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Comparative Evaluation of Zinc Coatings on Mild Steel: Microstructure and Corrosion Resistance
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Comparative Evaluation of Zinc Coatings on Mild Steel: Microstructure and Corrosion Resistance

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Abstract:

This study evaluates and compares the corrosion resistance of zinc coatings deposited on mild steel using three different techniques: electroplating, TREFISSOUD Company hot-dip galvanization, and conventional hot-dip galvanization. Coated and uncoated samples were characterized by electrochemical polarization, microscopic analyses (optical microscopy and SEM), and X-ray diffraction (XRD). Electrochemical results demonstrated a significant decrease in corrosion current density (Icorr) for all zinc-coated specimens compared to bare steel, confirming the protective effect of the coatings. Among the coatings, hot-dip galvanization exhibited superior performance, with the TREFISSOUD Company method achieving the lowest corrosion current and the highest polarization resistance, indicating enhanced corrosion protection. Electroplated zinc, although thinner, provided adequate resistance in moderately aggressive environments. XRD analysis revealed zinc oxide (ZnO) and iron oxide (Fe₂O₃) as the main corrosion products. Their intensity was more pronounced in galvanized coatings than in electroplated zinc. Microscopic observations confirmed uniform and adherent coatings, with hot-dip galvanization producing thicker layers and stronger adhesion than electroplating. Overall, the findings demonstrate that hot-dip galvanization, particularly the TREFISSOUD Company method, provides the best long-term protection for mild steel exposed to harsh conditions. Electroplated zinc, while less durable, remains suitable for applications where a thinner, uniform coating is required. These results highlight the importance of selecting the coating method according to specific service conditions in industrial applications such as construction, pipelines, and marine environments. This study provides a new comparative analysis between conventional and TREFISSOUD company hot-dip galvanization methods, which has not been reported previously in the literature. The results highlight the distinctive performance of the TREFISSOUD Company process in improving coating uniformity, adhesion, and corrosion resistance. This novelty contributes to a better understanding of industrial zinc coating optimization for mild steel.

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Periodical:

Applied Mechanics and Materials (Volume 931)

Pages:

3-10

DOI:

https://doi.org/10.4028/p-Z0zfPT

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Online since:

February 2026

Authors:

Fatima Zohra Lemmadi, Ines Hamdi*, Fouad Chabane

Keywords:

Corrosion Resistance, Electroplating, Hot-Dip Galvanization, Mild Steel, Zinc Coating

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© 2026 Trans Tech Publications Ltd. All Rights Reserved

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* - Corresponding Author

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