Cold spraying (CS) is a solid-state process where the coating is formed by powder particles impacting with high kinetic energy because of their high velocity. The coating is formed when particles impacting on the substrate surface are plastically deformed and adhere to the substrate (Ref
1). However, roughness, the treatment of a substrate, and the oxide passivation layer directly affect coating adhesion (Ref
2,
3). The cold spraying as an emerging coating technique has been developed to deposit high-quality metallic coatings. The advantages presented by low temperatures in cold spraying make it possible to deposit coatings on a wide range of materials. Among them, the authors (Ref
4) by CS method covered the surface of aluminum with copper layer. It turned out that CuAl
2 phase appeared on Al surface. Titanium and its alloys show excellent corrosion resistance and can be widely used for the protection of material substrates. The potentiodynamic polarization measurement reveals that cold-sprayed Ti coating has much higher corrosion resistance than carbon steel and can provide favorable protection for the steel substrate (Ref
5). Tantalum is a sought-after metal with very good resistance against corrosion in various acid solutions, salt solutions, and organic compounds even at elevated temperatures. Corrosion resistance of the CS Ta coating is ensured by the formation of the passive oxide film of Ta
2O
5 on surface of coating. Moreover, the electrochemical tests in concentrated alkaline solutions revealed the stable passive behavior of the CS tantalum coatings (Ref
6,
7). Zinc and its alloy coatings have been extensively used on steel substrates and components to protect them from corrosion and surface degradation in aqueous environments. The cold-sprayed zinc coatings are thick, dense and provide an efficient barrier protection for a mild steel surface without exposing the substrate to corrosion (Ref
8). The use of the CS processes on zinc coatings is still at the developmental stage. The study (Ref
9) shows that high temperatures and pressures provide necessary kinetic energy to affect a mechanical bond between the substrate and the coating powders. On the other hand, the microstructure of the CS coatings evidently points to the plastic deformation of metallic powders. Therefore, cold spray is mostly suitable for coatings on oxygen-sensitive or thermo-sensitive substrates, including magnesium. Xiong and Zhang (Ref
10) thoroughly investigated the effect of the cold-sprayed Al/Al
2O
3 composite coatings on magnesium alloy substrates. Mg alloys coated with the cold-sprayed Al/Al
2O
3 composite were found to show enhanced yield strength compared with uncoated materials, and the yield strength of coated magnesium alloys increases with the volume fraction of Al
2O
3 in the coatings. Considerable research (Ref
11) on coating magnesium alloys with aluminum powder using the CS technique and its effect on the corrosion resistance and mechanical properties of the Mg alloy has been done. The CS aluminum coating deposited on the magnesium alloy provided a significant protection of the substrate from the corrosion attack. Nickel and its alloys are employed in a wide range of industrial sectors where corrosion resistance is required. Koivuluoto et al. (Ref
12) investigated the corrosion resistance of Ni and NiCu coatings, which were produced by CS method. The electrochemical test results demonstrate that both coatings show comparable corrosion resistance with their bulk counterparts in a variety of solutions. Moreover, the corrosion resistance of the Ni coating increases with the gas temperature (Ref
13). In the work done by Bala et al. (Ref
14), the CS process was used to successfully deposit NiCr, NiCrTiC, and NiCrTiCRe powders on boiler steel. It turned out that all the examined coatings successfully decreased the erosion-corrosion rate of the substrate under boiler environment. Therefore, it is to be noted that the mechanical properties of the CS coatings are significantly influenced by the coating structure and the particle bonding. The overall quality of the bonding is dependent on metal and process conditions, such as material strength, particle velocity, and process temperature (Ref
15). The CS process was used to prepare of WC-Co coatings (Ref
16). The results show that there is no degradation of the WC-Co powder during the cold spray process and a well-bonded and phase pure WC coating can be produced. Moreover, cold-sprayed coatings were produced by spraying WC-25Co powders onto Al7075-T6 and low-carbon steel substrates (Ref
17). Mechanical properties of coatings on both substrates were found to be very similar to those obtained by the high-velocity oxy-fuel (HVOF) method. On the other hand, gas pressure and gas temperature are two critical factors for obtaining high-quality coatings (Ref
18). Furthermore, a number of investigations on the characteristic mechanical and tribological properties of the cold-sprayed titanium coatings on commercial Ti-6Al-4V substrates have been performed (Ref
19-
23). Most authors agree that mechanical properties of each coating mainly depend on its microstructure and thicknesses. Moreover, the surface preparation of a substrate is the essential first-stage treatment before the application of any coating. It is well-known that the correct preparation of the substrate has a significant effect on the adhesion of the coating to the metal surface. The abrasive grit-blasting treatment (ABT) of metals is widely used for the preparation of the substrate for the cold-sprayed coating process. Metal coating should protect the substrate against corrosion. Moreover, the same materials are used to regenerate the substrate surface, for example, nickel coatings are often applied to the nickel substrate. In addition, the coating and the substrate should have almost the same mechanical and corrosion properties. Therefore, we have tried to solve this interesting problem. However, in the literature, we have not found any information about the effect of the substrate (Ni
(s)) treatment on the corrosion resistance of the cold-sprayed nickel coating (Ni
(c)), especially in aggressive environments.
The paper deals with the corrosion resistance of the cold-sprayed nickel coatings on the nickel surface (i.e., Ni(c)/Ni(s)), without and with an abrasive grit-blasting treatment of the substrate. To treat the substrate, the corundum powder with different grain sizes was used. The corrosive environment contained an acidic chloride solution. The electrochemical method and other supporting techniques were applied.