The bond durability of epoxy-bonded hot-dip galvanized steel sheets with minimized spangle (fine-grained zinc crystals) exposed to a wet atmosphere has been investigated. Application of X-ray photoelectron spectroscopy and glow discharge spectroscopy to the surface and fractured interfaces revealed that both aluminum and lead segregate in the surface zone (particularly at the grain boundaries) of the zinc coating, causing the adhesion strength to decrease by stimulating the grain boundary corrosion during hot water immersion. Therefore, the degradation of bond durability is markedly improved by reducing the grain boundary segregation of these elements by adopting newly developed minimizing processes such as the use of a Pb-free galvanizing bath or zinc powder spraying for post-galvanization.
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Maeda et al. (1988) studied this question.
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