Technological and Chemical Drivers of Zinc Coating Degradation in DX51d+Z140 Cold-Formed Steel Sections

This study investigates the technological and chemical causes of early zinc-coating degradation on cold-formed steel sections produced from DX51D+Z140 galvanized coils. Commercially manufactured products exhibiting early corrosion symptoms were used in this study. The entire processing route, which included strip preparation, cold rolling, hot-dip galvanizing, passivation, multi-roll forming, storage, and transportation to customers, was analyzed with respect to the residual surface chemistry and process-related deviations that affect the coating integrity. Thirty-three specimens were examined using electromagnetic measurements of coating thickness. Statistical analysis based on the Cochran’s and Fisher’s criteria confirmed that the increased variability in zinc coating thickness is associated with a higher susceptibility to localized corrosion. Surface and chemical analysis revealed chloride contamination on the outer surface, absence of detectable Cr(VI) residues indicative of insufficient passivation, iron oxide inclusions beneath the zinc coating originating from the strip preparation, traces of organic emulsion residues impairing wetting and adhesion, and micro-defects related to deformation during roll forming. Early zinc coating degradation was shown to result from the cumulative action of multiple technological (surface damage during rolling, variation in the coating thickness) and environmental (moisture during storage and transportation) parameters. On the basis of the obtained results, a methodology was proposed to prevent steel product corrosion in industrial conditions.