Various electro-deposited zinc coatings were evaluated to determine the minimum thickness required for good cosmetic corrosion protection. Results indicated that current standard accelerated corrosion tests did not provide sufficient distinctions in performance among the zinc coatings tested. Long term tests were required to simulate the mechanisms and types of corrosion representative of actual automotive service and thus determine coating performance ratings. Data show that, of the coating thicknesses tested, good and consistent cosmetic corrosion protection, as measured by scribe cutback and blistering, was provided by zinc coatings of 60 g/m2 or greater. Preliminary attempts at modifying tests to provide for a more rapid distinction between materials performance will also be examined in this report.

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