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Optimization of In-Situ Shot-Peening-Assisted Cold Spraying Parameters for Full Corrosion Protection of Mg Alloy by Fully Dense Al-Based Alloy Coating

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Abstract

Magnesium-based alloys have excellent physical and mechanical properties for a lot of applications. However, due to high chemical reactivity, magnesium and its alloys are highly susceptible to corrosion. In this study, Al6061 coating was deposited on AZ31B magnesium by cold spray with a commercial Al6061 powder blended with large-sized stainless steel particles (in-situ shot-peening particles) using nitrogen gas. Microstructure and corrosion behavior of the sprayed coating was investigated as a function of shot-peening particle content in the feedstock. It is found that by introducing the in-situ tamping effect using shot-peening (SP) particles, the plastic deformation of deposited particles is significantly enhanced, thereby resulting in a fully dense Al6061 coating. SEM observations reveal that no SP particle is deposited into Al6061 coating at the optimization spraying parameters. Porosity of the coating significantly decreases from 10.7 to 0.4% as the SP particle content increases from 20 to 60 vol.%. The electrochemical corrosion experiments reveal that this novel in-situ SP-assisted cold spraying is effective to deposit fully dense Al6061 coating through which aqueous solution is not permeable and thus can provide exceptional protection of the magnesium-based materials from corrosion.

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Acknowledgments

This work is supported by National Nature Science Foundation (No. 50115814) and Shaanxi Co-Innovation Projects (2015KTTSGY03-03).

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Authors and Affiliations

  1. State Key Laboratory for Mechanical Behavior of Materials, School of Materials Science and Engineering, Xi’an Jiaotong University, Xi’an, 710049, Shaanxi, People’s Republic of China

    Ying-Kang Wei, Xiao-Tao Luo, Cheng-Xin Li & Chang-Jiu Li

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  1. Ying-Kang Wei
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  2. Xiao-Tao Luo
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Correspondence to Xiao-Tao Luo or Chang-Jiu Li.

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Wei, YK., Luo, XT., Li, CX. et al. Optimization of In-Situ Shot-Peening-Assisted Cold Spraying Parameters for Full Corrosion Protection of Mg Alloy by Fully Dense Al-Based Alloy Coating. J Therm Spray Tech 26, 173–183 (2017). https://doi.org/10.1007/s11666-016-0492-7

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