materials Science and Engineering Amar Malla 0000-0002-9133-7615 1 David Penney 0000-0002-8942-8067 2 Geraint Williams 3 F. E. Goodwin 4 Ana P. Domingos Cardoso 5 MATTHEW BROOKS 6 James Sullivan 0000-0003-1018-773X 7 72179__37066__d254b16150794423bc4d0e65565f7350.pdf 41529_2026_Article_800.pdf 2026-06-26T16:12:12.8100630 Output 3303825 application/pdf Version of Record true © The Author(s) 2026. This article is licensed under a Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 International License. true eng http://creativecommons.org/licenses/by-nc-nd/4.0/
title The effect of deformation-induced cracks on the corrosion behaviour of HDG Zn-Mg-Al coatings
spellingShingle The effect of deformation-induced cracks on the corrosion behaviour of HDG Zn-Mg-Al coatings
Amar Malla
David Penney
Geraint Williams
MATTHEW BROOKS
James Sullivan
title_short The effect of deformation-induced cracks on the corrosion behaviour of HDG Zn-Mg-Al coatings
title_full The effect of deformation-induced cracks on the corrosion behaviour of HDG Zn-Mg-Al coatings
title_fullStr The effect of deformation-induced cracks on the corrosion behaviour of HDG Zn-Mg-Al coatings
title_full_unstemmed The effect of deformation-induced cracks on the corrosion behaviour of HDG Zn-Mg-Al coatings
title_sort The effect of deformation-induced cracks on the corrosion behaviour of HDG Zn-Mg-Al coatings
author_id_str_mv 51d0d611e98814e99679d9bb21836e3d
869becc35438853f2bca0044df467631
0d8fc8d44e2a3c88ce61832f66f20d82
fa6725c93f5cac4415c60ad1a6ace0dc
40e32d66748ab74184a31207ab145708
author_id_fullname_str_mv 51d0d611e98814e99679d9bb21836e3d_***_Amar Malla
869becc35438853f2bca0044df467631_***_David Penney
0d8fc8d44e2a3c88ce61832f66f20d82_***_Geraint Williams
fa6725c93f5cac4415c60ad1a6ace0dc_***_MATTHEW BROOKS
40e32d66748ab74184a31207ab145708_***_James Sullivan
author Amar Malla
David Penney
Geraint Williams
MATTHEW BROOKS
James Sullivan
author2 Amar Malla
David Penney
Geraint Williams
F. E. Goodwin
Ana P. Domingos Cardoso
MATTHEW BROOKS
James Sullivan
format Journal article
container_title npj Materials Degradation
container_volume 10
container_issue 1
container_start_page 81
publishDate 2026
institution Swansea University
issn 2397-2106
doi_str_mv 10.1038/s41529-026-00800-0
publisher Springer Nature
college_str Faculty of Science and Engineering
hierarchytype
hierarchy_top_id facultyofscienceandengineering
hierarchy_top_title Faculty of Science and Engineering
hierarchy_parent_id facultyofscienceandengineering
hierarchy_parent_title Faculty of Science and Engineering
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
document_store_str 1
active_str 0
description Zn-Mg-Al coatings (ZMA) on steel can provide enhanced corrosion resistance compared to zinc coating (GI) and are often used in applications that require shaping processes. This study investigates the effect of deformation-induced cracking on the corrosion of ZMA coatings of different weights (310 and 80 g m-2) benchmarked against GI. Cracks were more prevalent and of greater depth in ZMA coatings due to the presence of MgZn2 in the eutectic. ZMA with 310 g m-2 weight (ZMA310), exhibited a ~ 3 times greater crack area than 80 g m-2 weight (ZMA80) through an increased eutectic volume fraction. This caused an increase in corrosion rate of 3.8 times for ZMA310 relative to its undeformed condition over 24 h, with increases between 1.5 and 1.7 times for ZMA80 and GI. Two phenomena cause this increase: deformation-accelerated corrosion due to differential aeration-induced anodic activation in non-through-coating cracks, and cathodic activation in through-coating cracks resulting from galvanic coupling with the steel.
published_date 2026-05-04T06:26:31Z
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score 11.110583

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