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Evaluation of Corrosion Resistance of Galvanized Steel Sheets Used in

Automotive Production

Article  in  Materials Science Forum · May 2015

DOI: 10.4028/www.scientific.net/MSF.818.141

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Materials Science Forum Vol. 818 (2015) pp 141-144 Submitted: 21.11.2014
© (2015) Trans Tech Publications, Switzerland Revised: 30.01.2015
doi:10.4028/www.scientific.net/MSF.818.141 Accepted: 11.02.2015

Evaluation of Corrosion Resistance of Galvanized Steel Sheets Used in

Automotive Production

KAŠČÁK Ľuboš1, a *, BREZINOVÁ Janette1, b and MUCHA Jacek2, c

1
Technical University of Košice, Faculty of Mechanical Engineering, Institute of Technology and
Management, Mäsiarska 74, 040 01 Košice, Slovakia
2
Rzeszow University of Technology, Faculty of Mechanical Engineering and Aeronautics,
ul. Wincentego Pola 2, 35-959 Rzeszów, Poland
a b c
lubos.kascak@tuke.sk, janette.brezinova@tuke.sk, j_mucha@prz.edu.pl

Keywords: tensile strength, corrosion resistance, spot welding.

Abstract. The steel sheets used for the car body production are protected against corrosion by zinc
coating. Resistance spot welding is used mainly for joining these sheets, because of its high speed
and adaptability for automation in high-rate production. However, resistance spot welding has a
negative influence on the corrosion resistance of joints. The paper focuses on the analysis of quality
of welds on galvanized steel sheets and their corrosive properties. Tensile test and accelerated
corrosion test in corrosive environment were used for evaluation of the welds’ quality. Protective
efficiency of zinc coatings for automobile sheets was evaluated as well, based on the determination
of their electrochemical characteristics in passivated and non-passivated state, as well as their
corrosion resistance in simulated corrosion environments. Two types of DX54D+Z material were
used for experiments: non-passivated and passivated with Cr3+.

Introduction
Resistance spot welding is a rapid joining technique extensively used to join thin-walled
assemblies in automotive applications. During the welding, a current with high intensity crosses
through the assembly to be welded which are held between two electrodes with a predefined
pressure. [1,2]. The created spot weld consists of three zones. They are named as weld metal (WM),
heat affected zone (HAZ) and base metals (BM). The need for lightweight alloys and quality welds
becomes a great interest in these industries for achieving improved fuel economy for ground
vehicles [2,3]. Resistance spot welding is the main joint mode in car body manufacturing but it is
also a complex process containing the thermoelectricity, metallurgy and many other coupling factors
[4,5]. Therefore it is necessary to study the performance indices of the spot welded joint and
determine the key influence factors. The performance indices of a welded joint mainly include
mechanical properties, failure mode, weld nugget size, microstructure and ductility, all of which are
usually evaluated through experimentations as well as corrosion resistance of weld surface [6,7].
The paper deals with the analysis of welds quality on galvanized steel sheets and their corrosive
properties. Protective efficiency of zinc coatings, based on the determination of their
electrochemical characteristics in passivated and non-passivated state, as well as their corrosion
resistance in simulated corrosion environments was evaluated.

Materials and Methods

Two of materials were used for the experiments:

sample A: DX54D+Z of thickness 0.70 mm, hot dip galvanized with weight of zinc coating
140 g.m-2, surface treatment: non-passivated (used for exterior car body panels e.g. roof)

sample B: DX54D+Z of thickness 0.70 mm, hot dip galvanized with weight of zinc coating
140 g.m-2, surface treatment: passivated with Cr3+ (used for exterior car body panels - doors)

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142 Surface Engineering and Materials in Mechanical Engineering

Test samples were prepared according to STN EN 05 1122 with dimensions of 90 x 40 mm,
lapping of 30 mm on the spot welding pneumatic machine BPK 20, welding electrodes CuCr of
ø5 mm. The welding parameters were based on the recommendations of British Standard (BS
1140): pressing force Fz =2.6 kN, welding time t = 14 periods, welding current 8.5 kA. Tensile tests
according to STN 05 1122 were used for the evaluation of mechanical properties of spot welds
before and after the exposure to the corrosive environments on the test machine TIRA-test 2300.
Resistance spot welds were exposed to salty environment of 5% NaCl solution and ecological
solution Solmag used during winter season on roads. The above mentioned environments simulated
conditions of vehicle operation. Gravimetric method was used for the evaluation of the corrosion
processes. Potentiodynamic polarization curves were measured for determination of the
electrochemical characteristics of these materials. The values of Ek - corrosion potential by Tafel, Ik
– corrosion current density and Rp - polarization resistance were measured as well. Electrochemical
characteristics of the tested samples were
evaluated before exposure to the corrosive
environment and after 240, 480 and 720
hours of exposure, according to Tafel and
Stern method. A computer-controlled
VOLTALAB 21 PGP201 with three-
electrode configuration and software
Fig. 1 The linear voltammetry scheme for VOLTAMASTER 4 was used for
measuring the corrosion characteristics: V- potentiodynamic measurements, Fig. 1. The
voltmeter, G-ammeter, 1-sample, 2-saturated microscopic observations were realized with
calomel electrode, 3-auxiliary electrode scanning electron microscope JEOL JSM -
7000F.

Results and Discussion

The average values of carrying capacities of the samples are shown in Fig. 2. The maximum
force Fmax before their exposure to the corrosive environments was about 11% higher in material B
than in material A. Both materials were exposed to the corrosive environment of 5% NaCl solution,
after which increased carrying capacity of the welds was observed in material B. Values of Fmax
increased after the exposure to the corrosive environment, in both types of spot-welds. Both
materials were exposed to the corrosive environment of ecological solution Solmag (Fig. 3), after
which increased carrying capacity of welds was observed in material B (passivated state).

Fig. 2 Average values of maximum Fig. 3 Spot weld surface after 10 days of
strength of both samples exposition in condensation chamber

Fig. 4 illustrates zinc layer before corrosion test and Fig. 5 shows the formation of the zinc
corrosion products on the sample surface after the corrosion tests in NaCl environments. It is
possible to observe white zinc hydroxide, products of corrosion. The formation of white corrosion is
caused by condensation of air moisture, and the effect of the electrolyte.
 Materials Science Forum Vol. 818 143

Fig. 4 Zinc layer before corrosion test Fig. 5 Zinc layer after corrosion test

When the samples were exposed to the environment of 5% NaCl solution up to 240 hours, their
weight increased - corrosion products formation. After 240 hours, there was a significant weight
loss of zinc coating - release of corrosion products into the electrolyte. The comparison of weight
losses of A and B samples in 5% NaCl solution showed a 53.66 % difference, Fig. 6 and 7. The
passivated samples are more resistant to mass loss than non-passivated ones in 5% NaCl solution.

Fig. 6 Weight loss in corrosion environment of Fig. 7 Weight loss in corrosion environment of
material A material B

When the ecological solution Solmag was used, the weight did not change significantly during
the time of exposure. The potentiodynamic polarization curves of both samples evaluated by Tafel
method are shown in Fig. 8.
Non-passivated sheet and passivated sheet in 5% NaCl solution after 720 hours exposure show
the same corrosion current densities Jk, i.e. passivation is effective only in the early phase of
exposure, as show in Fig. 8.

Fig. 8 Tafel method for determination of Jk Fig. 9 Stern method for determination of Rp

The influence of chloride corrosive environment on galvanized sheets is so intense, that after
several tens of hours‘ exposure there is no significant difference between passivated and non-
passivated surface in zinc-coated steel sheet. An interesting phenomenon occured between 240 to
480 hours of passivated zinc-coated steels exposure in nonaggressive environment, when the
corrosion products show a high polarization resistance Rp to corrosion current flow (1.2–1.6 MΩ;
Fig. 9). However, after 720 hours of exposure, this passive layer is damaged even in low-aggressive
environment.
 144 Surface Engineering and Materials in Mechanical Engineering

Summary
The carrying capacity of the welds on passivated sheets is higher than that of the welds on non-
passivated sheets. Both types of samples were exposed to two corrosive environments, and the
carrying capacity of the welds on passivated sheets increased even further. This is the effect of the
formation of zinc corrosion products, which, in spite of their low adhesion to the substrate, increase
the carrying capacity of welds.
Microscopic analysis showed the welds were of high quality, which implies that optimum
technological welding parameters were used. Flashing of zinc layer was observed locally in the
contact place of the welding electrodes. When the samples were exposed to corrosive environments,
condensation of air moisture or effects of the electrolyte resulted in the formation of zinc corrosion
products, so-called “white corrosion”.
As a result of accrued zinc corrosion products, the weight of those samples that were exposed to
ecological solution Solmag increased during corrosion tests. Moreover, the corrosion process was
slower than when samples were exposed to NaCl solution. On the other hand, when samples were
exposed to the relatively aggressive corrosive environment of NaCl sloution, a significant weight
loss occurred.
The potentiodynamic electrochemical measurements of both types of samples showed that after
720 hours of exposure to corrosive environments, the corrosion current densities of both passivated
and non-passivated sheets were the same. That brings us to the conclusion that passivation is
effective only in the early phase of exposure of materials to corrosive environments. The corrosion
products that form on the surface of the passivated samples have a high polarization resistance Rp,
and maintain their favorable properties up to approximately 500 hours of exposure to corrosive
environments.

Acknowledgments
This work was supported by project KEGA No. 059TUKE-4/2012 “Implementation of new
methods and forms into education of engineering technology and materials”

References
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