Coating Performance and Durability of Zn-Based Composite Materials Prepared by Using Low-Pressure Cold Spraying

The aim of this work is to characterize the performance and durability of Zn-based composite coatings produced by low-pressure cold spraying and evaluate their potential for use in repair and restoration applications. Mechanically blended Zn+Al+Al₂O₃, Zn+Cu+Al₂O₃, and Zn+Ni+Al₂O₃ powder mixtures were deposited on grit-blasted carbon steel (Fe52), copper, aluminum, and nodular cast iron substrates using optimized feed rates. In addition, round samples were drilled and the holes were repaired by handheld spraying. Coated substrates are assessed based on microstructural analysis, laser shock adhesion testing (LASAT), and thickness and hardness measurements. Hole repairs are evaluated based on bond strength and gas permeability measurements. The procedures are described and the finding are presented and discussed.