Corrosion mechanisms and performance of zinc and zinc–aluminum alloy coatings under neutral salt spray conditions

IF 2.1 4区材料科学 Q3 MATERIALS SCIENCE, MULTIDISCIPLINARY

Bulletin of Materials Science Pub Date : 2026-02-09 DOI:10.1007/s12034-026-03545-3

Jiachang Yang, Herong Zhou, Zhiheng Fan, Yijin Lin, Yiwei Cao, Kui Xiao

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Abstract

This study comprehensively investigates the corrosion behavior and underlying mechanisms of zinc and zinc–aluminum alloy coatings under neutral salt spray conditions. A multi-scale analytical approach integrating macroscopic and microscopic morphological characterization, corrosion kinetics analysis, and conventional electrochemical techniques was employed to elucidate the complete corrosion process. The corrosion resistance of both coatings was systematically evaluated, revealing the superior durability of the zinc–aluminum alloy coating, which is attributed to its distinct corrosion-inhibiting mechanisms. Significant differences in phase composition and corrosion product film structure were observed between the two coatings. The zinc coating consists of a single zinc phase, whereas the zinc–aluminum alloy coating contains zinc, aluminum, and Zn–Al intermetallic phases. The predominant corrosion products of the zinc coating are ZnO and Zn₅(OH)₈Cl₂·H₂O, while those formed on the zinc–aluminum alloy coating are primarily Al₂O₃ and ZnAl₂(OH)₈CO₃. In the zinc–aluminum alloy system, the zinc phase preferentially corrodes, providing sacrificial anodic protection, while the formation of a passive aluminum oxide film further enhances corrosion resistance. In addition, the generation of layered double hydroxides (LDHs) contributes to the dynamic self-healing of the corrosion product layer. Compared with conventional zinc coatings, the zinc–aluminum alloy coating exhibits a 2.5- to 3-fold improvement in corrosion resistance.

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中性盐雾条件下锌及锌铝合金涂层的腐蚀机理与性能

本研究全面探讨了锌及锌铝合金涂层在中性盐雾条件下的腐蚀行为及其机理。采用宏观和微观形态表征、腐蚀动力学分析和常规电化学技术相结合的多尺度分析方法来阐明整个腐蚀过程。系统地评价了两种涂层的耐腐蚀性，揭示了锌铝合金涂层的优异耐久性，这归因于其独特的缓蚀机制。两种涂层在相组成和腐蚀产物膜结构上存在显著差异。锌涂层由单一的锌相组成，而锌铝合金涂层则包含锌、铝和锌-铝金属间相。锌镀层的腐蚀产物主要是ZnO和Zn5(OH)8Cl2·H2O，而锌铝合金镀层的腐蚀产物主要是Al2O3和ZnAl2(OH)8CO3。在锌-铝合金体系中，锌相优先腐蚀，提供牺牲阳极保护，而被动氧化铝膜的形成进一步增强了耐腐蚀性。此外，层状双氢氧化物（LDHs）的生成有助于腐蚀产物层的动态自愈。与传统锌涂层相比，锌铝合金涂层的耐腐蚀性提高了2.5 ~ 3倍。

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来源期刊

Bulletin of Materials Science 工程技术-材料科学：综合

CiteScore

3.40

自引率

5.60%

发文量

209

审稿时长

11.5 months

期刊介绍： The Bulletin of Materials Science is a bi-monthly journal being published by the Indian Academy of Sciences in collaboration with the Materials Research Society of India and the Indian National Science Academy. The journal publishes original research articles, review articles and rapid communications in all areas of materials science. The journal also publishes from time to time important Conference Symposia/ Proceedings which are of interest to materials scientists. It has an International Advisory Editorial Board and an Editorial Committee. The Bulletin accords high importance to the quality of articles published and to keep at a minimum the processing time of papers submitted for publication.