PVD ZnCr coatings exhibit different metastable crystal structures δ, ζ, Γ depending on
the Cr content and the deposition conditions. Here we describe the different mechanical
and electrochemical properties of these phases. We show that by introducing an appropriate
Cr concentration profile it is possible to produce a ZnCr coating with a thin Γ-phase
interface layer optimized for substrate adhesion and a δ-phase matrix with a strong
basal texture which possesses excellent cold forming properties. This alloy coating is
tailored so that the application of a short low temperature annealing step after forming,
such as an automotive paint bake hardening treatment, transforms the textured δ-phase
into a nanocrystalline ı-phase with no marked texture. The latter microstructure provides
significantly improved primary corrosion protection.