The effect of grain refinement on the deformation and cracking resistance in Zn–Al–Mg coatings

The present study is dedicated to explore the effect of grain refinement on cracking resistance of hot-dip galvanized Zn–Al–Mg coatings on steel substrate. In this work, we demonstrate the enhancement of plastic deformation and cracking resistance by refining the microstructure (primary zinc grains) of the Zn–Al–Mg coatings. For this purpose, two types of Zn–Al–Mg coatings namely, fine grained and coarse grained microstructures are investigated utilizing in-situ scanning electron microscopy tensile tests. Electron backscatter diffraction technique is used to illuminate the deformation behavior at the scale of grains (and/or within grains). The results reveal that the coating with fine grained microstructure possesses higher ductility and cracking resistance, whereas the coating with coarse grain microstructure induces more transgranular cracking during deformation. Moreover, primary zinc grain refinement has been shown to decrease the fraction of coarse deformation twins that serve as undesirable sites of micro-cracking. In particular, both deformation mechanisms and cracking behavior are found to be grain size-dependent in these coatings.