Effect of fluxing chemical: An option for Zn-5wt.%Al alloy coating on wire surface by single hot dip process

► New flux was formulated based on DTA for Zn-5 wt.% Al alloy coating. ► Formulated flux is ensured by the black spot-free alloy coating using single hot dip process. ► Zn-5wt.%Al alloy coating consists of alternative layers of zinc rich and aluminium rich phases. ► Alloy coating shows around 4 times improved corrosion resistance compared to the pure zinc coating.