Aluminum/zinc-coated steel bimetallic composites were successfully prepared.
Formation mechanism of intermetallic phases at the interface were discussed.
A uniform and compact interface with an average thickness of 650 μm was formed.
Interface consisted of τ6-Al4.5FeSi, α-Al rich, α + η eutectoid, η-Zn and Si phases.
Zinc coatings increased shear stress of the composites by 71%.