Metallographic

preparation of zinc
coatings Application
The coating of steel or iron with
Notes
zinc using various processes is
called "galvanizing". Metallic zinc
is used for corrosion protection of
cast irons, mild steels and low al-
loy steels. The zinc or zinc alloy
cathodically protects the steel sur-
face. In zinc coatings on parts that
are exposed to air and water the
Fig.1: Galvalume, etched
zinc forms zinc carbonate that ad- with 1% Nital, 500x , SEM
ting
ditionally protects inc coa
o f h o t-dip z
against corrosion. The S urface

coated products are

mainly used for ex-
posed automotive ap-
plications, household
goods, electrical appli-
ances and in the build-
ing industry. To increase corrosion
protection or the decorative element Fig. 2: Colored building facade of
of galvanized steel sheets, organic galvanized steel sheets
coatings such as foils or paint can
be applied onto the zinc coating. quire information only provided by The metallography of galvanized
metallographic microstructural products includes thickness mea-
Although general production con- analysis. surements of the coatings, micro-
trol of galvanized sheet steel is structure analysis of coatings and
done on-line and carried out with Practical examples: If a zinc coat- basemetal, adhesion checks and
physical tests, metallography is an ing is too thick problems during failure analysis. Depending on the
important tool for obtaining a vari- welding can arise, if during forming galvanizing method, zinc coatings
ety of information not achievable the coating is chafed subsequent vary in hardness and thickness
by other analytical methods. An painting and consequently corro- and therefore behave differently
understanding of forming, welding sion protection can suffer. There- during metallographic preparation.
and finishing processes of pro- fore metallography plays its part in In addition, some of the zinc coat-
ducts, product research and deve- improving products and advancing ings react with water, which makes
lopment and failure analysis re- coating technology. the preparation particularly difficult.

Difficulties during metallographic preparation

Mounting: Shrinkage gaps between sample Softness of coatings: Reaction with water:
and resin result in stains from water and Scratches from grinding Discoloration and attack of zinc.
alcohol, rounded edges and trapped grinding and polishing. 500 x 1000 x
debris. 200 x

Solution: Proper mounting, fine grinding with diamond on rigid discs, using waterfree diamond
suspensions and lubricants for polishing and proper cleaning.
Production and applications
of zinc coatings

Principles of
Hot Dip Coating Air knives

Pickling Preheat Cooling

→
Fig. 4: Facade of Galvalume sheet with
organic coating

Hot Metal bath

Hot dip iron. The coating is stronger and

The steel sheet runs through a has a higher wear resistance and
molten bath of zinc in a continu- weldability than the plain hot dip
ous process, during which clean- coating. On its rough surface paint
The Galfan coating has a fine eu-
ing, temperature, coating thick- adheres particularly well, which
tectic structure (see Fig. 10), which
ness etc. are automatically con- gives an additional corrosion pro-
is suited for bending, deep draw-
trolled. The coating contains more tection when painted.
ing and welding, and has an excel-
than 99% zinc and has usually a Application: primarily pressed au-
lent corrosion resistance after
thickness between 7-15 µm, but tomotive components that are
painting. Application: construction,
can vary according to specifica- coated with organic coatings,
automotive and household appli-
tions. outer and inner body panels.
ance industry.
Application: primarily for automo-
tive applications, construction and Galvalume™ 1)
Electrogalvanizing
household goods, such as wash- This is a hot dip coating from a
This zinc coating is electrolytically
ing machines. bath containing 55% aluminium,
deposited on the steel sheet and
43.4% zinc and 1.6% silicon. This
produces a very thin, uniform layer
Galvaneal coating has a good heat-oxidation
of pure zinc. The coating thickness
After the hot dip the coated sheet resistance.
is between 2-6 µm, and it is espe-
can be heat treated, changing the Application: construction, mainly
cially suitable for subsequent
zinc coating into a zinc-iron coat- facade coverings, also automotive
painting. A typical application is for
ing, containing approximately 10% components.
car automotive bodies.
Galfan™ 2)
This is a hot dip coating from a
zinc bath containing 5% aluminium
and traces of rare earths.

1) 2)
Galvalume™ and Galfan™ are proprietary
galvanizing methods. Galvalume™ in Canada
is a registered trademark of Dofasco Inc and
in the USA Galvalume™ is a registered
trademark of BIEC INC. Galfan™ is a
registered trademark of the International Lead
and Zinc Research Organization in USA.
Fig. 3: Pressed floor panel Fig. 5: Electrolytically deposited zinc coating,
polished to 1 µm and final cleaning/polish
with pure alcohol, 1000 x
 Difficulties in the
preparation of zinc
coatings

The main problems of preparing

zinc coatings for microscopic
observation are:
1. Shrinkage gaps between mount-
ing resin and coated steel sheets.
These gaps make it difficult to
clean the samples, especially on
clamped sheet packs.
Mounting zinc coatings constitutes
a major problem because the
Fig. 6: Post-fabrication zinc coating, etched mounting needs to guarantee that Fig. 7: Hot dip coating cleaned with water,
with 0.5% Nital, with γ phase on the border to the resin adheres properly to the 500 x
the base metal and large δ columns in the
zinc matrix, 200 x. sample material, so that no gaps
appear. If zinc coatings are pre-
The thickness of zinc coatings of pared for production control, a
continuous galvanized products is conflict arises between number of
usually specified by weight, g/m² samples and available time so that
or oz/ft2 and can range between compromises in mounting are com-
6 µm and more than 20 µm de- mon. This usually results in a
pending on the application of the mounting method that produces
final product. shrinkage gaps next to the zinc
coating, which makes it difficult to
For post fabrication hot dip galva- clean the specimens and achieve
nizing of finished parts, such as an optimal edge retention. Result- Fig. 8: Hot dip coating cleaned with alcohol,
ing water and alcohol stains ob- 500 x
cast iron construction parts, the
finished product is immersed into struct proper thickness measure-
the molten zinc bath. These coat- ment and structure interpretation
ings are much thicker than the on the coating.
continuously galvanized coatings Recommendations for
2. The softness of zinc and its re-
(Fig. 6).
action with water can leave the the preparation of
coatings with scratches, discolo-
red or even etched.
zinc coatings
The purer the zinc of the coating is, Cutting steel sheet is
the softer and the more water-sen- not difficult and can
sitive it becomes. Therefore, plain be done with appro-
hot dip and electrolytically depos- priate abrasive alu-
ited coatings are soft and prone to minium oxide wheels.
mechanical deformation and they Sometimes sheets are
cannot be cleaned with water (Figs cut with a guillotine or
7 and 8). Ethanol or Isopropanol tin snips, which may
have to be used for cleaning. Due be sufficient for very thin sheets,
to the addition of aluminium, re- but can bend the sheet severely
spectively heat treatment, GalfanTM, and crack the coating when it is
Galvalume TM and Galvaneal coat- thicker. A subsequent longer
ings are harder than plain hot dip grinding time to the undamaged
and electrolytically deposited coat- area of the sheet is necessary.
ings. Generally they create fewer Cutting with an abrasive wheel is
problems during polishing and their the more economical alternative in
reaction with water is less vehement. these cases.
 Preparation Method
Grinding

Step PG FG 1

Surface SiC-paper, #320 MD-Largo

DiaPro
Suspension
Allegro-Largo

Mounting Lubricant Water

The above-mentioned problem of

shrinkage gaps between mounting rpm 300 150
resin and coated specimen can be
avoided by degreasing the speci-
Force [N] 30 per sample 30 per sample
men with acetone before mounting
and using proper
mounting resins. Time As needed 4 min.
Slow curing, cold
mounting epoxy has
Polishing
a negligible shrink-
age and adheres
Step DP 1 DP 2 OP
very well to the
specimen. Hot com-
pression mounting with a phenolic Surface MD-Dac MD-Dur OP-Chem
resin containing carbon fibres
(PolyFast) is highly recommended Suspension DP-Susp. A, 3 µm DP-Susp. A, 1 µm
as it leaves no gaps between resin
and coating and the resin has the
Lubricant DP-Yellow DP-Yellow Ethanol*
right hardness to keep the sam-
ples flat.
rpm 150 150 150
For both mounting methods, indi-
vidual sheet specimens are held Force [N] 25 per sample 20 per sample 15 per sample
upright with plastic
clips. Because
these sample clips Time 4-6 min. 4-6 min. 15-20 sec.

can only hold a few

sheets, these meth- Comments *Ethanol denatured with isopropyl alcohol
ods are too slow for
high production
quality control labo- hot mounting the resulting packs coatings at 1000 x. For the subse-
ratories. In these laboratories the in PolyFast eliminates the gaps quent polishing, two diamond po-
most common method for holding and has the advantage of provid- lishing steps with 3 µm and 1 µm
coated steel sheets is clamping ing a properly mounted, clean are sufficient. With this method,
them in packs: the cut pieces are sample (see Fig. 9.) the grinding and polishing steps
put into packs and held together have been reduced from six to four.
by a steel clamp. Grinding and polishing
Galvanized steel sheets have tradi- Although the different zinc coat-
This method makes it possible to tionally been ground with various ings vary in hardness, it is possible
hold large quantities of sheets, grits of silicon carbide paper, fol- to grind and polish them automati-
however it does not eliminate the lowed by two or three diamond cally with the same preparation
problem of the gaps between the polishing steps. Replacing the fine method. When grinding/polishing
sheets. The clamps are difficult to grinding on silicon carbide paper equipment without
clean and dry because of the with a special fine grinding disc an automatic dos-
screws and parts they contain, (MD-Largo), onto which diamond ing system is
and structure interpretation and spray or suspension is applied, used, diamond
thickness measurements are ob- can now shorten this procedure. spray gives excel-
structed by alcohol bleeding from MD-Largo also gives excellent lent results, as it
the gap. Gluing the sheets to- edge retention, which is particu- contains no water.
gether with instant glue and then larly important when observing the For automatic
 Fig. 9:
Galfan coating,
etched with 0.5%
Nital. Primary
dendritic structure,
500 x

dosing systems, waterfree dia- Fig.10: Same

coating as Fig. 9,
mond suspensions and lubricants higher magnification
are necessary to avoid staining of shows lamellar
the coatings. Silk cloths keep the eutectic structure,
1000 x
samples flat although not com-
pletely scratchfree. Polishing with
soft, napped cloths should be avoi-
ded as it can result in some relief.

Using automatic grinding/polishing

equipment with automatic dosing,
Fig.11: Galvaneal
such as the RotoSystem, has the coating etched
advantage of giving reliably, very with 1% Nital,
good and reproducible results. The 1000 x

preparation method shown on the

previous page, for 30 mm mounted
individual samples or multiple sam-
ples in holders, has successfully
been used for galvanized and elec-
trolytically deposited zinc coatings.

Cleaning Fig. 9 shows a Galfan coating automatic grinding and polishing

Zinc reacts with water, which etched with 0.5% Nital. It shows a can be made:
makes the cleaning of the samples primary dentritic structure.
difficult. During grinding the effect - Despite varying hardness, all
of the reaction with water is negli- Fig.10, Galfan coating as fig. 9, groups of zinc coatings can be
gible, but between diamond pol- showing a zinc rich solid solution automatically prepared using the
ishing steps swabbing and rinsing α and a lamellar eutectic structure same method.
with ethanol denatured with iso- consisting of α and the aluminium - The main prerequisite for a suc-
propyl alcohol is recommended, rich phase, β. cessful polish is a good mount
followed by drying with clean com-
without shrinkage gaps between
pressed air. Fig.11 shows a Galvaneal etched resin and sample.
For final cleaning, a very brief with a 1% Nital. A thin, iron rich
polish with ethanol denatured with - Fine grinding with diamond on
diffusion layer γ shows between
isopropyl alcohol on a MD-Chem rigid disc gives excellent flatness.
steel base and zinc coating. The
polishing cloth, followed by rinsing structure of the coating is zinc-iron - Waterfree diamond suspensions
and drying, has given the best re- with varying concentrations de- and lubricants keep the zinc
sults. If an automatic dosing sys- pending on the distance from the coatings from staining.
tem is used, a large dose of water- base metal. Some of this structure - Silk cloths keep the coatings flat
free lubricant can be programmed can be revealed using a more so- during polishing.
to follow after the final seconds of phisticated etchant containing pic-
polishing. This will make the sub- - All cleaning steps during
ric and nitric acid. (For the details
sequent cleaning easier. polishing have to be carried out
of this etchant please, see the
with ethanol denatured with
Struers e-Metalog.)
isopropyl alcohol.
Etching and Interpretation
The most common etchant for zinc Summary The given preparation method can
coatings is a 0.5%-2% alcoholic To make the preparation of zinc be used as a base for further cus-
nitric acid. Etching times are very coatings easier and more repro- tomising the grinding and polishing
brief (seconds!) and over-etching ducible, and to improve the im- procedure in individual laborato-
occurs very easily, and each coat- ages for structure interpretation, ries, depending on the variety of
ing reacts differently. the following recommendations for coatings to be polished.
Application
Notes
Metallographic preparation of
zinc coatings Struers A/S
Valhøjs Allé 176
Elisabeth Weidmann, DK-2610 Rødovre
Phone +45 36 70 35 00
Struers A/S, Copenhagen Fax +45 38 27 27 01
e-mail: struers@[Link]
[Link]

Credits:
We wish to thank DOFASCO Inc., and DEUTSCHLAND
STELCO Inc., Hamilton, Canada, Struers GmbH
Karl-Arnold-Strasse 13 B
Fa. Julius Blum GmbH, Höchst, Austria, D - 47877 Willich
Telefon +49/(0) 21 54/4 86-0
Rautaruukki Steel, Hämeenlinna, Finland, Telefax +49/(0) 21 54/4 86-222
e-mail: [Link]@[Link]
for generously supplying sample material
ÖSTERREICH
and related information, and Voestalpine Struers GmbH
Zweigniederlassung Österreich
Stahl GmbH, Linz, Austria, and Ginzkeyplatz 10
5020 Salzburg
Zinkberatung Ingenieurdienste GmbH, Telefon (0662) 625711
Telefax (0662) 625711-78
Düsseldorf, Germany, for contributing e-mail: [Link]@[Link]
general information on zinc coatings. Schweiz
Struers GmbH
We thank Stahl-Informations-Zentrum, Zweigniederlassung Schweiz
Düsseldorf, Germany for giving Weissenbrunnenstrasse 41
CH - 8903 Birmensdorf
permission to reproduce the following Telefon (01) 77763-07
Telefax (01) 77763-09
images: Washing machine and Fig. 4 e-mail: [Link]@[Link]

from Charakteristische Merkmale 095 HOLLAND

Struers GmbH Nederland
and Fig. 3 from Dokumentation 535. Electraweg 5
NL- 3144 CB Maassluis
We thank Rautaruukki Steel, Hämeenlinna, Tel.: +31 (0) 10 599 72 09
Fax: +31 (0) 10 599 72 01
Finnland for giving permission to e-mail: [Link]@[Link]
reproduce the following images: Fig. 2 FRANCE
Struers S.A.S.
and harvest combine, and SEM images 370, rue du Marché Rollay
F - 94507 Champigny
on the first and last page. sur Marne Cedex
Téléphone +33 1 55 09 14 30/31
Télécopie +33 1 55 09 14 49
Bibliography: e-mail: struers@[Link]
BELGIQUE
Charakeristische Merkmale 092 Struers S.A.S.
„Schmelztauchveredeltes Band und 370, rue du Marché Rollay
F - 94507 Champigny
Blech“, 1998 sur Marne Cedex
Téléphone +32 43 70 93 18
Charakteristische Merkmale 095 Télécopie +32 43 70 93 19
e-mail: struers@[Link]
„Elektrolytisch verzinktes Band
JAPAN
und Blech“ Marumoto Struers K.K.
Takara 3rd Building
Dokumentation 535 „Weiterverarbeitung 18-6, Higashi Ueno 1-chome
Taito-ku, Tokyo 110-0015,
von verzinktem und beschichtetem Phone: +81 3 5688-2914
Fax: +81 3 5688-2927
Stahlblech“, 1997 e-mail: struers@[Link]
All: Stahl-Informations-Zentrum, SINGAPORE
Struers A/S
Düsseldorf, Germany 10 Eunos Road 8
#12-06 North Lobby
Singapore Post Centre
Singapore 408600
Phone +65 6299 2268
Fax +65 6299 2661
e-mail: [Link]@[Link]
UNITED KINGDOM
Struers Ltd.
Erskine Ferry Road
Old Kilpatrick
Glasgow, G60 5EU
Phone 01 389 877 222
Fax 01 389 877 600
e-mail: info@[Link]
USA
Struers Inc.
810 Sharon Drive
Westlake, OH 44145
Phone (888) 787-8377
Surface of Fax (440) 871 8188
Galvanealed coating e-mail: info@[Link]

05.02 / 62140102
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