Evaluation of microstructure and corrosion performance of cold gas-sprayed Al and Al-50Al2O3 composite coatings on AZ31B magnesium: a comparative study
Year: 2025
Type: article
Abstract: This study evaluates cold gas sprayed (CGS) Al and Al-50wt%Al₂O₃ coatings on AZ31B magnesium substrates at different standoff distances (10, 20, 30 mm) and gas pressures (10, 20, 30 bar). Increasing gas pressure and standoff distance reduced porosity in Al coatings from 4.6% to 1.9%, and in composite coatings from 5.2% to 3.4%, due to higher particle impact velocities and deformation. Higher porosity in composite coatings is attributed to porosity within Al₂O₃ particles. Corrosion tests on optimized coatings (30 bar, 30 mm) showed corrosion rates 90.7 times lower for Al and 10.5 times lower for composite coatings compared to uncoated AZ31B. Charge transfer resistance was 102 times higher for Al and 7.6 times higher for composite coatings. Better corrosion resistance of Al coatings is linked to the mechanically bonded Al–Al₂O₃ interface, which in composites may create channels for corrosive agents, accelerating localized corrosion.
Source: Results in Engineering
Institution: Tarbiat Modares University
Language: English
Subfield: Aerospace Engineering
Field: Engineering
Domain: Physical Sciences
Open Access status: gold
Estimated APC paid: $1,940
OpenAlex ID: W4412464722