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Effect of the Outer Layer of Al Coatings Deposited by Cold Gas Spray on the Microstructure, Mechanical Properties and Corrosion Resistance of the AA 7075-T6 Aluminum Alloy

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Abstract

The corrosion of AA 7075-T6 aluminum alloy is a critical issue for many industries. In this study, aluminum coatings were deposited onto AA 7075-T6 by cold gas spray and the effect of the porous outer layer on different properties of the coating, including corrosion–resistance was investigated. As-prepared and polished samples were used to study the microstructure, morphology, mechanical properties and corrosion resistance of the coating in 3.5 wt.% NaCl solution. Cross-sectional analysis showed a dense structure, low porosity (0.8%) and thickness up to 300 µm (~ 100 µm for the porous outer layer and ~ 200 µm for the compact inner layer). The sliding wear test resulted in a volume loss of 3.2 × 10−4 mm3/Nm with an adhesive wear mechanism. The abrasive wear test showed a wear rate of 1.1 × 10−4 mm3/Nm for the as-prepared coating and 0.8 × 10−4 mm3/Nm for the polished coating. The as-prepared coating pores and interparticle spacing in the outer layer were mostly responsible for the increase in wear rate. For the polished coating immersed in 3.5 wt.% NaCl solution during 900 h, the electrolyte reached some specific points of the substrate as revealed by the cross-sectional analysis. Inspection of the as-prepared coating demonstrated that the coating/substrate interface was completely damaged after long immersion times (~ 900 h).

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Acknowledgments

The authors thank CNPq (Conselho Nacional de Pesquisa, procs. 153177/2014-4 and 201325/2014-4), and CAPES (Coordenação de Aperfeiçoamento do Pessoal de Ensino Superior) for financial support and scholarships.

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  1. Institute of Chemistry, UNESP - São Paulo State University, Rua Prof. Francisco Degni 55, P.O. Box 355, Araraquara, SP, 14800-060, Brazil

    F. S. da Silva & A. V. Benedetti

  2. CPT, Barcelona University, Martí I Franqués 1, 08028, Barcelona, Spain

    F. S. da Silva, N. Cinca, S. Dosta, I. G. Cano & J. M. Guilemany

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  1. F. S. da Silva
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da Silva, F.S., Cinca, N., Dosta, S. et al. Effect of the Outer Layer of Al Coatings Deposited by Cold Gas Spray on the Microstructure, Mechanical Properties and Corrosion Resistance of the AA 7075-T6 Aluminum Alloy. J Therm Spray Tech 29, 1040–1053 (2020). https://doi.org/10.1007/s11666-020-01023-8

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