Influence of Temperature on Diffusion Behavior and Infiltration Layer Structure of Sherardizing on Structural Steel

YU Tianjian; LI Haiyang; ZHANG Shizhao; LIU Shujing; WANG Shuaixing; LIU Xiaohui; DU Nan

doi:10.16490/j.cnki.issn.1001-3660.2026.10.005

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Surface Technology ›› 2026, Vol. 55 ›› Issue (10) : 61-70. DOI: 10.16490/j.cnki.issn.1001-3660.2026.10.005

Corrosion and Protection

Influence of Temperature on Diffusion Behavior and Infiltration Layer Structure of Sherardizing on Structural Steel

YU Tianjian¹, LI Haiyang¹, ZHANG Shizhao¹, LIU Shujing², WANG Shuaixing^1,*, LIU Xiaohui¹, DU Nan¹

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Abstract

Power sherardizing can form a Zn-Fe protective layer on the surface of steel through atomic thermal diffusion. Temperature is a key parameter to regulate the sherardizing process. Systematically studying its influence on the microstructure, phase composition and distribution of the infiltration layer for structural steel is helpful to optimize the quality of the infiltration layer and improve the sherardizing effect. A mixture of 70wt.% zinc powder, 0.8wt.% NH₄Cl, and 29.2wt.% α-Al₂O₃ power is selected as the infiltration agent system. Power sherardizing on the Q235 steel is carried out in this activated system at 340-400 ℃. The cross-sectional morphology, element distribution, and phase composition of the zinc infiltration layer at different temperature are analyzed using scanning electron microscopy (SEM) combined with energy dispersive spectroscopy (EDS) and X-ray diffraction (XRD). The energy changes during the zincizing process are investigated by differential scanning calorimetry (DSC). The growth kinetics of the zinc infiltration layer and a growth mechanism model of the infiltration layer is established. Meanwhile, the corrosion resistance and corrosion behavior of different infiltration layers are studied through potentiodynamic polarization curve and electrochemical impedance spectroscopy.
Results show that the thickness of the zinc infiltration layer increases with the increase of sherardizing temperature and insulation time. Under 6 hours of insulation, the thickness of the zinc infiltration layer increases from 10.80 μm to 43.90 μm when the sherardizing temperature rises from 340 ℃ to 400 ℃. The phases of the infiltration layer obtained at different temperature are mainly composed of a δ phase and a Γ phase, and the Γ phase is mainly distributed near the matrix. The excessive Γ phase at low temperature can cause cracking at the interface between the matrix and the infiltration layer. As the temperature increases, the Zn/Fe ratio in the infiltration layer increases, the content of the δ phase is higher, the infiltration layer becomes denser, and the corrosion resistance will be improved accordingly. However, the increase extent in the corrosion resistance of the infiltration layer is relatively small after the temperature exceeds 380 ℃. The corrosion current densities of the infiltration layers obtained at 380~400 ℃ are all low, approximately 1.16×10^-6-9.78×10^-7 A/cm².
The growth process of the zinc infiltration layer mainly includes three stages: the formation and diffusion of active zinc atoms, and the formation and growth of the infiltration layer. The active zinc atoms mainly originate from the decomposition of zinc chloride formed by the infiltration reaction. The formation and growth of the infiltration layer is a dynamic process in which atoms continue to diffuse and push inward. The diffusion coefficient of zinc element at 380 ℃ is 2.34×10^-13 m²/s; the thickness of the infiltration layer increases from 12.10 μm to 81.60 μm when the insulation time is extended from 2 h to 10 h, but the penetrating cracks are present in the infiltration layer when the insulation time exceeds 6 hours. If the microstructure, corrosion resistance and sherardizing efficiency of the infiltration layer are comprehensively considered, a better sherardizing effect can be achieved in the ammonium chloride-activated system at 380 ℃ with a insulation time of 6 hours.

Key words

structural steel / power sherardizing / sherardizing temperature / infiltration layer microstructure / sherardizing kinetics

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YU Tianjian, LI Haiyang, ZHANG Shizhao, LIU Shujing, WANG Shuaixing, LIU Xiaohui, DU Nan. Influence of Temperature on Diffusion Behavior and Infiltration Layer Structure of Sherardizing on Structural Steel[J]. Surface Technology. 2026, 55(10): 61-70

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