Skip to main content
SpringerLink
Log in

Enhancement of Corrosion Resistance and Tribological Properties of LA43M Mg Alloy by Cold-Sprayed Aluminum Coatings Reinforced with Alumina and Carbon Nanotubes

  • PEER REVIEWED
  • Published:
Journal of Thermal Spray Technology Aims and scope Submit manuscript

Abstract

Magnesium is a suitable material for structural and aerospace applications owing to its high strength to weight ratio, yet the wide usage of Mg alloys is restricted due to their poor corrosion and mechanical properties. In this study, cold gas spraying method was used to produce pure Al, Al-Al2O3 and Al-Al2O3-CNTs coatings with feedstock powder containing Al admixed with 5 wt.% Al2O3 and 1 wt.% CNTs to improve electrochemical and tribological properties of Mg-LA43M alloy. X-ray diffraction spectroscopy and scanning electron microscopy were performed for compositional and microstructural analysis of feedstock powders as well as coatings. Furthermore, corrosion properties of coatings were examined by photodynamic polarization, electrochemical spectroscopy and long-term immersion test in 3.5% NaCl solution. The obtained results were correlated with microstructural analysis and we found that reinforcement of hard particles, especially CNTs, resulted in better corrosion resistance of MMC coatings as compared to Mg substrate and pure Al coatings. Reinforcements of Al2O3 and CNTs also improved the sliding wear resistance of the coatings. Al-Al2O3-CNTs exhibited lower coefficient of friction and wear rate than the Mg substrate, pure Al, and Al-Al2O3 coatings due to the denser microstructure.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10

Similar content being viewed by others

References

  1. G. Manoj and M. Ling, Magnesium, Magnesium Alloys and Magnesium Composites, Mater. Sci. Appl., 2010, 09, p 1021-1035

    Google Scholar 

  2. C. Xianhua, G. Yuxiao, and P. Fusheng, Research Progress in Magnesium Alloys as Functional Materials, Rare Met. Mater. Eng., 2016, 45, p 2269-2274

    Article  Google Scholar 

  3. Y. Kojima, T. Aizawa, and S. Kamado, Magnesium Alloys Development Towards the 21st Century, Mater. Sci. Forum, 2010, 350, p 19-30

    Google Scholar 

  4. Y. Sun, R. Wang, C. Peng, Y. Feng, and M. Yang, Corrosion Behavior and Surface Treatment of Superlight Mg-Li Alloys, Trans. Nonferrous Met. Soc. China, 2017, 27, p 1455-1475

    Article  CAS  Google Scholar 

  5. J. Gray and B. Luan, Protective Coatings on Magnesium and Its Alloys—A Critical Review, J. Alloys. Compd., 2003, 336, p 87-113

    Google Scholar 

  6. M. Parco, M.C. Merin, M. Mohedano, P. Casajús, A.E. Coy, and R. Arrabal, Investigation of HVOF Spraying on Magnesium Alloys, Surf. Coat. Technol., 2001, 201, p 3269-3274

    Article  Google Scholar 

  7. H. Pokhmurska, B. Wielage, and T. Lampke, Post-treatment of Thermal Spray Coatings on Magnesium, Surf. Coat. Technol., 2009, 202, p 4515-4524

    Article  Google Scholar 

  8. Z. Wei, L. Liu, and J. Ding, Al Arc Spray Coating on AZ31 Mg Alloy and Its Corrosion Behavior, Mater. Sci. Forum, 2005, 102, p 685-688

    Article  Google Scholar 

  9. H. Zhou, C. Li, G. Ji, S. Fu, H. Yang, X. Luo, G. Yang, and C. Li, Local Microstructure Inhomogeneity and Gas Temperature Effect in In-Situ Shot-Peening Assisted Cold-Sprayed Ti-6Al-4 V Coating, J. Alloys Compd., 2018, 766, p 694-704

    Article  CAS  Google Scholar 

  10. S.-L. Fu, C.-X. Li, Y.-K. Wei, X.-T. Luo, G.-J. Yang, C.-J. Li, and J.-L. Li, Novel Method of Aluminum to Copper Bonding by Cold Spray, J. Therm. Spray Technol., 2018, 27, p 624-640

    Article  CAS  Google Scholar 

  11. E. Irissou, J.G. Legoux, B. Arsenault, and C. Moreau, Investigation of Al-Al2O3 Cold Spray Coating Formation and Properties, J. Therm. Spray Technol., 2007, 16, p 661-667

    Article  CAS  Google Scholar 

  12. C. Borchers, F. Gärtner, and T. Stoltenhoff, Microstructural Bonding Features of Cold Sprayed Face Centered Cubic Metals, J. Appl. Phys., 2003, 96, p 4288-4292

    Article  Google Scholar 

  13. A. Zuniga, B. Jodoin, and E.J. Lavernia, Cold Gas Dynamic Spraying of a High Temperature Al Alloy, Surf. Coat. Technol., 2006, 201, p 2109-2116

    Article  Google Scholar 

  14. K. Kang and S. Bong, Tungsten/Copper Composite Deposits Produced by a Cold Spray, Scripta Mater., 2009, 49, p 1169-1174

    Article  Google Scholar 

  15. Y.-K. Wei, X.-T. Luo, Y. Ge, X. Chu, G.-S. Huang, and C.-J. Li, Deposition of Fully Dense Al-Based Coatings via In-Situ Micro-forging Assisted Cold Spray for Excellent Corrosion Protection of AZ31B Magnesium Alloy, J. Alloys Compd., 2019, 806, p 1116-1126

    Article  CAS  Google Scholar 

  16. J. Hoddera, H. Izadia, A. McDonald, and P. Gerlichc, Fabrication of Aluminum–Alumina Metal Matrix Composites via Cold Gas Dynamic Spraying at Low Pressure Followed by Friction Stir Processing, Mater. Sci. Eng., A, 2012, 556, p 114-121

    Article  Google Scholar 

  17. S. Ngai, T. Ngai, F. Vogel, W. Story, G.B. Thompson, and L.N. Brewer, Saltwater Corrosion Behavior of Cold Sprayed AA7075 Aluminum Alloy Coatings, Corros. Sci., 2018, 130, p 231-240

    Article  CAS  Google Scholar 

  18. X.C. Zhang, B.S. Xu, Y.X. Wu, F.Z. Xuan, and S.T. Tu, Porosity, Mechanical Properties, Residual Stresses of Supersonic Plasma-Sprayed Ni-Based Alloy Coatings Prepared at Different Powder Feed Rates, Appl. Surf. Sci., 2008, 254, p 3879-3889

    Article  CAS  Google Scholar 

  19. D. Poirier, J. Legoux, and L. Drew, Consolidation of Al2O3/Al Nanocomposite Powder by Cold Spray, J. Therm. Spray Technol., 2012, 20, p 275-284

    Article  Google Scholar 

  20. K. Spencer, M. Fabijanic, and X. Zhang, The Use of Al-Al2O3 Cold Spray Coatings to Improve the Surface Properties of Magnesium Alloys, Surf. Coat. Technol., 2009, 204, p 336-344

    Article  CAS  Google Scholar 

  21. H. Kim, C. Lee, and S. Hwang, Superhard Nano WC-12%Co Coating by Cold Spray Deposition, Mater. Sci. Eng., A, 2005, 391, p 243-248

    Article  Google Scholar 

  22. A. Kin and D. Hui, The Revolutionary Creation of New Advanced Materials—Carbon Nanotube Composites, Compos. B Eng., 2002, 33, p 263-277

    Article  Google Scholar 

  23. A. Aborkin, K. Khorkov, E. Prusov, A. Obedkov, K. Kremlev, I. Perezhogin, and M. Alymov, Effect of Increasing the Strength of Aluminum Matrix Nanocomposites Reinforced with Microadditions of Multiwalled Carbon Nanotubes Coated with TiC Nanoparticles, Nanomaterials, 2019, 9, p 1596-1599

    Article  CAS  Google Scholar 

  24. J. Lou, A. Cheng, P. Zhao, R. Misra, and H. Feng, The Significant Impact of Carbon Nanotubes on the Electrochemical Reactivity of Mg-Bearing Metallic Glasses with High Compressive Strength, Materials, 2019, 12, p 2989-2997

    Article  CAS  Google Scholar 

  25. R. Wong and D. Knitter, Manufacturing of Ceramic Microcomponents by a Rapid Prototyping Process Chain, Adv. Eng. Mater., 2001, 23, p 23-29

    Google Scholar 

  26. I. Ozdemir, S. Ahrens, and S. Mucklich, Nanocrystalline Al-Al2O3p and SiCp Composites Produced by High-Energy Ball Milling, J. Mater. Process. Technol., 2008, 205, p 111-118

    Article  CAS  Google Scholar 

  27. B. Prabhua, C. Suryanarayan, L. Anab, and R. Vaidyanathan, Synthesis and Characterization of High Volume Fraction Al-Al2O3 Nanocomposite Powders by High-Energy Milling, Mater. Sci. Eng., A, 2006, 425, p 192-200

    Article  Google Scholar 

  28. Y. Lui and L. Wang, XRD and SEM Analysis Near the Diffusion Bonding Interface of Mg/Al Dissimilar Materials, Vacuum, 2007, 52, p 15-19

    Article  Google Scholar 

  29. G. Sun, J. Young, and J. Kirkpatrick, The Role of Al in C-S-H: NMR, XRD, and Compositional Results for Precipitated Samples, Cem. Concr. Res., 2006, 36, p 18-29

    Article  CAS  Google Scholar 

  30. Q. Jin, G. Tian, J. Li, Y. Zhao, and H. Yan, The Study on Corrosion Resistance of Superhydrophobic Magnesium Hydroxide Coating on AZ31B Magnesium Alloy, Colloids Surf. A, 2019, 577, p 8-16

    Article  CAS  Google Scholar 

  31. G. Zhang, L. Wu, A. Tang, Y. Ma, G. Song, D. Zheng, B. Jiang, A. Atrens, and F. Pan, Active Corrosion Protection by a Smart Coating Based on a MgAl-Layered Double Hydroxide on a Cerium-Modified Plasma Electrolytic Oxidation Coating on Mg Alloy AZ31, Corros. Sci., 2018, 139, p 370-382

    Article  CAS  Google Scholar 

  32. M. Yin, A. Boiuyt, and M. Sun, Self-Healing Plasma Electrolytic Oxidation Coatings Doped with Benzotriazole Loaded Halloysite Nanotubes on AM50 Magnesium Alloy, Corros. Sci., 2016, 11, p 753-769

    Google Scholar 

  33. Y. Zhu, G. Yu, and B. Hu, Electrochemical Behaviors of the Magnesium Alloy Substrates in Various Pretreatment Solutions, Appl. Surf. Sci., 2010, 256, p 2988-2994

    Article  CAS  Google Scholar 

  34. S. Pyun and W. Lee, The Effect of Prior Cl− Ion Incorporation into Native Oxide Film on Pure Aluminium in Neutral Chloride Solution on Pit Initiation, Corros. Sci., 2001, 43, p 353-363

    Article  CAS  Google Scholar 

  35. H. Hongwwi, Y. Li, and F. Wang, Improvement on the Corrosion Resistance of AZ91D Magnesium Alloy by Aluminum Diffusion Coating, J. Mater. Sci. Technol., 2007, 24, p 29-38

    Google Scholar 

  36. Y. Tao, T. Xiong, and C. Sun, Microstructure and Corrosion Performance of a Cold Sprayed Aluminium Coating on AZ91D Magnesium Alloy, Corros. Sci., 2010, 34, p 3191-3197

    Article  Google Scholar 

  37. H. Bu, M. Yandozi, C. Lu, and B. Jodoin, Effect of Heat Treatment on the Intermetallic Layer of Cold Sprayed Aluminum Coatings on Magnesium Alloy, Surf. Coat. Technol., 2011, 205, p 4665-4671

    Article  CAS  Google Scholar 

  38. Y. Tao, T. Xiong, and C. Sun, Effect of α-Al2O3 on the Properties of Cold Sprayed Al/α-Al2O3 Composite Coatings on AZ91D Magnesium Alloy, Appl. Surf. Sci., 2009, 256, p 261-266

    Article  CAS  Google Scholar 

  39. J. Colin and A. Kuhn, Electrochemical and Density Functional Theory Study of Bis(cyclopentadienyl) Mono(β-diketonato) Titanium(IV) Cationic Complexes, Electrochim. Acta, 2010, 56, p 257-264

    Article  Google Scholar 

  40. M. Diab, X. Pang, and H. Jahed, The Effect of Pure Aluminum Cold Spray Coating on Corrosion and Corrosion Fatigue of Magnesium (3% Al-1% Zn) Extrusion, Surf. Coat. Technol., 2017, 309, p 423-435

    Article  CAS  Google Scholar 

  41. P. Long, C. Zui, and C. Xu, Wear and Corrosion Resistance of Laser Cladding AISI, 304 Stainless Steel/Al2O3 Composite Coatings, Surf. Coat. Technol., 2014, 252, p 9-14

    Google Scholar 

  42. S. Salven and S. Ramanathan, Dry Sliding Wear Behavior of As-Cast ZE41A Magnesium Alloy, Mater. Des., 2010, 31, p 1930-1936

    Article  Google Scholar 

  43. Q. Song, N. Shang, and X. Zhang, Wear Behaviour of AZ91D Magnesium Alloy with a Nanocrystalline Surface Layer, Surf. Coat. Technol., 2008, 202, p 2859-2864

    Article  Google Scholar 

  44. F. Silvaa, N. Cincab, and S. Dostab, Corrosion Behavior of WC-Co Coatings Deposited by Cold Gas Spray onto AA 7075-T6, Corros. Sci., 2010, 108, p 111-115

    Google Scholar 

Download references

Acknowledgment

This work was supported by the National Key Research and Development Program of China (Basic Research Project, Grant No. 2017YFB0306100) and the National Key Research and Development Program of China (China-USA Intergovernmental Cooperation Project, Grant No. 2017YFE0105900).

Author information

Authors and Affiliations

  1. State Key Laboratory for Mechanical Behavior of Materials, School of Materials Science and Engineering, Xi’an Jiaotong University, Xi’an, Shaanxi, China

    Usman Ahmed, Lui Yi, Lu Fei Fei, Chang-Jiu Li & Cheng-Xin Li

  2. Department of Materials Science and Engineering, Institute of Space and Technology, Islamabad, 44000, Pakistan

    Usman Ahmed & Muhammad Yasir

Authors
  1. Usman Ahmed
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Lui Yi
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Lu Fei Fei
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Muhammad Yasir
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Chang-Jiu Li
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Cheng-Xin Li
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Cheng-Xin Li.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Ahmed, U., Yi, L., Fei, L.F. et al. Enhancement of Corrosion Resistance and Tribological Properties of LA43M Mg Alloy by Cold-Sprayed Aluminum Coatings Reinforced with Alumina and Carbon Nanotubes. J Therm Spray Tech 30, 668–679 (2021). https://doi.org/10.1007/s11666-020-01146-y

Download citation

  • Received:

  • Revised:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s11666-020-01146-y

Keywords

Search

Navigation