TY - JOUR
T1 - Cold spray Al-5% Mg coatings for the corrosion protection of magnesium alloys
AU - DeForce, Brian S.
AU - Eden, Timothy J.
AU - Potter, John K.
N1 - Funding Information:
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.
PY - 2011/12
Y1 - 2011/12
N2 - 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.
AB - 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.
UR - https://www.scopus.com/pages/publications/84855648700
UR - https://www.scopus.com/inward/citedby.url?scp=84855648700&partnerID=8YFLogxK
U2 - 10.1007/s11666-011-9675-4
DO - 10.1007/s11666-011-9675-4
M3 - Review article
AN - SCOPUS:84855648700
SN - 1059-9630
VL - 20
SP - 1352
EP - 1358
JO - Journal of Thermal Spray Technology
JF - Journal of Thermal Spray Technology
IS - 6
ER -