Hot-dip Al-Si alloy coatings with excellent resistance to corrosion and high-temperature oxidation have emerged as promising lightweight substitutes for conventional corrosion-resistant coatings. The introduction of Mg can be an effective strategy for enhancing the sacrificial protection capability of Al-Si coatings. In this study, the effects of Mg addition on the morphology, electrochemical behavior, and mechanical properties of Al-Si coatings were investigated, along with the Mg-content optimization of the coating layer. Adding Mg promoted the formation of finely distributed eutectic intermetallic phases, such as Al/Mg2Si and the primary Mg2Si phase. Notably, the Mg2Si phase coarsened significantly when ≥15 wt.% of Mg was added. In addition, an Al3Mg2 intermetallic compound was observed in coating layers containing >20 wt.% of Mg, reducing the adhesion of the coating layers. Samples containing 5-10 wt.% of Mg exhibited excellent corrosion resistance (owing to a uniform distribution of the fine eutectic Al/Mg2Si phase and the formation of stable corrosion products), whereas those containing 20 wt.% of Mg exhibited unremarkable corrosion resistance (owing to the formation of an Al3Mg2 phase that is susceptible to intergranular corrosion).
Keywords: Al3Mg2; Al–Si coated steel; corrosion resistance; hot-dip coating.