Microstructure Characterization and Corrosion Resistance of Zinc Coating Obtained on High-Strength Grade 10.9 Bolts Using a New Thermal Diffusion Process

The article presents the results of research on the application of innovative thermal diffusion zinc coating technology with the recirculation of the reactive atmosphere to high-strength grade 10.9 bolts. The innovation of this method consists in the introduction of reactive atmosphere recirculation and the application of coating powder mix which contains zinc powder and activator. Recirculation of the reactive atmosphere ensures its uniform composition, while the presence of an activator intensifies the process of saturating steel surface with zinc, which boosts the efficiency of active agents. Coatings were created at 440 °C and a heat soaking time of 30–240 min. Coating structure (SEM) was exposed, chemical composition in microsites (EDS) was defined, and coating phase structure (XRD) was identified. The kinetics of coating growth were defined. It was found that the increment of coating thickness was controlled by square root of soaking time. Coatings obtained using innovative thermal diffusion zinc coating technology had a two-layer structure. At the substrate, a compact layer of phase Γ(1) (Fe(11)Zn(40)) was created, which was covered with a layer of phase δ(1) (FeZn(10)). The new method of thermal diffusion zinc coating will alow for the creation of coatings of very good corrosion resistance while maintaining strength properties of bolts defined as strength class 10.9.