Multi-pass multi-directional forging (MDF) was employed to alter the microstructure and enhance the corrosion resistance of Zn-1Fe alloy. The findings indicate that, the MDF refined the irregularly-shaped coarse primary FeZn13 intermetallics and promoted their uniform distribution within the alloy matrix. Compared to the as-cast state, the first, third, and fifth passes of the MDF reduced the average size of FeZn13 particles to 27.515.5 m, 8.85.4 m, and 7.55.1 m, indicating reduction of about 71%, 85%, and 88%, respectively. The MDF notably enhanced the distribution of FeZn13 particles within the matrix, with their number density increasing from 134106 particles/mm2 in the as-cast microstructure to 632207, 776170, 1146265, and 1301294 particles/mm2, in one-pass, two-pass, three-pass, and five-pass MDFed alloys, respectively. Concerning corrosion characteristics, the MDF enhanced the corrosion resistance of the alloys in comparison to that of the as-cast alloy. The two-pass MDFed sample exhibited corrosion resistance that was double that of the as-cast one. However, the corrosion resistance of the five-pass alloy was merely 1.2 times greater than that of the as-cast alloy. This was ascribed to the formation of microcracks within the alloy’s microstructure during excessive passes.
