The study of corrosion protection of magnesium and aluminum becomes increasingly important as the use of these alloys increases rapidly in the automotive and aerospace industries due to their advantages of light-weight, adequate mechanical properties and moderate cost. Corrosion, however, limits the application of magnesium and aluminum alloys. Fasteners, spot welds of dissimilar materials and their galvanic corrosion is of major concern in automotive applications. The paper presents first results of Low Pressure Cold Spray (LPCS) of Al based coatings for corrosion protection. The corrosion protection provided by these coatings was evaluated by electrochemical measurements in 1M NaCl electrolyte. The microstructures and electrochemical behavior of the coated joints were investigated. The electrochemical corrosion mechanisms of the coatings and microstructure were discussed.

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