COMPLAS 2025

Crystal Plasticity Simulation of Rough Zinc Coating for Wear Predictions

  • Pandey, Kismat (University of Groningen)
  • Baart, Pieter (Tata Steel, R&D)
  • Van der Giessen, Erik (University of Groningen)
  • Maresca, Francesco (University of Groningen)

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Zinc coatings are widely used to provide cathodic protection for steel, effectively preventing corrosion in automotive and other industrial applications . However, during metal forming processes, where high contact pressures are applied, the zinc coating is prone to wear, often manifesting as flakes or powders . These detached zinc particles can adhere to tool surfaces, subsequently causing scratches on the unblemished zinc surface. This phenomenon, known as galling, represents a severe form of adhesive wear. While zinc coatings are indispensable for corrosion protection, they are mechanically vulnerable due to poor wear resistance. Zinc's hexagonal close-packed (HCP) crystal structure contributes to this weakness, as its anisotropic plastic behaviour is governed by the exceptional ratio between the basal (a) and prismatic (c) lattice parameters. Zinc primarily accommodates deformation through basal slip, with twinning occurring only under higher critical resolved shear stresses (CRSS). Combined, these mechanisms fail to provide sufficient independent deformation modes for compatible polycrystalline deformation leading to wear. To investigate the plastic deformation behaviour of zinc coatings under conditions typical of metal forming, we employ Crystal Plasticity Finite Element Method (CPFEM) incorporating contact boundary conditions with primal-dual active set strategy. We study the influence of anisotropic plasticity in contact area prediction in comparison with isotropic plasticity. To quantify wear, our approach builds on recent findings by Aghababaei et al. [1]. Their work identified a critical contact area, beyond which fracture and debris formation dominate, and below which smoothening occurs via atomic removal or plastic deformation. We leverage these findings to predict wear volume by comparing the real contact area with the critical contact area for individual asperities.