Effect of interlayer insertion on adhesion properties of Zn–Mg thin films on steel substrate by PVD method

The surface morphology of Zn–Mg thin film prepared by vacuum evaporation PVD method has formed a structure of various shapes by diffusion of metal particles which is generated migration resulting from accelerated evaporation condition. The surface morphology became smaller as gas pressure increased. Consequently, the grain size decreased further on the low surface energy (101) plane than on the high surface energy (002) plane, which appeared in a vertical direction towards the metal surface due to the influence of residual gases in the vacuum chamber. Also, grain size became smaller with the increase of Mg contents by grain size miniature effect. The grain size of Zn–Mg thin films prepared by the PVD decreased as Mg content increased, and good corrosion resistance increased as well. Also, Zn–Mg thin films have been promoted not only film minuteness but also formation of passivation to corrosion course with the formative increase of intermetallic compound, i.e. MgZn2, Mg2Zn11.