Zn-Al-Mg coatings remain at the forefront of anti-degradation coatings for protecting various steel substrates. Despite extensive literature on the microstructure and properties of these coatings, covering a wide compositional spectrum, engineering an optimized coating with simultaneously superior cracking and corrosion resistance (under harsh environmental conditions) remains a challenge. This perspective article provides innovative insights into the materials physics underlying such an optimized Zn-Al-Mg coating. In particular, this work presents a framework for microstructural design based on phase optimization, quaternary alloying elements, multi-scale defects, crystallographic texture, strengthening mechanisms, and anti-corrosive solutions, among other factors. The collective insights offered here aim to stimulate the development of more sustainable Zn-Al-Mg coatings.
Ahmadi, M. (2026). Toward optimized cracking and corrosion resistance in Zn-Al-Mg coatings. Materials Today Communications, 50(114278). https://doi.org/10.1016/j.mtcomm.2025.114278 (Original work published 2026)