<p> Aluminum is usually added to the zinc bath to form an Fe-Al interfacial layer which retards the formation of a series of Fe-Zn intermetallic compounds during the hot-dip galvanizing process. However, experimentally exploring the inhibition layer formation and obtaining useful experimental data to understand the mechanisms is quite challenging due to short times involved in this process. In this study, a galvanizing simulator was used to perform dipping times as short as O.ls and rapid spot cooling techniques have been applied to stop the reaction between the molten zinc coating and steel substrate as quickly as possible. In addition, the actual reaction time has been precisely calculated through the logged sample time and temperature during the hot-dipping process. The kinetics and formation mechanism of the inhibition layer was characterized using SEM, ICP and EBSD based on the total reaction time. For bath containing 0.2wt% dissolved AI, the results show that FeA13 nucleates and grows during the initial stage of the inhibition layer formation and then Fe2Als forms by a diffusive transformation. The evolution of the interfacial layer formed in a zinc bath with 0.13wt% dissolved AI, including Fe-Aland Fe-Zn intermetallic compounds, was a result of competing reactions. In the initial period, the Fe-Al reaction dominated due to high thermodynamic driving forces. After the zinc concentration reached a critical composition in the substrate grain boundaries, formation of Fe-Zn intermetallic compounds was kinetically favoured. Fe-Zn intermetallic compounds formed due to zinc diffusing to the substrate via short circuit paths and continuously grew by consuming Fe-Al interfacial layer after samples exited the zinc bath due to the limited Al supply. A mathematical model to describe the formation kinetics as a function of temperature for the 0.2wt% Al zinc bath was proposed. It indicated that the development of microstructure of the interfacial layer had significant influence on the effective diffusion coefficient and growth of this layer. However, the model underestimates the AI uptake by the interfacial layer, particularly at higher temperatures. This is thought to be due to the effect of the larger number of triple junctions in the inhibition layer leading to an underestimation of the effective diffusivity. </p> / Thesis / Master of Science (MSc)