Difficulties in choosing appropriate material(s) for a particular application and the control of environmental menaces cannot be over emphasized. Films of Zn and Zn–Al were electrodeposited on mild steel substrates using Zn and Zn–Al alloy plating solutions respectively. Focus ion beam scanning electron microscope (FIB-SEM) images and Atomic force microscope (AFM) were used to study the surface morphology, the topography and the surface adherent properties of the coatings. The elemental composition and the phases evolved in composite coatings were measured by means of X-ray diffractometer (XRD) and energy dispersive spectrometer (EDS). The cyclic voltammetry techniques were used to explain deposition process. The microhardness measurements and the electrochemical and wear behaviours of the deposits were investigated. Experimental results showed that Zn-Al coatings had homogeneous distribution of the fine particles deposited. These coatings had higher corrosion and wear resistances over the Zn deposited coatings as well as the substrate.
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