Corrosion Protection of Light Alloys Using Low Pressure Cold Spray

Corrosion attack of aluminum- and magnesium-based alloys is a major issue worldwide. This study provides a report on the electrochemical behavior of several types of protective metal coatings obtained by low pressure cold spray (LPCS) and describes the performance of the latter’s corrosion resistance properties. In this manner several metal feedstock compositions were cold sprayed on AA2024-T3 Alclad substrate. Electrochemical methods, such as open circuit potential and potentiodynamic polarization, were used in combination with materials characterization techniques to assess the performance of LPCS protective coating layers. All sprayed samples were tested in the accelerated corrosion salt spray chamber for a time period of up to 500 h to obtain corrosion kinetics data, and with specific attention being focused on the characterization of the coating’s microstructural and mechanical properties. The overall conclusion of this study is that the LPCS process could be utilized to deposit corrosion protection coatings of light alloys as well as to repair aluminum and aluminum cladding structures during overhaul maintenance schedule in industry.