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Investigating the corrosion behavior of hot-dip galvanized Zn and Zn-10Al coatings on carbon steel without top coating in chloride-rich immersion environments

Mechanical Engineering for Society and Industry · Vol. 5 No. 2 (2025) · hlm. 367–384

DOI
10.31603/mesi.13743
ISSN
2798-5245
Terbit
2025-12-28
Penerbit
Universitas Muhammadiyah Magelang
Bahasa
en

Abstrak

This study investigates the corrosion resistance, surface hardness, morphological structure, and predicted lifetime of carbon steel coated with pure zinc (Zn) and zinc aluminum alloy (ZnAl) in chloride rich environments. Coatings were applied by hot dip galvanizing, and characterized using Field Emission Scanning Electron Microscopy Energy Dispersive X-ray Spectroscopy (FESEM-EDS), Vickers hardness testing, and salt spray testing. Before exposure, both coatings confirmed homogeneity with smooth, topographically uniform surfaces, and no macroscopic defects. ZnAl coatings also delivered superior hardness compared to pure Zn and uncoated steel. After exposure, ZnAl maintained smoother, more stable surfaces with smaller and fewer pitting defects, whereas pure Zn suffered medium to severe damage. Pure Zn coatings showed fluctuating corrosion behavior with an average rate of 7.8944 µm/year, while ZnAl coatings exhibited minimal fluctuations within ±0.1 µm/year, indicating high resistance to chloride concentration. Predicted lifetime ranged from 3.7 to 5.5 years for pure Zn (average 4.7 years) and 5.9 to 6.5 years for ZnAl (average 6.2 years). Despite being thinner, ZnAl provided superior corrosion protection and structural stability. These findings indicate that ZnAl alloy coatings provide superior corrosion protection, structural stability, and mechanical performance for carbon steel in chloride rich environments.

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  • Indonesia University of Education
  • Universiti Brunei Darussalam
  • Institute of Industrial Science, The University of Tokyo
  • Universitas Halu Oleo
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Asep Bayu Dani NandiyantoAfiliasi tidak diketahui8
Dwi Novia Al HusaeniAfiliasi tidak diketahui3
Meli FiandiniAfiliasi tidak diketahui3
Dwi Fitria Al HusaeniAfiliasi tidak diketahui3
Atiek Rostika NoviyantiAfiliasi tidak diketahui3
Enda PermanaAfiliasi tidak diketahui3
Akrajas Ali UmaarAfiliasi tidak diketahui3
Muhammad Roil BiladUniversiti Brunei Darussalam2
Abdulkareem Sh. Mahdi Al-ObaidiAfiliasi tidak diketahui2
Dwi Fitria Al HusaeniIndonesia University of Education1
Tedi KurniawanAfiliasi tidak diketahui1
Muhammad AzizInstitute of Industrial Science, The University of Tokyo1
Muji SetiyoAfiliasi tidak diketahui1
Abdulkareem Sh. Mahdi Al ObaidiAfiliasi tidak diketahui1
Arif HidayatAfiliasi tidak diketahui1
Erna PiantariIndonesia University of Education1
Aisha Nadhira SyazwanyAfiliasi tidak diketahui1
Karina Nur SyarafahAfiliasi tidak diketahui1
Themy Sabri SyuhadaAfiliasi tidak diketahui1
Obie FarobieAfiliasi tidak diketahui1
Dian UsdiyanaAfiliasi tidak diketahui1
Sri AnggraeniAfiliasi tidak diketahui1
Gabriela Chelvina Santiuly GirsangAfiliasi tidak diketahui1
Rina MaryantiAfiliasi tidak diketahui1
Fajar Miraz FauziAfiliasi tidak diketahui1
Putri SakinahAfiliasi tidak diketahui1
Asita Puji AstutiAfiliasi tidak diketahui1
Mauseni Wantika DewiAfiliasi tidak diketahui1
Jarot RaharjoAfiliasi tidak diketahui1
Yayan SunaryaAfiliasi tidak diketahui1
Asnul Dahar MinghatAfiliasi tidak diketahui1
Farid FadhillahAfiliasi tidak diketahui1
Agus SetiawanUniversitas Halu Oleo1
Poppy PuspitasariAfiliasi tidak diketahui1
Diki Dwi PramonoAfiliasi tidak diketahui1
Mohammad TauviqirrahmanAfiliasi tidak diketahui1

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Sumber metadata: OAI-PMH (metadata jurnal) https://journal.unimma.ac.id/index.php/mesi/oai, pertama di-harvest 9 Nov 2026, terakhir terlihat 9 Nov 2026.
Metadata asli (oai_dc) 
<oai_dc:dc xmlns="http://www.openarchives.org/OAI/2.0/" xmlns:dc="http://purl.org/dc/elements/1.1/" xmlns:oai_dc="http://www.openarchives.org/OAI/2.0/oai_dc/" xmlns:xsi="http://www.w3.org/2001/XMLSchema-instance" xsi:schemaLocation="http://www.openarchives.org/OAI/2.0/oai_dc/  http://www.openarchives.org/OAI/2.0/oai_dc.xsd">
	<dc:title xml:lang="en">Investigating the corrosion behavior of hot-dip galvanized Zn and Zn-10Al coatings on carbon steel without top coating in chloride-rich immersion environments</dc:title>
	<dc:creator xml:lang="en">Solehudin, Agus</dc:creator>
	<dc:creator xml:lang="en">Salam, Haipan</dc:creator>
	<dc:creator xml:lang="en">Ragadhita, Risti</dc:creator>
	<dc:creator xml:lang="en">Maulana, Muhammad Irfansyah</dc:creator>
	<dc:subject xml:lang="en">Corrosion resistance</dc:subject>
	<dc:subject xml:lang="en">Zinc alloy</dc:subject>
	<dc:subject xml:lang="en">Hot-dip galvanizing</dc:subject>
	<dc:subject xml:lang="en">Hardness</dc:subject>
	<dc:subject xml:lang="en">Carbon steel</dc:subject>
	<dc:subject xml:lang="en">Salt spray</dc:subject>
	<dc:description xml:lang="en">This study investigates the corrosion resistance, surface hardness, morphological structure, and predicted lifetime of carbon steel coated with pure zinc (Zn) and zinc aluminum alloy (ZnAl) in chloride rich environments. Coatings were applied by hot dip galvanizing, and characterized using Field Emission Scanning Electron Microscopy Energy Dispersive X-ray Spectroscopy (FESEM-EDS), Vickers hardness testing, and salt spray testing. Before exposure, both coatings confirmed homogeneity with smooth, topographically uniform surfaces, and no macroscopic defects. ZnAl coatings also delivered superior hardness compared to pure Zn and uncoated steel. After exposure, ZnAl maintained smoother, more stable surfaces with smaller and fewer pitting defects, whereas pure Zn suffered medium to severe damage. Pure Zn coatings showed fluctuating corrosion behavior with an average rate of 7.8944 µm/year, while ZnAl coatings exhibited minimal fluctuations within ±0.1 µm/year, indicating high resistance to chloride concentration. Predicted lifetime ranged from 3.7 to 5.5 years for pure Zn (average 4.7 years) and 5.9 to 6.5 years for ZnAl (average 6.2 years). Despite being thinner, ZnAl provided superior corrosion protection and structural stability. These findings indicate that ZnAl alloy coatings provide superior corrosion protection, structural stability, and mechanical performance for carbon steel in chloride rich environments.</dc:description>
	<dc:publisher xml:lang="en">Universitas Muhammadiyah Magelang</dc:publisher>
	<dc:date>2025-12-28</dc:date>
	<dc:type>info:eu-repo/semantics/article</dc:type>
	<dc:type>info:eu-repo/semantics/publishedVersion</dc:type>
	<dc:format>application/pdf</dc:format>
	<dc:identifier>https://journal.unimma.ac.id/mesi/article/view/13743</dc:identifier>
	<dc:identifier>10.31603/mesi.13743</dc:identifier>
	<dc:source xml:lang="en">Mechanical Engineering for Society and Industry; Vol. 5 No. 2 (2025); 367-384</dc:source>
	<dc:source>2798-5245</dc:source>
	<dc:language>en</dc:language>
	<dc:relation>https://journal.unimma.ac.id/mesi/article/view/13743/6390</dc:relation>
	<dc:rights xml:lang="en">Copyright (c) 2025 Agus Solehudin, Haipan Salam, Risti Ragadhita, Muhammad Irfansyah Maulana</dc:rights>
</oai_dc:dc>