The corrosion resistance of cold sprayed Al-Zn-Al2O3 composite coatings

Al-Al<sub>2</sub>O<sub>3</sub>, Zn-Al<sub>2</sub>O<sub>3</sub>, Al-Zn-Al<sub>2</sub>O<sub>3</sub> composite coatings were cold sprayed using low-pressure method, and their organizational structure and corrosion performance were studied. Al coating contains Al phase and alumina phase, Zn coating contains Zn phase and alumina phase, and Al-Zn composite coating contains Al, alumina and Zn phases. The coating and substrate are tightly bonded, no defects such as delamination or cracks in the coating are detected. The internal densities of the coatings are high, with good bonding between the particles and only a few small pores. Al coatings are corroded and then their surface alumina content increases. After corrosion, the products of Zn coatings are hydroxychlorinated Zn<sub>5</sub>(OH)<sub>8</sub>Cl<sub>2</sub>-H<sub>2</sub>O, ZnO and Zn(OH)<sub>2</sub>. The products of Al-Zn composite coatings are mainly Zn<sub>5</sub>(OH)<sub>8</sub>Cl<sub>2</sub>·H<sub>2</sub>O, ZnO, and Al<sub>2</sub>O<sub>3</sub>. Al-Zn composite coating formed more lamellate Zn<sub>5</sub>(OH)<sub>8</sub>Cl<sub>2</sub>·H<sub>2</sub>O after corrosion, which reduced the coating corrosion rate and improved the coating corrosion resistance.

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Publication Details

Published
2025-04-25
DOI
https://doi.org/10.1117/12.3067299
Primary Topic
Materials Engineering and Processing
Type
article
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The corrosion resistance of cold sprayed Al-Zn-Al2O3 composite coatings

Hongjian Zhao, Huacheng Wu, Chao Li, Peng Li et al.
Materials Engineering and Processing
article

The corrosion resistance of cold sprayed Al-Zn-Al2O3 composite coatings

Hongjian Zhao, Huacheng Wu, Chao Li, Peng Li, Xijun Wang, Liping Ding
article en

Abstract

Al-Al<sub>2</sub>O<sub>3</sub>, Zn-Al<sub>2</sub>O<sub>3</sub>, Al-Zn-Al<sub>2</sub>O<sub>3</sub> composite coatings were cold sprayed using low-pressure method, and their organizational structure and corrosion performance were studied. Al coating contains Al phase and alumina phase, Zn coating contains Zn phase and alumina phase, and Al-Zn composite coating contains Al, alumina and Zn phases. The coating and substrate are tightly bonded, no defects such as delamination or cracks in the coating are detected. The internal densities of the coatings are high, with good bonding between the particles and only a few small pores. Al coatings are corroded and then their surface alumina content increases. After corrosion, the products of Zn coatings are hydroxychlorinated Zn<sub>5</sub>(OH)<sub>8</sub>Cl<sub>2</sub>-H<sub>2</sub>O, ZnO and Zn(OH)<sub>2</sub>. The products of Al-Zn composite coatings are mainly Zn<sub>5</sub>(OH)<sub>8</sub>Cl<sub>2</sub>·H<sub>2</sub>O, ZnO, and Al<sub>2</sub>O<sub>3</sub>. Al-Zn composite coating formed more lamellate Zn<sub>5</sub>(OH)<sub>8</sub>Cl<sub>2</sub>·H<sub>2</sub>O after corrosion, which reduced the coating corrosion rate and improved the coating corrosion resistance.

Electric Power Research Institute (US), Hebei University of Technology (CN)
Openalex Percentile: Top 92%
Materials Engineering and Processing
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