Characterization and prediction of cracks in coated materials: direction and length of crack propagation in bimaterials

The behaviour of materials is governed by the surrounding environment. The contact area between the material and the surrounding environment is the likely spot where different forms of degradation, particularly rust, may be generated. A rust prevention treatment, like bluing, inhibitors, humidity control, coatings, and galvanization, will be necessary. The galvanization process aims to protect the surface of the material by depositing a layer of metallic zinc by either hot-dip galvanizing or electroplating. In the hot-dip galvanizing process, a metallic bond between steel and metallic zinc is obtained by immersing the steel in a zinc bath at a temperature of around 460°C. Although the hot-dip galvanizing procedure is recognized to be one of the most effective techniques to combat corrosion, cracks can arise in the intermetallic layer. These cracks can affect the life of the coated material and decrease the lifetime service of the entire structure. In the present paper the mechanical response of hot-dip galvanized steel submitted to mechanical loading condition is investigated. Experimental tests were performed and corroborative numerical and analytical methods were then applied in order to describe both the mechanical behaviour and the processes of crack/cracks propagation in a bimaterial as zinc-coated material.