Layer-by-layer analysis of hot-dip zinc coating by anodic dissolution in acetate bath

To analyze the distribution of the alloying elements in hot-dip zinc coatings, a layer-by-layer electrochemical dissolution method was studied by using an acetate bath. The research was performed by means of galvanostatic anodic polarization, chemical analysis and metallographic analysis. A suitable cell was constructed to perform this study. Results show that the electrochemical dissolution of η-phase is uniform, while δ-phase dissolves partially together ζ-phase, due to the formation of cracks in the coating during polarization. Faraday's law was used to demonstrate that galvanostatic dissolution of hot-dip zinc coating at 12.7mA cm−2 proceeds by electrochemical mechanism without chemical dissolution; on the contrary, the occurrence of this second process was found at lower stripping current density. During polarization, the formation of a black film which interferes with the subsequent dissolution process was found. Mechanical removal of black film from electrode surface leads to the decrease of cracks formation and to a more uniform layer-by-layer dissolution. A method to obtain layer-by-layer analysis of the alloying elements of a hot-dip zinc coating, as a function of its thickness, by controlled electrochemical dissolution is suggested.