Improved Corrosion Protection of Magnesium Alloys AZ31B and AZ91 by Cold-Sprayed Aluminum Coatings

Magnesium (Mg) alloys have a high strength/weight ratio, high dimensional stability, good machinability, and the ability to be recycled. However, their poor corrosion resistance in humid environments limits their usage for exterior aerospace components. This study aims to improve the corrosion resistance of two Mg alloys (AZ31B and AZ91) by using aluminum coatings. The latter have been deposited by a low pressure and temperature cold spray process. An aluminum powder (60 wt%) with a particle size ranging between 1 and 8 µm and nickel powder (40 wt%) with a particle size of about 70 µm were blended and used as feedstock powder. The coating thickness was about 240 μm. Its densification was achieved by the in-situ hammering effect of the nickel particles. The shot-peening effect also resulted in an enhanced coating hardness. The microstructure, mechanical properties, and corrosion resistance of the coatings have been investigated. They showed that the aluminum had a face centered cubic structure. Potentiodynamic polarization tests were performed along with a combination of materials characterization techniques to assess the corrosion resistance of the coatings when immersed in a 3.5 wt% NaCl solution for long durations. The results revealed that the corrosion resistance increased with the immersion time because of the formation of a protective oxide layer on the surface. These results were supported by elemental and structural analyses. This study shows that cold-sprayed aluminum coatings are a promising candidate for enhancing the corrosion resistance of AZ31B and AZ91Mg alloys compared to other thermal spray processes.