Objective To provide a certain theoretical basis for the design and preparation of high-performance thermal spraying Zn-Al alloy coating and also its application to turnout of maglev vehicle so as to improve the corrosion resistance and extend the working life of the turnout of maglev. Methods The Zn-Al alloy coatings were prepared on Q235B steel substrate by means of 3 kinds of wire flame coating processes in the present work. The thickness, corrosion resistance and adhesion of the prepared coatings were analyzed and measured based on the method of magnetic measurement, neutral salt spray test and adhesion test. Results The thermal sprayed Zn-Al alloy coating had a smooth surface. Under the condition of other parameters not changed, the thickness of the coating increased with the gradual decrease of the spraying distance and the increase of the spraying times. When spraying distance was 150 mm and spray times was 10, the thickness of coating reached the maximum value 126 μm. The increase of the coating thickness improved the corrosion resistance of the coating, and the adhesion of the coating was maintained at level 1. The conservative calculation showed that the theoretical anti-corrosive life of a 126 μm thermal sprayed Zn-Al alloy coating might reach 40 years. Conclusion Thermal spraying Zn-Al alloy coating has a great double protective effect on the substrate, i.e. shielding and cathodic protection, which can extend the service life and reduce the maintenance cost for the turnout. Based on the analysis and comparison of the process parameters, the optimum spray parameters have been obtained. The coating made under such conditions shows high strength and good corrosion resistance.