Thermodynamic analysis and experimental study on the oxidation of the Zn-Al-Mg coating baths

Abstract Surface oxidation of molten Zn-6Al baths containing 0.0, 3.0 and 6.0 wt. % Mg were analyzed using X-ray photoelectron spectroscopy. γ-Al2O3 is formed on the surface of the Zn-6Al bath, while MgAl2O4 and MgO occur at 460 °C in the Zn-6Al-3Mg and Zn-6Al-6Mg baths, respectively. Thermodynamic analysis on the oxidation of the Zn-Al-Mg baths was performed. Calculated phase diagrams at 460 °C and 560 °C show good agreements with the experimental results. MgO or MgAl2O4 exists in almost the entire composition range of the calculated oxidation diagrams. According to the calculation, oxidation products depend on the composition and temperature of the baths. The primary and secondary oxidation products of the Zn-Al-Mg baths can be reasonably explained by oxidation phase diagrams. Utilizing these results, the favorable practical bath melts and operating conditions can be designed.