Sacrificial coatings, such as Zn and Cd, are used to protect steel against corrosion. During the electrodeposition of metals, hydrogen is evolved due to electrolysis. The evolved hydrogen may diffuse outward and become trapped in the substrate/coating interface or migrate inward into the steel lattice causing delayed embrittlement when the component is subjected to stress. This study reports two principal variables for Zn, Zn–Ni, and Cd coatings: (i) the quantity of hydrogen absorbed by the coating and substrate by vacuum thermal desorption and (ii) the permeability of the coating material to hydrogen by electrochemical permeation. The findings were analyzed in correlation with the microstructural characteristics of both the coating material and the coating/substrate interface. With Zn–Ni, both coating process and coating material combined to significantly reduce the risk of internal hydrogen embrittlement by (i) introducing the least amount of hydrogen during the electrodeposition process and (ii) by the ease with which hydrogen can be extracted by baking due to the presence of cracks in the coating.
