Enhanced Electrochemical and Tribological Properties of AZ91D Magnesium Alloy via Cold Spraying of Aluminum Alloy

Sumera Siddique, Cheng Xin Li, Ayrton A. Bernussi, Syed Wilayat Hussain, Muhammad Yasir

Research output: Contribution to journalArticlepeer-review

15 Scopus citations


Magnesium (Mg) alloys have remarkable physical and mechanical properties for various aerospace applications. However, the high corrosion susceptibility and low wear resistance of Mg alloys restrict their wider use. To overcome these problems, 6061 Al alloy coatings were fabricated via the cold spraying process on the AZ91D Mg alloy substrate and a detailed comparative study on the wear and corrosion properties was carried out. The microstructure analysis of the compact coatings revealed low porosity with no phase change during the deposition process. The coatings showed improved corrosion resistance up to seven times as confirmed by potentiodynamic polarization and electrochemical impedance spectroscopy measurements in 3.5 wt.% NaCl aqueous solution. The as-deposited coatings were also compared with commercial bulk alloys of similar composition for their suitability to industrial applications. The tribological behavior of the coatings and substrate was investigated using tribometer. The wear resistance of the coatings improved more than two orders of magnitude as compared to the substrate. Abrasive and oxidative wear mechanisms were dominant in the coatings and substrate. The results showed that cold spraying of 6061 Al alloy on AZ91D Mg alloy could be an auspicious process to overcome the poor corrosion and wear resistance of this Mg alloy for practical industrial applications.

Original languageEnglish
Pages (from-to)1739-1748
Number of pages10
JournalJournal of Thermal Spray Technology
Issue number7
StatePublished - Oct 1 2019


  • cold-sprayed coatings
  • corrosion protection
  • magnesium alloy
  • wear resistance


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