Cold spray Al-5% Mg coatings for the corrosion protection of magnesium alloys

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

Research output: Contribution to journalReview articlepeer-review

104 Scopus citations


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 custommade 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 H v100, and an adhesion strength, over 60 MPa, when treated for over 1000 h in a salt spray chamber and with a low galvanic current.

Original languageEnglish (US)
Pages (from-to)1352-1358
Number of pages7
JournalJournal of Thermal Spray Technology
Issue number6
StatePublished - Dec 2011

All Science Journal Classification (ASJC) codes

  • Condensed Matter Physics
  • Surfaces, Coatings and Films
  • Materials Chemistry


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