The purpose of this study is to investigate the effect of aluminum in Zn coating on electrode life of Hot-dip galvanized steel sheet. It was concluded that aluminum in coating affects electrode life by changing the melting point of coating layers between electrode and steel during welding. In case of high-Al content, Fe-Al alloy was observed at coating-steel interface. Because this alloy suppresses Fe diffusion into Zn coating during welding, melting point of coating layers remains low. This phenomenon causes electrode-coating alloying reaction easily and also increases electrode wearing.
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