热浸镀Zn-Al-Mg合金镀层研究进展

刘志宏¹, 梁国威², 孙国庆³, 赖德林²

1. 天津友发钢管集团股份有限公司
2. 华南理工大学材料科学与工程学院
3. 中国表面工程协会
通信作者: 赖德林 (1989-), 博士, 副研究员, 主要从事涂层制备、表面腐蚀与防护研究, E-mail: flyaaa01@163.com

Research Progress of Hot Dip Zn-Al-Mg Alloy Coatings

LIU Zhihong¹, LIANG Guowei², SUN Guoqing³, LAI Delin²

1. Tianjin Youfa Steel Pipe Group Co., Ltd.
2. School of Materials Science and Engineering, South China University of Technology
3. China Surface Engineering Association
Corresponding Author: LAI Delin (1989-), Ph.D., Associate Researcher, Research Focus: Coating Preparation, Surface Corrosion and Protection, E-mail: flyaaa01@163.com

文章历史: 收稿日期: 2026-06-10

摘    要
随着复杂工况及各类基础行业的发展，钢铁材料在服役期间的腐蚀失效问题日益凸显。热浸镀Zn-Al-Mg合金镀层凭借其卓越的耐蚀性与切边自修复能力，被认为是极具发展潜力的第三代高耐蚀镀层。为此，系统综述了不同铝含量体系（微铝、低铝、中铝、高铝）Zn-Al-Mg镀层的显微组织特征及相界演化规律；深入总结了其耐蚀机理，详细阐释了早期的微电偶选择性溶解行为、中期Mg元素的pH值缓冲效应、后期层状双金属氢氧化物（LDH）的原位成膜屏蔽机制，以及切口处的碱化钝化与双重防护效应。在此基础上，进一步综述了该镀层的工程应用性能与表面质量情况。最后，针对重型钢结构的“批量热浸镀锌”工艺，剖析了该高合金化体系面临的常规助镀剂失效漏镀、锌渣剧增且厚度受限，以及熔体流动性劣化与氧化加剧等工程挑战，并对微合金化批量热浸镀锌技术的发展方向进行了展望，以期为该技术的规模化工程应用提供理论参考。

Abstract
Corrosion-induced degradation of steel structures accounts for approximately 3%-5% of global GDP annually, posing severe threats to industrial safety and economic sustainability. Conventional hot-dip galvanizing (HDG) and Zn-Al alloy coatings, while widely used, suffer from limited long-term corrosion resistance and poor self-healing capability at cut edges and damaged areas. Hot-dip Zn-Al-Mg alloy coatings have emerged as the most promising third-generation high-corrosion-resistant coatings, exhibiting 3-10 times longer service life than traditional HDG coatings and unique cut-edge self-healing properties. This review systematically categorized Zn-Al-Mg coatings into four systems based on aluminum content (micro-Al, low-Al, medium-Al, and high-Al) and comprehensively analyzed their microstructural characteristics, phase composition evolution, and phase boundary behaviors. The multi-stage corrosion protection mechanism was elucidated in detail: initial selective dissolution of Mg-rich phases formed a protective barrier via micro-galvanic effects; intermediate Mg element released provides pH buffering to suppress localized acidification; and late-stage in-situ formation of layered double hydroxides (LDH) with excellent ion-exchange capacity created a dense, self-healing protective film. Additionally, the dual cut-edge protection mechanism involving alkalization-induced passivation and LDH deposition was thoroughly discussed. On this basis, the research progress in engineering application performance and surface quality of the coating was further reviewed. Focusing on batch hot-dip galvanizing processes for heavy steel structures, this review critically examined key engineering challenges, including flux decomposition and uncoated defects, excessive dross formation limiting coating thickness, and deteriorated melt fluidity with accelerated oxidation. Finally, future research directions were proposed, such as micro-alloying optimization, novel flux development, and process parameter tuning, to facilitate the large-scale industrial application of Zn-Al-Mg coatings in marine engineering, power transmission, and infrastructure sectors.

关键词
Zn-Al-Mg合金镀层; 显微组织; 腐蚀; 批量热浸镀锌

Keywords
Zn-Al-Mg alloy coating; microstructure; corrosion; batch hot-dip galvanizing

引用文本
刘志宏, 梁国威, 孙国庆, 等. 热浸镀Zn-Al-Mg合金镀层研究进展[J]. 表面工程与再制造, 2026, 26(4): 52-63. DOI:10.26935/j.issn.2097-5317.2026.0024.

LIU Zhihong, LIANG Guowei, SUN Guoqing, et al. Research Progress of Hot Dip Zn-Al-Mg Alloy Coatings[J]. Surface Engineering & Remanufacturing, 2026, 26(4): 52-63. DOI:10.26935/j.issn.2097-5317.2026.0024.

中图分类号
TG174.4

基金项目
广东省重点领域研发计划项目 (2023B0101200008)

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