Enhancing the Corrosion Resistance of Low Pressure Cold Sprayed Metal Matrix Composite Coatings on AZ31B Mg Alloy Through Friction Stir Processing

To improve the corrosion resistance of Mg alloy, Al alloy/alumina metal matrix composite (MMC) coatings were formed by low pressure cold spraying (LPCS) technology followed by post friction stir processing. The phase structure, microstructure, and corrosion properties of the cold-sprayed metal matrix composite coatings before and after friction stir processing were investigated. The effect of the friction stir process (FSP) on the corrosion characteristics of MMC coatings at 3.5 weight percent of NaCl solution was explored using a Tafel polarisation plot. Microstructural studies were examined to investigate the electrochemical behaviour of the cold spray (CS) and FSPed MMC coatings. The results demonstrated that an enhancement in corrosion protection of the MMC deposits occurred at the 1st and 2nd runs of FSP, with superior corrosion performance observed at the 2nd run of FSP. The enhanced surface state is the primary enhancement mechanism of the electrochemical properties of the FSPed MMC coatings. For the higher run of FSP (3rd run), the electrochemical performance of the specimens was lower owing to the amalgamate action of the enhanced surface state with the aggravated interface of interior deposits.