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Cold Spray Al-5% Mg Coatings for the Corrosion Protection of Magnesium Alloys

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Abstract

Poor corrosion resistance is a significant limitation of magnesium alloys as structural materials. To address this problem, the objective of this study was to apply to a magnesium alloy a corrosion-resistant barrier coating that has galvanic compatibility with magnesium and a hardness value no less than that of magnesium. Aluminum coatings were applied to ZE41A-T5 Mg by the cold spray process. A custom-made high-purity Al-5 wt.% Mg powder was produced by spray metal forming for the coating evaluation. In addition, coatings of commercially pure Al (99.5 wt.%), high-purity Al (99.95 wt.%), AA5356, and AA4047 were used for comparison. Coating evaluation included mechanical testing (hardness and adhesion strength) and corrosion testing (salt spray, galvanic coupling, and crevice corrosion). The Al-5% Mg powder resulted in the best overall performance, including a high hardness, 125 Hv100, and an adhesion strength, over 60 MPa, when treated for over 1000 h in a salt spray chamber and with a low galvanic current.

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Acknowledgments

This project was supported by the Office of Naval Research under Contract No. N00024-02-D-6604/0548. The authors wish to acknowledge the assistance provided by Aaron Isaacson, Chris Wertz, and Scott Hills of the Material Processing group at the Penn State Applied Research Lab; and Brock Golesich, Steve Toma, Steve Schroth, Kevin Anderson, and Mike Steele of the API Defense Systems.

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Authors and Affiliations

  1. Applied Research Lab, Pennsylvania State University, University Park, PA, 16802, USA

    Brian S. DeForce, Timothy J. Eden & John K. Potter

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  1. Brian S. DeForce
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  2. Timothy J. Eden
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  3. John K. Potter
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Correspondence to Brian S. DeForce.

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DeForce, B.S., Eden, T.J. & Potter, J.K. Cold Spray Al-5% Mg Coatings for the Corrosion Protection of Magnesium Alloys. J Therm Spray Tech 20, 1352–1358 (2011). https://doi.org/10.1007/s11666-011-9675-4

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  • DOI: https://doi.org/10.1007/s11666-011-9675-4

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