Thermodynamic Simulation Calculations of Phase Transformations in Low-Aluminum Zn-Al-Mg Coatings.

This study delves into the formation, transformation, and impact on coating performance of MgZn and MgZn phases in low-aluminum Zn-Al-Mg alloy coatings, combining thermodynamic simulation calculations with experimental verification methods. A thermodynamic database for the Zn-Al-Mg ternary system was established using the CALPHAD method, and this alloy's non-equilibrium solidification process was simulated using the Scheil model to predict phase compositions under varying cooling rates and coating thicknesses. The simulation results suggest that the MgZn phase might predominate in coatings under simulated production-line conditions. However, experimental results characterized using XRD phase analysis show that the MgZn phase is the main phase existing in actual coatings, highlighting the complexity of the non-equilibrium solidification process and the decisive effect of experimental conditions on the final phase composition. Further experiments confirmed that cooling rate and coating thickness significantly influence phase composition, with faster cooling and thinner coatings favoring the formation of the metastable phase MgZn.