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The present study explores the feasibility of sputter deposition of two Sn-rich Sn(Zn) alloy coatings (Sn-8.8 wt.% Zn and Sn-30 wt.% Zn) using single or identical twin jet magnetron sputtering for improving surface mechanical and corrosion properties of interstitial free steel. The thickness, average grain size and hardness of the deposit varied with the target composition and deposition parameters. Detailed studies reveal that coating deposited from a single pre-alloyed (Sn-30Zn) target offered the most attractive combination of the highest hardness (HV0.01 175 ± 6) and improvement in wear and corrosion resistance. However, the highest corrosion resistance in terms of higher or more active corrosion potential was obtained when sputter deposition was made from twin targets of Sn-8.8Zn. The results indicate that Sn-rich Sn(Zn) alloy may reduce or even substitute total dependence on pure Zn coating (i.e., galvanizing) for corrosion and scratch protection of steel.

This investigation aims to enhance both wear and corrosion resistance of interstitial-free (IF) steel through deposition of pre-determined thickness of pure Sn or Zn or alternate elemental Sn–Zn layers by twin-target magnetron sputtering at desired deposition rate. The thickness, average grain size, hardness and resistance to wear and corrosion of the deposit depend on the deposition parameters. Deposition of either Sn or Zn from single target seems more effective than that from twin target in improving these tribo-corrosion properties of IF steel. The results indicate that sputter deposition of Sn or Zn offers a superior wear and corrosion resistance to galvanized steel and can be a potential route to replace the conventional practice of hot dip galvanizing for the said objective.