Despite their excellent specific mechanical properties magnesium-based alloys are not widely used in the industry due to their high affinity to oxygen. Given the need for lightweight design, there are increasing efforts to replace high density materials by magnesium. One way to cope with the high oxygen affinity of magnesium is the use of thermally sprayed anti-corrosion coatings. However, conventional thermal coating processes have various process-related limitations. A case in point is coating of complex geometries and internal coatings with small diameters that often cannot be realized by conventional processes. Due to the changed process order some of the limitations of conventional coating methods can be resolved by the transplantation of thermally sprayed coatings. This method is a composite casting process for the coating of die cast components, where the thermally sprayed coating is applied to the corresponding area of the mold prior to the casting process. The aim of this study is to compare the effectiveness of transplanted thermally sprayed coatings with corrosion protection properties to conventional coatings deposited by thermal spraying and to discuss the ramifications with respect to industrial applications.

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