Corrosion Behavior of Cold-spray Aluminum Coating in Marine Environment

Aluminum coatings were prepared by cold spray on mild carbon steel Q235. Scanning electron microscopy shows that the bond zone has good bonding between the substrate and the coating and the coatings consist of interlocked particles. The corrosion behaviors of the coatings in marine environment were studied by electrochemical methods. Free corrosion potentials of aluminum coatings are much lower than that of Q235. Potentiodynamic polarization measurements show that the curves of aluminum coatings have activity anodic dissolution zone, passivation zone and super-passivation zone. Corrosion morphology and energy dispersive spectrometers show that Cl- can penetrate into the coating and some of the substrate has been corroded. Corrosion only can happen on the coating surface and specific deeper sites, where Cl- can penetrate through pores. Cold spray aluminum coatings can protect the substrate from corrosion in marine environment.