摘要
腐蚀被视为“钢铁材料的癌症”,其引发的危害和经济损失遍及整个制造领域。粉末渗锌是基于固态热扩散原理,将锌等耐蚀元素扩散至金属构件表面形成冶金结合多功能合金防护渗层的一种表面强化技术。该技术能够赋予钢铁材料优异的耐磨、耐蚀和抗高温氧化等性能,是钢铁材料腐蚀的有效“疗法”,已广泛应用于汽车、船舶、建筑、铁路等领域。从前处理改性、渗剂配方优化、工艺参数影响和后处理强化等方面综述了钢铁表面粉末渗锌合金化技术的最新研究进展。首先介绍了粉末渗锌合金化制备技术的演变过程,分析了包埋渗、机械能助渗和真空粉末渗的基本原理、主要特点以及技术优势。随后,重点阐述了基体与主渗剂纳米化、多元共渗和稀土活化对渗层活性原子扩散、组织和性能的影响,梳理了渗锌工艺参数对渗层厚度的作用规律,概括了复合后处理技术对渗层耐蚀性的强化效果,分析了典型多元渗层的形成机制。最后,提出了钢铁表面粉末渗锌合金化技术面临的挑战以及未来的发展方向,以期为制备高性能渗层、推动粉末渗锌合金化技术创新及应用提供参考。
The corrosion of steel materials is a globally prevalent common issue.The tremendous economic,safety,and environmental hazards the corrosion has caused continue to drive innovation and development of advanced anti-corrosion materials and technologies.Sherardizing technology is an anti-corrosion process of preparing zinc alloy diffusion layers on steel surfaces based on the principles of chemical vapor deposition and atomic thermal diffusion.It offers advantages such as excellent corrosion resistance,high bonding strength,a hydrogen embrittlement-free process,suitability for complex-shaped components,and environmental friendliness.Consequently,it has gained significant popularity in the field of steel corrosion protection and is widely applied in industries such as automotive,shipbuilding,construction,tunneling,railways,water conservancy,and wind energy.Therefore,the work aims to focus on the study of five aspects,including technological evolution,pre-treatment,alloying,post-treatment,and mechanisms,to review the recent research progress of sherardizing technology in China and abroad.Firstly,the evolution process of sherardizing preparation technology was introduced.The basic principles,main characteristics,and technical advantages of pack cementation,mechanical energy-assisted sherardizing,and vacuum sherardizing were analyzed.Then,special emphasis was placed on elucidating the effects of substrate and main agent nano-modification,multicomponent co-cementation,and rare earth activation on the diffusion of active atoms,microstructure,and properties of the sherardized coatings.The relationship between sherardizing parameters and coating thickness was systematically examined.The strengthening effects of composite post-treatment technologies on the corrosion resistance of cementation coatings were summarized.The formation mechanisms of typical multicomponent co-cementation coatings were analyzed.Finally,the challenges faced by the sherardizing technology for steel surfaces were presented,along with future development directions.This review aimed to provide references for preparing high-performance sherardized coatings and promoting technological innovation and application of sherardizing.In terms of pre-treatment,the substrate surface nanocrystallization technology could effectively reduce the zinc diffusion temperature,shorten the diffusion cycle,and simultaneously improve the atomic penetration depth,thickness,surface hardness,and corrosion resistance of the sherardized coatings.Regarding alloying,researchers focused on penetrant formulations and rare earth activation.By leveraging the complementary advantages and synergistic effects of various elements,high-corrosion-resistance metal elements such as Al,Ni,Cr,Mg,Cu,Mn,and Ti were introduced to prepare binary or even ternary zinc-based alloy sherardized coatings,significantly enhancing comprehensive properties such as wear and corrosion resistance.Based on the high activity of rare earth elements like Y,Ce,and La,the activation energy for sherardized coating formation was reduced,while their grain boundary pinning and microstructure regulation effects were utilized to achieve synergistic improvement in wear and corrosion resistance of the sherardized coatings.For post-treatment,technologies such as"passivation+organic sealing"and composite coating were employed,relying on physical shielding,electrochemical corrosion resistance,and passivation effects,to elevate the corrosion resistance of the sherardized coatings to over 2000 hours.Concerning the formation mechanism of the sherardized coatings,the formation mechanisms of mono-and binary sherardized coatings were clarified based on the atomic diffusion theory.In the future,as steel materials face increasingly harsh application environments,higher demands will be placed on the protective performance of sherardized coatings.Sherardizing technology will continue to develop in directions such as multi-component powder diffusion and composite coating post-treatment.Simultaneously,to promote the application of sherardized coatings in extreme environments,research on the environmental adaptability of sherardized coatings should be strengthened.This includes revealing the environmental damage mechanisms of sherardized coatings under typical extreme natural conditions and establishing correlations between laboratory accelerated tests and natural environmental tests.
作者
彭冬
吴护林
周中锋
李忠盛
黄俊
宋凯强
代野
吴永鹏
黄安畏
丛大龙
PENG Dong;WU Hulin;ZHOU Zhongfeng;LI Zhongsheng;HUANG Jun;SONG Kaiqiang;DAI Ye;WU Yongpeng;HUANG Anwei;CONG Dalong(Southwest Technology and Engineering Research Institute of CSCC,Chongqing 400039,China;Chongqing University,Chongqing 400044,China;JiangLu Machinery Electronics Group Co.,Ltd.,Hunan Xiangtan 411100,China)
出处
《表面技术》
北大核心
2025年第12期17-36,共20页
Surface Technology
关键词
粉末渗锌技术
多元共渗
合金化
后处理
渗层形成机理
sherardizing technology
multi-element sherardizing
alloying
post-treatment
formation mechanism of sherardized coatings
