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Effect of KCl–ZnCl2 Ball-Milling Fluxing on Microstructure and Corrosion of Iron Ingot Hot-Dip Zinc Coating

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Abstract

In this study, scanning electron microscopy, differential scanning calorimetry, X-ray photoelectron spectroscopy, and electrochemical workstation were used to study the effect of KCl–ZnCl2 ball-milling fluxing on the microstructure and corrosion of iron ingot hot-dip zinc coatings. The results show that compared with the solvent fluxing (S) NH4Cl–ZnCl2 and NH4Cl–ZnCl2–FeCl2, ball-milling fluxing (BM) KCl–ZnCl2 increases the thermal decomposition temperature of the ZnCl2·H2O salt and increases the thermostability of the fluxing salt film. KCl replaces NH4Cl, avoiding the white smoke particles produced by the condensation of NH3 and HCl. There are ζ and δ layers in the coating obtained by S-(NH4Cl–ZnCl2–FeCl2). The coatings obtained by S-(NH4Cl–ZnCl2) and BM-(KCl–ZnCl2) are the same, with η, ζ, and δ layers. In electrochemical corrosion, the η layer acts as the sacrificial anode, which delays the corrosion of the ζ layer and plays the sacrificial protection for the coating. Besides, in corrosion, the corrosion products generated by the η-layer are deposited on the coating surface. These corrosion products constitute the passivation film, which hinders the further development of corrosion and plays the barrier protection for the coating.

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Acknowledgments

Financial support from the National Nature Science Foundation of China (Grant Nos. 51871030 and 51971039), and a project funded by Jiangsu Province Postgraduate Research and Practice Innovation (KYCX21-2800).

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The authors report no declarations of interest.

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Authors and Affiliations

  1. School of Petroleum and Natural Gas Engineering, Changzhou University, Changzhou, 213164, Jiangsu, China

    Zhiwei Li & Haoping Peng

  2. School of Materials Science and Engineering, Changzhou University, 21 Gehuzhong Road, Changzhou, 213164, Jiangsu, China

    Zhiwei Li, Haoping Peng, Changjun Wu & Jianhua Wang

  3. Chemical and Biomolecular Engineering, National University of Singapore, Singapore, 119077, Singapore

    Zhiwei Li & Aijun Xie

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  1. Zhiwei Li
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Correspondence to Jianhua Wang.

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Li, Z., Peng, H., Xie, A. et al. Effect of KCl–ZnCl2 Ball-Milling Fluxing on Microstructure and Corrosion of Iron Ingot Hot-Dip Zinc Coating. Metall Mater Trans A 54, 2744–2758 (2023). https://doi.org/10.1007/s11661-023-07051-7

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