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<p>As a critical control parameter in industrial manufacturing, the cooling rate profoundly influences the solidification kinetics of electrodeposited or molten alloys by regulating dendritic growth directions, the precipitation sequence of intermetallic compounds, and the compactness of the resulting microstructure. Building upon previous work by this group, which identified 2% Mg as yielding optimal corrosion resistance in hot-dip Al–Zn–Si–Mg coatings, this study prepared three Al–Zn–Si–2&#xa0;Mg coatings (wind cooling, foggy cooling, and water cooling)—with cooling rates of 5&#xa0;℃/s, 40&#xa0;℃/s, and 300&#xa0;℃/s, respectively. Their microstructure and corrosion resistance were systematically investigated. Results reveal that as the cooling rate increased, concurrently, the coating microstructure underwent significant refinement, accompanied by a reduction in surface dendrite spacing, an increase in Al-rich phase, a decrease in MgZn<sub>2</sub>, and an elevation in Mg<sub>2</sub>Si. Electrochemical measurements and full-immersion tests demonstrated that the wind-cooling (5&#xa0;℃/s) coating displayed the highest corrosion resistance, characterized by the largest values of corrosion product film resistance (<i>R</i><sub>f</sub>) and charge transfer resistance (<i>R</i><sub>ct</sub>). This study provides theoretical guidance for enhancing the corrosion resistance of hot-dip galvanized Al–Zn–Si–2&#xa0;Mg coatings in industrial production by regulating cooling rates.</p>

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Effect of cooling rate on microstructure and corrosion resistance of Al–Zn–Si–2 Mg coating

  • 期刊论文

  • 发表日期：

    2026年6月2日

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  • Zihan Zhao,
  • Zhaoyang Zheng,
  • Dong Han,
  • Tianyu Zhang,
  • Jianlong Wang,
  • Yong Wang,
  • An Du,
  • Zhiying Zhang,
  • Shigang Jia,
  • Ruina Ma,
  • Yongzhe Fan,
  • Xue Zhao

摘要

As a critical control parameter in industrial manufacturing, the cooling rate profoundly influences the solidification kinetics of electrodeposited or molten alloys by regulating dendritic growth directions, the precipitation sequence of intermetallic compounds, and the compactness of the resulting microstructure. Building upon previous work by this group, which identified 2% Mg as yielding optimal corrosion resistance in hot-dip Al–Zn–Si–Mg coatings, this study prepared three Al–Zn–Si–2 Mg coatings (wind cooling, foggy cooling, and water cooling)—with cooling rates of 5 ℃/s, 40 ℃/s, and 300 ℃/s, respectively. Their microstructure and corrosion resistance were systematically investigated. Results reveal that as the cooling rate increased, concurrently, the coating microstructure underwent significant refinement, accompanied by a reduction in surface dendrite spacing, an increase in Al-rich phase, a decrease in MgZn2, and an elevation in Mg2Si. Electrochemical measurements and full-immersion tests demonstrated that the wind-cooling (5 ℃/s) coating displayed the highest corrosion resistance, characterized by the largest values of corrosion product film resistance (Rf) and charge transfer resistance (Rct). This study provides theoretical guidance for enhancing the corrosion resistance of hot-dip galvanized Al–Zn–Si–2 Mg coatings in industrial production by regulating cooling rates.