This study investigated the corrosion performance of wire arc deposited zinc-aluminum pseudo alloy coating (Zn-Al pseudo alloy) with higher aluminum content and Zn-15Al alloy coating in the aggressive chloride environment. The performance of both coatings was assessed by employing morphological analysis, chemical composition and material characterization tests, and electrochemical studies. Micrographs of the as-deposited coatings revealed a denser and compact microstructure in the pseudo alloy coating compared to Zn-15Al coating. The electrochemical test results demonstrated that the pseudo alloy coating exhibited a four times lower corrosion rate and four times higher corrosion resistance compared to the Zn-15Al coating. Although, the formation of simonkolleite is noticed in the corrosion products of both the coatings, a more thin and compact corrosion product layer is observed in the pseudo alloy coating. The superior performance of Zn-Al pseudo alloy coating can be attributed to the presence of higher aluminum content and the existence of zinc-rich and aluminum-rich areas in the coating microstructure, where zinc offers sacrificial protection at the aluminum-rich region boundaries, in addition to the formation of stable corrosion products of zinc at zinc-rich areas, passivation of aluminum at the aluminum-rich areas, reduced the overall rate of corrosion in such coatings.

本研究研究了铝含量较高的焊丝电弧沉积锌铝伪合金涂层（Zn-Al 伪合金）和 Zn-15Al 合金涂层在腐蚀性氯化物环境中的腐蚀性能。通过形态分析、化学成分和材料表征测试以及电化学研究评估了两种涂层的性能。与 Zn-15Al 涂层相比，沉积涂层的显微照片显示，伪合金涂层中的微观结构更致密和致密。电化学测试结果表明，与 Zn-15Al 涂层相比，伪合金涂层的腐蚀速率降低了四倍，耐腐蚀性提高了四倍。虽然在两种涂层的腐蚀产物中都注意到了 simonkolleite 的形成，在伪合金涂层中观察到更薄和更致密的腐蚀产物层。Zn-Al伪合金涂层的优越性能可归因于较高的铝含量和涂层微观结构中富锌和富铝区域的存在，其中锌在富铝区域边界处提供牺牲保护，除了在富锌区域形成稳定的锌腐蚀产物外，在富铝区域钝化铝，降低了此类涂层的整体腐蚀速率。