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Enhanced wear and corrosion resistances of Al coated Mg alloy using high pressure cold sprayed commercially pure-zirconium coating

•Considerable densification of beneath deposited Al layers caused by Zr particles.•Highest Rpol and |Z|f=0.01Hz values were obtained for Zr/Al coated Mg alloy.•Surface film thickness was 34.40 for Al and 29.90 nm for Zr/Al after 24 h immersion.•Zr/Al coating immersed for 24 h showed a passive potent...

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Bibliographic Details
Published in:Materials letters 2023-09, Vol.346, p.134473, Article 134473
Main Authors: Daroonparvar, M., Helmer, A., Ralls, A.M., Farooq Khan, M.U., Kasar, A.K., Menezes, P.L., Misra, M., Gupta, R.K.
Format: Article
Language:English
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Summary:•Considerable densification of beneath deposited Al layers caused by Zr particles.•Highest Rpol and |Z|f=0.01Hz values were obtained for Zr/Al coated Mg alloy.•Surface film thickness was 34.40 for Al and 29.90 nm for Zr/Al after 24 h immersion.•Zr/Al coating immersed for 24 h showed a passive potential for a wide range of pHs.•Zr with smaller crystallite size/higher dislocation density showed lower wear rate. Commercially pure (CP) Zr coating with high microhardness (387 ± 26 HV0.025) was produced on CP-Al coated Mg alloy by a high pressure cold spray (HPCS) system. Substantial densification of Al layers, beneath deposited Zr coating, was observed because of shot-peening influence by Zr particles. The electrochemical impedance spectroscopy after 24 h of immersion in 3.5 wt% NaCl electrolyte revealed highest charge transfer resistance (Rct), polarization resistance (Rpol), and corrosion resistance (|Z|f=0.01Hz) for the Zr/Al coated Mg alloy. Also, wear rate for the Zr/Al coating was lowest which could be attributed to its higher hardness caused by smaller crystallite size and higher dislocation density.
ISSN:0167-577X
1873-4979
DOI:10.1016/j.matlet.2023.134473