助镀液锌氨配比对钢构件热镀锌镀层性能影响

邹向丹, 邓新敏

中电建武汉铁塔有限公司
邓新敏 (1987-), 硕士, 工程师, 研究方向: 表面处理, 邮箱: dengxinmin_wm@163.com

Effect of Zinc-Ammonia Ratio in Flux on the Performance of Hot-Dip Galvanized Coatings on Steel Components

ZOU Xiangdan, DENG Xinmin

Power China Wuhan Tower Co., Ltd.
Corresponding Author: DENG Xinmin (1987-), MS, Engineer, Research Focus: Surface Treatment, E-mail: dengxinmin_wm@163.com

文章历史: 收稿日期: 2026-03-15

摘    要
助镀作为热镀锌前处理的关键工序，工业主流助镀液以氯化锌-氯化铵双盐体系为主，锌氨配比决定盐膜稳定性、表面润湿性与高温分解行为，配比失当易引发盐膜吸潮、氯化铵过量发烟、活化不足漏镀、镀层脆化等问题。为此以铁塔生产中常用的Q235角钢为研究对象，通过厚度测量，结合强度测量，以及盐雾和电化学测试等手段，研究了助镀溶液中Zn²⁺、NH⁴⁺的不同浓度配比对钢构件热浸镀锌层的形貌、组织结构、厚度、黏结强度、耐腐蚀性能的影响。通过试验研究发现，当ρ(Zn²⁺):ρ(NH⁴⁺)(质量分数比)=1.0:1.7时，镀层厚度的均匀性有效提升，在中性盐雾试验中其耐腐蚀时间延长，镀层结合强度提高至17.5 MPa。将该最佳助镀液配比在某铁塔厂进行工程化验证，镀锌缺陷率从4.5%降至0.6%,锌耗降低9.49%。研究结果为输电线路铁塔的防腐工艺优化提供理论和应用支撑。

Abstract
Fluxing, as a critical pretreatment process in hot-dip galvanizing, primarily employs a zinc chloride-ammonium chloride double-salt system in the industrial mainstream. The Zn²⁺-NH⁴⁺ ratio determines the stability of the salt film, surface wettability, and high-temperature decomposition behavior; improper ratios can easily lead to salt film moisture absorption, excessive ammonium chloride fuming, insufficient activation causing missed plating, and embrittlement of the coating. To address this, Q235 angle steel commonly used in tower production was selected as the research object. Through thickness measurement combined with strength measurement, as well as salt spray and electrochemical tests, the effects of different concentration ratios of Zn²⁺ and NH⁴⁺ in the flux solution on the morphology, microstructure, thickness, bonding strength, and corrosion resistance of the hot-dip galvanized coating on steel components were investigated. Experimental results showed that when the mass fraction ratio ρ(Zn²⁺):ρ(NH⁴⁺) was 1.0:1.7, the uniformity of the coating thickness was effectively improved, the corrosion resistance time in the neutral salt spray test was extended, and the coating bonding strength increased to 17.5 MPa. Engineering verification of this optimal flux solution ratio at a tower factory reduced the galvanizing defect rate from 4.5% to 0.6% and decreased zinc consumption by 9.49%. The results provide theoretical and application support for the optimization of corrosion protection processes for transmission line towers.

关键词
热浸镀锌; 助镀溶液; 锌氨配比; 铁塔; 镀层性能

Keywords
hot-dip galvanizing; flux solution; zinc-ammonia ratio; steel tower; coating performance

引用文本
邹向丹, 邓新敏. 助镀液锌氨配比对钢构件热镀锌镀层性能影响[J]. 表面工程与再制造, 2026, 26(2): 42-46. DOI:10.26935/j.issn.2097-5317.2026.0011.

ZOU Xiangdan, DENG Xinmin. Effect of Zinc-Ammonia Ratio in Flux on the Performance of Hot-Dip Galvanized Coatings on Steel Components[J]. Surface Engineering & Remanufacturing, 2026, 26(2): 42-46. DOI:10.26935/j.issn.2097-5317.2026.0011.

中图分类号
TG174.4

基金项目
无

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