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Enhanced Electrochemical and Tribological Properties of AZ91D Magnesium Alloy via Cold Spraying of Aluminum Alloy

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Abstract

Magnesium (Mg) alloys have remarkable physical and mechanical properties for various aerospace applications. However, the high corrosion susceptibility and low wear resistance of Mg alloys restrict their wider use. To overcome these problems, 6061 Al alloy coatings were fabricated via the cold spraying process on the AZ91D Mg alloy substrate and a detailed comparative study on the wear and corrosion properties was carried out. The microstructure analysis of the compact coatings revealed low porosity with no phase change during the deposition process. The coatings showed improved corrosion resistance up to seven times as confirmed by potentiodynamic polarization and electrochemical impedance spectroscopy measurements in 3.5 wt.% NaCl aqueous solution. The as-deposited coatings were also compared with commercial bulk alloys of similar composition for their suitability to industrial applications. The tribological behavior of the coatings and substrate was investigated using tribometer. The wear resistance of the coatings improved more than two orders of magnitude as compared to the substrate. Abrasive and oxidative wear mechanisms were dominant in the coatings and substrate. The results showed that cold spraying of 6061 Al alloy on AZ91D Mg alloy could be an auspicious process to overcome the poor corrosion and wear resistance of this Mg alloy for practical industrial applications.

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Acknowledgments

This work was financially supported by the Pakistan Science Foundation (PSF/NSFC-II/ENG/C-IST (10)). We are thankful to the thermal spraying laboratory of Xian Jiaotong University for their technical support and help.

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Authors and Affiliations

  1. Department of Physics and Astronomy, Texas Tech University, Lubbock, TX, 79409, USA

    Sumera Siddique

  2. NanoTech Center, Texas Tech University, Lubbock, TX, 79409, USA

    Sumera Siddique & Ayrton A. Bernussi

  3. 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

    Cheng-Xin Li

  4. Department of Electrical and Computer Engineering, Texas Tech University, Lubbock, TX, 79409, USA

    Ayrton A. Bernussi

  5. Department of Materials Science and Engineering, Institute of Space Technology (IST), 1-Islamabad Highway, Islamabad, 44000, Pakistan

    Syed Wilayat Hussain & Muhammad Yasir

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  1. Sumera Siddique
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Siddique, S., Li, CX., Bernussi, A.A. et al. Enhanced Electrochemical and Tribological Properties of AZ91D Magnesium Alloy via Cold Spraying of Aluminum Alloy. J Therm Spray Tech 28, 1739–1748 (2019). https://doi.org/10.1007/s11666-019-00915-8

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  • DOI: https://doi.org/10.1007/s11666-019-00915-8

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