In this work, a new cold-spray shot-peening process was used to achieve surface nanocrystallization on a magnesium alloy deposit. The results of various examinations and tests show that nanocrystalline layers up to 40 µm thick with an average grain size in range of 50-80 nm can be prepared on AZ91D deposits using the new process. The nanocrystalline layers also exhibit good microhardness and tribological properties.

Magnesium light weight alloys are currently being studied as implants due to their biodegradability. However, its applications are limited by high rate hydrogen evolution during corrosion. Coating on this substrate is one of the ways to reduce the rate of corrosion and increase the life of this type of implant. Hence, hydroxyapatite (HA) was coated on the substrates by using high velocity oxy- fuel (HVOF) spraying. The main purpose of such coatings is increasing bioactivity as well as corrosion resistance of the Mg alloy. Crystal structure was characterized by X-ray diffraction (XRD). Crystallinity of the coating was about 70% in which HA is dominant phase. The amounts of hydrogen gas released during magnesium corrosion tests in simulated body fluid (SBF) were measured to evaluate the corrosion resistance of the coated samples. This coating could decrease hydrogen evolution from 100 per cm 2 .mL to about 15 per cm 2 .mL after 29h of immersion time.

WC-12 Co powder was thermal sprayed on AZ91D Magnesium alloy using HVOF technique. Laser texturing substrate preparation technique was used to roughen the surface for good coating adhesion. Adhesion strength of the coating was determined using ASTM 633C adhesion strength test for thick coatings. were used to investigate coating microstructure. Coating was characterized for porosity, micro hardness and Scanning electron microscopy and X- ray diffraction techniques. The coating hence prepared, were found to achieve good adhesion strength, micro hardness and low porosity.

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.

In this study, pure Al coatings were deposited on ZK60-T5 Mg alloy substrates via in-situ shot-peening assisted cold spray in order to study the effect of the Al coating on fatigue behavior of coated samples. Fatigue behavior of the coated and un-coated samples has been investigated through experimental tests. The size and shape distribution of powders, microstructural characteristics of coatings and fractography of fatigue test samples have been studied using scanning electron microscopy. The average microhardness of pure Al coating is higher than 70 HV50. In order to obtain the fatigue S-N diagram for each set, coated and un-coated samples have been tested in a load-controlled condition. The tension-compression fatigue experiments reveal that the fatigue property of ZK60-T5 alloy coated with pure Al coatings has significantly deteriorated compared with un-coated samples.

An alumina-silicon dioxide composite coating was fabricated by cold spraying on AZ31 magnesium alloy. The microstructure, mechanical properties (microhardness, bonding strength and tribological behaviour) and anticorrosion property of the coating as a function of the ceramic volume were investigated. The results show that the composite coating presents higher bonding strength and microhardness. Addition of silicon dioxide significantly enhances the anti-wear and anti-corrosion performances of AZ31 magnesium alloy.

This study demonstrates a novel method for improving the corrosion resistance of cold sprayed Al6061 coatings. Large stainless steel particles were added to a commercial Al6061 powder and the mixture was deposited on Mg alloy AZ31B substrates using nitrogen gas at low working pressure and temperature. It is shown that the stainless steel particles had a shot-peening effect, thus increasing the density as well as the corrosion resistance of Al6061 coatings. SEM examination showed that no stainless steel particles were incorporated in the coating.

This study investigates the use of cold gas spraying (CGS) for depositing braze filler coatings. In the experiments, pure Cu layers were sprayed onto Mg alloy substrates, which were then joined to AlSi steel by contact reaction brazing in a vacuum furnace. The bonding temperature influenced the dissolution of Cu as well as the eutectic reaction between the coating and substrate. The thickness of the brazed seam was found to be 300 μm although the initial thickness of the Cu layer was just 50 μm. The shear strength of the joint peaked at 37 MPa, corresponding to a brazing temperature of 530 °C. Intermetallic phases and interfacial defects of various types were responsible for the low strength of the joints.

In this study, a 30 kW RF plasma reactor is used to synthesize metallic (Ni) and intermetallic (Mg 2 Ni) nanoparticles along with carbon-encapsulated Ni. The system was configured with injection probes at the top and bottom of the torch to facilitate the synthesis of compounds as well as core-shell particle structures. Materials used as precursors include methane, Ni, Mg, and pre-alloyed Mg 2 Ni powder. By feeding Ni together with methane, nickel nanoparticles encapsulated with 6-10 layers of graphite were produced. The core-shell particles and other samples collected were analyzed using X-ray diffraction and electron imaging techniques and were found to be spherical in shape and less than 100 nm in diameter.

In this study, a suspension containing Mg-Al-spinel nanopowder was deposited on bond-coated IN738 and stainless steel disks by suspension plasma spraying with and without substrate cooling. Coating surfaces and cross-sections were examined by SEM, EDS, and XRD analysis and thermal cycling tests were performed. SEM images of coatings obtained on cooled stainless steel show a unique columnar microstructure with a cauliflower-like surface. XRD spectra of the nanopowder and coatings revealed evidence of phase changes in the material deposited on cooled substrates. In preparing samples for thermal cycling tests, a YSZ layer was deposited on bond-coated IN738 prior to spraying the suspension. Double-layered Mg-Al-spinel/YSZ thermal barrier coatings produced on cooled substrates exhibited a thermal cycling lifetime of 2000 cycles at 1390°C, compared to 101 cycles for the TBCs sprayed without substrate cooling. The superior performance of the TBCs sprayed with substrate cooling is attributed to the densification of the coatings, revealed by SEM images, and possibly the formation of CaO-6Al 2 O 3 needles and Al 2 O 3 precipitates as identified by EDS measurements.

In this work, Al and Al-Al 2 O 3 coatings up to 8 mm thick were cold sprayed on AZ91D magnesium alloy substrates. Microstructure, microhardness, bond strength, and corrosion and wear resistance were studied to assess the viability of using these coatings to restore dimensionally degraded parts and protect them from further corrosion and wear.

Due to the demand for improved fuel economy as well as increased safety features, weight reduction is one of the major aims in the automotive industry. Future lightweight automotive components for the next car generation will probably use lots of magnesium alloy. These will form galvanic couples with other materials and may induce phenomena accelerating the corrosion rate of automotive components. The materials used were magnesium alloy AZ31B and several types of cold sprayed coating. The relative performance of each cold sprayed corrosion preventive compounds (CPC) was assessed in combination with the materials under several different electrochemical and accelerated corrosion tests. Baseline data for AZ31B with no CPC applied was also collected. CPC characteristics and properties are also included and discussed. The studies on bare Mg/Steel couples validated accelerated corrosion but found that CPC cold sprayed coatings mitigate corrosion rates. Thus Mg/Fe interfaces with defect-free cold sprayed coatings CPC can prevent buildup of corrosion products and reduce galvanic corrosion of automotive components.

The repair of damaged Ion Vapor Deposition Aluminum coatings on high strength steel aircraft components has generally required the use of brush plating with hazardous materials including cadmium. Inovati has developed a unique Al-Trans (aluminum-transition metal) coating using the Kinetic Metallization process that permits repairs of IVD-Al coatings on high strength steels. Originally the Al-Trans coating formulation was developed for commercial application on telecommunication equipment steel racks as an electrically conductive grounding strip with excellent corrosion resistance. Recent research was completed with NAVAIR to further develop this coating formulation and the Kinetic Metallization process for repair of IVD-Al coatings on aircraft components. This presentation will describe the KM repair process and the tests completed to qualify the repaired coatings. Inovati has recently developed a KM-Mobile Coating System with a handheld Spray Gun for the field repair of corrosion damaged magnesium and aluminum alloy aircraft components.

Magnesium and magnesium alloys are the lightest structural materials with an approximate density of 1.7 g/cm³ (density of aluminium ~2.7 g/cm³). Due to the poor corrosion and wear resistance properties, they need to be coated for usage in lightweight constructions. AlSi20 was found to be a suitable coating material to improve the properties of parts made of the magnesium alloy AZ31B. Within this work, coatings are applied by thermal spraying, laser cladding and the combination of both processes. These coatings were investigated regarding corrosion protection in 3.5 % chlorine solution in a three electrode setup to obtain electrochemical corrosion characteristics. Abrasive wear was investigated using a pin-on-disc tribometer and abrasion rate was calculated. Resistance against shock loads was tested by applying a cyclic load at 50 Hz in order to investigate the resistance against impact stresses.

High velocity oxygen fuel has been used as fabrication technique for manufacturing aluminium coatings reinforced with different weight percents of silicon carbide particles on Mg-Zn alloys used as substrates. The aim of the investigation is to improve the tribological performance of the ZE41A magnesium alloy. The parameters of the thermal projection system have been optimized in order to maximize the SiC particles incorporation in the aluminium matrix of the coating. Pin-on-disc tests were developed to characterize the tribological behavior of the different specimens. Minor degradation of the magnesium alloy was achieved after . Composite coatings with thicknesses of about 120 µm, reinforced with about 10 wt.% and with high adhesion to the substrate were achieved. After the coating parameters were optimized, the wear rate of the magnesium with the composite coatings decreased by two orders of magnitude in comparison to that of the uncoated magnesium alloy.

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.

In this paper, a commercial AZ91D magnesium alloy powder and its mixture with 30 vol.% SiC powder were used to deposit coatings by cold spraying. Two types of converging-diverging nozzles with different cross-sectional shapes were employed. The velocity and temperature of in-flight particles under different operating conditions were simulated using the FLUENT software. The simulated results show that the particle velocity through the rectangular cross-section nozzle is the same with that through the circular one. However, the coating observation shows that the AZ91D coating and its composite could only be deposited using the rectangular cross-section nozzle. The increase of gas temperature has little effect on the coating microstructure, porosity and microhardness. Furthermore, the observation of the composite coating produced under the gas temperature of 600°C shows that the SiC content in the composite is about 23 vol.%. The microhardness of the composite is improved to about 140 HV 0.3 due to the enhancement of SiC particles, compared to that of about 100 HV 0.3 for the AZ91D coating.

Surface treatment has become an effective method to improve corrosion resistance of magnesium alloys which are the lightest commercial structural alloys with superior specific strength and stiffness. Low pressure cold spraying is used to locally deposit aluminium on AZ31 in order to enhance general and galvanic corrosion of magnesium. This study is aimed at numerical estimation of the residual stress profile due to cold spray coating using FEM. The impact of particles on the substrate is modelled in Abaqus Explicit. The challenge of AZ31 simulations is the intrinsic yield asymmetry and anisotropy which results different behaviour of the material along different direction both in tension and compression. On the other hand, there is no precise material model capable of considering the yield asymmetry and anisotropy experienced by AZ31 in Abaqus. This paper studies the effect of anisotropy of the AZ31 on residual stress induced by cold spray. The results are compared with experimental X-Ray diffraction measurements. It is suggested that an isotropic analysis in the dominant stress direction of AZ31 may result in good estimation of the residual stress profile.

A composite coating using mixed powders of pure Al and α-Al 2 O 3 as feedstock was deposited on AZ91D alloy substrate by cold spraying. The content of α-Al 2 O 3 in mixed powders was 50wt%. Electrochemical experiments were carried out using 3.5wt.% NaCl solution as electrolyte. Because of dense structure, the composite coating could separate substrate from electrolyte thoroughly for long time immersion. The corrosion behavior of the composite coating was evaluated by using electrochemical impedance spectroscopy (EIS) and potentiodynamic polarization measurements. It is found that the composite coating presented much better corrosion resistance than bare AZ91D alloy, even than bulk 1050 aluminum by electrochemical studies in 3.5wt.% NaCl solution.

Saving energy is a major concern in every aspect of the economy, especially in the automotive and aerospace industry. The use of lightweight materials is one way to reduce weight of moving parts and thus energy consumption. Research activities to improve the porosity on the one hand, and the coating properties like wear and corrosion resistance on the other hand, show the potential of a hybrid coating process. The creation of thermal-sprayed coatings and a laser post-treatment enable a minimization of porosity and an improvement of wear properties. Different coating materials (e.g. Al-Si alloy) have been investigated regarding microstructure, hardness, wear- and corrosion protection.