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Post-heat Treatment Effects on Cold-Sprayed Aluminum Coatings on AZ91D Magnesium Substrates

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Abstract

Commercially pure aluminum (CP-Al) powder was deposited by the cold spray process onto AZ91D magnesium (Mg) substrates that had been subjected to three different heat-treatment conditions: namely, as-cast (F), homogenized (T4), and artificially aged (T6). The substrate hardness was measured to be 80.7 ± 1.8, 73.7 ± 4.0, and 103.6 ± 7.4 HV0.025 for the F-, T4-, and T6-Mg alloy substrates respectively. Thick (~400 μm) and dense (below 1% porosity) Al coatings have been obtained. After post-deposition heat treatment at 400 °C, the intermetallic Mg17Al12 (β) and Al3Mg2 (γ) phases with different thicknesses were found to have formed at the coating/substrate interface depending on the holding time. While no significant thickness differences of the intermetallic layers were detected in the cases of F- and T6-AZ91D substrates, thicker layers formed on the T4-AZ91D substrate. It is believed that the higher Al concentration in the T4-AZ91D solid solution within the α-Mg could diffuse and contribute more easily to the growth of the intermetallic phases. The hardness of the β- and γ-phase was measured to be 260.5 ± 10.7 HV0.025 and 279.6 ± 13.7 HV0.025, respectively. Shear strength test results revealed lower adhesion strength after heat treatment, which is attributed to the presence of brittle intermetallic layers at the coating/substrate interface.

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Acknowledgments

The authors would like to thank the University of Ottawa for providing the cold spray system and Shanghai JiaoTong University for the financial support given to this work.

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Authors and Affiliations

  1. National Engineering Research Center of Light Alloy Net Forming, School of Materials Science and Engineering, Shanghai JiaoTong University, Shanghai, 200240, People’s Republic of China

    Hengyong Bu & Chen Lu

  2. Mechanical Engineering Department, University of Ottawa, Ottawa, ON, K1N 6N5, Canada

    Mohammed Yandouzi & Bertrand Jodoin

Authors
  1. Hengyong Bu
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  2. Mohammed Yandouzi
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  3. Chen Lu
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  4. Bertrand Jodoin
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Corresponding author

Correspondence to Mohammed Yandouzi.

Additional information

This article is an invited paper selected from presentations at the 2011 International Thermal Spray Conference and has been expanded from the original presentation. It is simultaneously published in Thermal Spray 2011: Proceedings of the International Thermal Spray Conference, Hamburg, Germany, September 27-29, 2011, Basil R. Marple, Arvind Agarwal, Margaret M. Hyland, Yuk-Chiu Lau, Chang-Jiu Li, Rogerio S. Lima, and André McDonald, Ed., ASM International, Materials Park, OH, 2011.

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Bu, H., Yandouzi, M., Lu, C. et al. Post-heat Treatment Effects on Cold-Sprayed Aluminum Coatings on AZ91D Magnesium Substrates. J Therm Spray Tech 21, 731–739 (2012). https://doi.org/10.1007/s11666-012-9785-7

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  • DOI: https://doi.org/10.1007/s11666-012-9785-7

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