In this study, different coating systems, including solvent-based epoxy and water-based acrylic resins, were evaluated for their potential as an alternative to chromate coatings in order to avoid Cr(VI) toxic hazards. The resins were used as either pigment-free coatings or were formulated with 20-wt% zinc/aluminum pigments. The coatings were subsequently applied on galvanized ST12 steel plates and their corrosion resistance was investigated by electrochemical impedance spectroscopy (EIS) evaluations. The effect of the binder and pigment type on the impact resistance of two different polymeric coatings was also evaluated. The results of impact tests revealed completely peeled film from the substrate for epoxy coatings. However, under the same experimental conditions, very few small cracks were created in water-based acrylic coatings for both pigmented and pigment-free cases. In addition, some other parameters such as drying time and coating cost were taken into account to select a good alternative to chromate coatings. The results of this work can facilitate the introduction of an inexpensive environmentally friendly acrylic coating as a promising self-healing alternative to chromate coating.

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