In this work, the effect of treatment time on the performance of Cr(III) conversion coatings (TCC) on hot dip Zn–55Al–1.6Si (Zn55Al) coated steel sheet were investigated. The surface 3D morphology and roughness of TCCs were examined by a 3D topography instrument and the structure, chemical composition, and elemental depth distribution were studied by means of scanning electron microscope (SEM), X-ray photoelectron spectroscopy (XPS), and auger electron spectroscopy (AES). The results indicated

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... hat during the formation of TCC, the macro-roughness of Zn55Al surface was reduced, but the micro-roughness increased, which are considered to be key factors in enhancing the adhesion strength of epoxy primers. The AES depth profiles showed a two-layer TCC for both dendritic and inter-dendritic regions and chemical composition analysis of XPS showed that the surface of TCC was mainly oxides, fluoride and a small number of hydroxides. Overall, Zn55Al specimen prepared in a diluted commercial Cr(III)-based solution for 180 s at 40 °C performed a better adhesion strength to epoxy primer and had the largest polarization resistance among all TCCs in this work. Additionally, longer Cr(III) passivation process (TCP) treatment time will increase the sensitivity of the TCC to micro-cracks.