AZ31 alloy is used as a lightweight material for structural application in the automobile and aircraft production. However, alloy AZ31 is known to have poor corrosion resistant due to high electrochemical activity. In this study, the possibility of improving the corrosion resistance by applying protective coatings deposited by the low pressure cold spray process was investigated. The relative performance of each cold sprayed corrosion preventive coatings was assessed in accordance with American Society for Testing and Materials standards. The data for the bare AZ31 alloy were initially obtained and used as a reference point to compare the corrosion protective performance of different preventive coatings. Electrochemical behaviour of each coating composition was analyzed after a given time period of the accelerated corrosion test. Microstructure and mechanical properties of the deposited preventive coatings are also discussed. The cold sprayed preventive coatings provide sufficient protection to substantially reduce the corrosion rate of alloy AZ31.
Get full access to this article
View all access options for this article.
References
1.
GhassemiehE.: ‘Materials in automotive application, state of the art and prospects’, in ‘New trends and developments in automotive industry’; 2011, Rijeka, Croatia, InTech.
2.
JamesM., KihiuJ. M. and RadingG. O.: ‘Automobile weight optimization using magnesium alloy AZ31B’, Proc. of the 2012 Mechanical Engineering Conference on Sustainable Research and Innovation4, ; 2012.
3.
XiaoL., LiuL., ChenD. L., EsmaeiliS. and ZhouY.: ‘Resistance spot weld fatigue behavior and dislocation substructures in two different heats of AZ31 magnesium alloy’, Mater. Sci. Eng. A, 2011, A529, 81–87.
4.
NeugebauerR., KrausC. and DietrichS.: ‘Advances in mechanical joining of magnesium’, Proc. Conf. CIRP Manuf. Technol., 2008, 57, 283–286.
5.
GerstmayrM. and EichlsederL.: ‘On the applicability of high strength self-tapping aluminum bolts in magnesium nut materials for automotive applications’, Mater. Corros., 2010, 61, (5), 379–387.
6.
HanS., WuY., GaoY. and ZengQ.: ‘Study on clinching of magnesium alloy sheets with different lower die parameters based on DEFORM 2D’, Proc. 2nd International Conference on Electronic & Mechanical Engineering and Information Technology (EMEIT-2012).
7.
WestphalK. and MulherkarT.: ‘Joining of magnesium components using Al fasteners’, Light Met. Age, 2005, 4, (63), 42–44.
ChakherlouT. N., RazaviM. J., AghdamA. B. and AbazadehB.: ‘An experimental investigation of the bolt clamping force and friction effect on the fatigue behaviour of aluminum alloy 2024-T3 double shear lap joint’, Mater. Des., 2011, 32, 4641–4649.
10.
IbrahimR. A. and PettitC. L.: ‘Uncertainties and dynamic problems of bolted joints and other fasteners’, J. Sound Vib., 2005, 279, 857–936.
11.
DifallahB. B., KharratM., DammakM. and MonteilG.: ‘Microstructure, friction and wear analysis of thermoplastic based composites with solid lubricant’, Mech. Ind., 2012, 13, (5), 337–346.
12.
KorsunskyA., TorosyanA. R. and KimK.: ‘Development and characterization of low-friction coatings for protection against fretting wear in aerospace components’, Met. Finish., 2009, 107, (2), 45–52.
13.
GhaliE.: ‘Corrosion resistance of aluminum and magnesium alloys: understanding, performance, and testing’, 140; 2010, Hoboken, NJ, John Wiley & Sons.
14.
PanT. and SantellaM.: ‘Corrosion behavior of mixed-metal joint of magnesium to mild steel by ultrasonic spot welding’, SAE Technical Paper 2012-01-0472; 2012.
15.
KainerK. U. and KaiserF.: ‘Magnesium alloys and technology’; 2003, Weinheim, Wiley-VCH GmbH.
16.
JiaJ. X., SongG. L. and AtrensA.: ‘Influence of geometry on galvanic corrosion of AZ91D coupled to steel’, Corros. Sci., 2006, 48, 2133–2153.
17.
BaldwinK. R., RobinsonM. J. and SmithC. J. E.: ‘The corrosion behavior of electrodeposited zinc–nickel alloy coatings on exposure to the marine atmosphere’, Proc. Conf. UK Corrosion 94, Institute of Corrosion3, 165–175; 1994, Bournemouth, UK, The Chameleon Press, London.
18.
TangJ. and AzumiK.: ‘Effect of copper pretreatment on the zincate process and subsequent copper electrodeposition of AZ31 magnesium alloy’, J. Electrochem. Soc., 2011, 158, (9), 535–540.
MaevR. G. and LeshchinskyV.: ‘Low pressure gas dynamic spray: shear localization during particle shock consolidation’, Proc. Conf. 2006 International Thermal Spray Conference, May 15–18; 2006, (Seattle, WA, USA), ASM International.
23.
AttiaH., MeshrekiM., KorsanyA., ThomsonV. and ChangV.: ‘Fretting wear characteristic of cold gas-dynamic sprayed aluminum alloys’, Tribol. Int., 2011, 44, 1407–1416.
24.
JiaJ. X., AtrensA. and SongG.: ‘Simulation of galvanic corrosion of magnesium coupled to a steel fastener in NaCl solution’, Mater. Corros., 2005, 56, 468–474.
25.
IsmailK. M. and VirtanenS.: ‘Electrochemical behavior of magnesium alloy AZ31 in 0·5 M KOH solution’, Electrochem. Solid-State Lett., 2007, 10, (3), 9–11.
26.
SalmanS. A., IchinoR. and OkidoM.: ‘A comparative electrochemical study of AZ31 and AZ91 magnesium alloy’, Int. J. Corros., 2010, 2010, 412129.
27.
ShiZ. and AtrensA.: ‘An innovative specimen configuration for the study of Mg corrosion’, Corros. Sci., 2011, 53, 226–246.
28.
SherifEl-Sayed M.: ‘Corrosion and corrosion inhibition of aluminum in Arabian gulf seawater and sodium chloride solutions by 3-amino-5-mercapto-1,2,4-triazole’, Int. J. Electrochem. Sci., 2011, 6, 1479–1492.
29.
DzhurinskiyD., MaevaE. and MaevR. G.: ‘Corrosion protection of light alloys using low pressure cold spray’, J. Therm. Spray Technol., 2012, 21, (2), 304–313.
30.
JiangY. F., ZhaiC. Q. and LiuL. F.: ‘Zn–Ni coatings pulse-plated on magnesium alloy’, Surf. Coat. Technol., 2005, 191, 393–399.
31.
SongG. L. and AtrensA.: ‘Understanding magnesium corrosion—a framework for improved alloy performance’, Adv. Eng. Mater., 2003, 5, 837–858.
32.
BreslinC. B., TreacyG. and CornellW. M.: ‘Studies on the passivation of aluminium in chromate and molybdate solutions’, Corros. Sci., 1994, 36, (7), 1143–1154.
33.
BonoraP. L., AndreiM., EliezerA. and GutmanE. M.: ‘Mechanoelectrochemical behavior and creep corrosion of magnesium alloys’, Corros. Sci., 2002, 44, 729.
34.
MüllerC., SarretM. and BenballaM.: ‘Some peculiarities in the codeposition of zinc–nickel alloys’, Electrochim. Acta, 2001, 46, 2811.
35.
AbdelA.: ‘Protective coating for magnesium alloy’, J. Mater. Sci., 2008, 43, 2947–2954.
36.
PardoA., MerinoM. C., CoyA. E. and ArrabalR.: ‘Corrosion behaviour of magnesium/aluminium alloys in 3·5 wt% NaCl’, Corros. Sci., 2008, 50, 823.
37.
DeForceB., EdenT., PotterJ., ChampagneV., LeymanP. and HelfritchD.: ‘Application of aluminum coatings for the corrosion protection of magnesium by cold spray’, Proc. Conf. 2007 tri-service corrosion conference.
38.
SpencerK., FabijanicD. M. and ZhangM. X.: ‘The use of Al–Al2O3 cold spray coatings to improve the surface properties of magnesium alloys’, Surf. Coat. Technol., 2009, 204, 336–344.
39.
NguyenN., SeoO. S., LeeC. A., LeeM., KimJ. and KimH. Y.: ‘Mechanical behavior of AZ31B Mg alloy sheets under monotonic and cyclic loadings at room and moderately elevated temperatures’, Materials, 2014, 7, 1271–1295.
