Cold spray Al-5% Mg coatings for the corrosion protection of magnesium alloys

Brian S. DeForce, Timothy John Eden, John K. Potter

Research output: Contribution to journalReview article

49 Citations (Scopus)

Abstract

Poor corrosion resistance is a significant limitation of magnesium alloys as structural materials. To address this problem, the objective of this study was to apply to a magnesium alloy a corrosion-resistant barrier coating that has galvanic compatibility with magnesium and a hardness value no less than that of magnesium. Aluminum coatings were applied to ZE41A-T5 Mg by the cold spray process. A custommade high-purity Al-5 wt.% Mg powder was produced by spray metal forming for the coating evaluation. In addition, coatings of commercially pure Al (99.5 wt.%), high-purity Al (99.95 wt.%), AA5356, and AA4047 were used for comparison. Coating evaluation included mechanical testing (hardness and adhesion strength) and corrosion testing (salt spray, galvanic coupling, and crevice corrosion). The Al-5% Mg powder resulted in the best overall performance, including a high hardness, 125 H v100, and an adhesion strength, over 60 MPa, when treated for over 1000 h in a salt spray chamber and with a low galvanic current.

Original languageEnglish (US)
Pages (from-to)1352-1358
Number of pages7
JournalJournal of Thermal Spray Technology
Volume20
Issue number6
DOIs
StatePublished - Dec 1 2011

Fingerprint

Corrosion protection
magnesium alloys
Magnesium alloys
sprayers
corrosion
coatings
Coatings
hardness
Hardness
Bond strength (materials)
Corrosion
Powders
Magnesium
magnesium
purity
adhesion
Salts
Aluminum coatings
salts
aluminum coatings

All Science Journal Classification (ASJC) codes

  • Condensed Matter Physics
  • Surfaces, Coatings and Films
  • Materials Chemistry

Cite this

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abstract = "Poor corrosion resistance is a significant limitation of magnesium alloys as structural materials. To address this problem, the objective of this study was to apply to a magnesium alloy a corrosion-resistant barrier coating that has galvanic compatibility with magnesium and a hardness value no less than that of magnesium. Aluminum coatings were applied to ZE41A-T5 Mg by the cold spray process. A custommade high-purity Al-5 wt.{\%} Mg powder was produced by spray metal forming for the coating evaluation. In addition, coatings of commercially pure Al (99.5 wt.{\%}), high-purity Al (99.95 wt.{\%}), AA5356, and AA4047 were used for comparison. Coating evaluation included mechanical testing (hardness and adhesion strength) and corrosion testing (salt spray, galvanic coupling, and crevice corrosion). The Al-5{\%} Mg powder resulted in the best overall performance, including a high hardness, 125 H v100, and an adhesion strength, over 60 MPa, when treated for over 1000 h in a salt spray chamber and with a low galvanic current.",
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Cold spray Al-5% Mg coatings for the corrosion protection of magnesium alloys. / DeForce, Brian S.; Eden, Timothy John; Potter, John K.

In: Journal of Thermal Spray Technology, Vol. 20, No. 6, 01.12.2011, p. 1352-1358.

Research output: Contribution to journalReview article

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AB - Poor corrosion resistance is a significant limitation of magnesium alloys as structural materials. To address this problem, the objective of this study was to apply to a magnesium alloy a corrosion-resistant barrier coating that has galvanic compatibility with magnesium and a hardness value no less than that of magnesium. Aluminum coatings were applied to ZE41A-T5 Mg by the cold spray process. A custommade high-purity Al-5 wt.% Mg powder was produced by spray metal forming for the coating evaluation. In addition, coatings of commercially pure Al (99.5 wt.%), high-purity Al (99.95 wt.%), AA5356, and AA4047 were used for comparison. Coating evaluation included mechanical testing (hardness and adhesion strength) and corrosion testing (salt spray, galvanic coupling, and crevice corrosion). The Al-5% Mg powder resulted in the best overall performance, including a high hardness, 125 H v100, and an adhesion strength, over 60 MPa, when treated for over 1000 h in a salt spray chamber and with a low galvanic current.

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