journal article·2022-01-24Open access

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

Ashokkumar Mohankumar, Thirumalaikumarasamy Duraisamy, Ramachandran Chidambaramseshadri, Thirumal Pattabi, Sathiyamoorthy Ranganathan, Murugan Kaliyamoorthy, Guruprasad Balachandran, Deepak Sampathkumar, Pradeep Raj Rajendran

Coatings· Volume 12· Issue 2

Abstract

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.
Source: crossref · Quality: baseline

Research context

OpenAlex topics: Aluminum Alloys Composites Properties · High-Temperature Coating Behaviors · Magnesium Alloys: Properties and Applications

SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.

Affiliations

Department of Manufacturing Engineering, Annamalai University, Annamalai Nagar 608002, India

Department of Materials Science and Engineering, The State University of New York (SUNY) at Stony Brook, New York, NY 11794, USA

Department of Mechanical Engineering, Government College of Engineering, Krishnagiri 635104, India

Department of Mechanical engineering, Institute of Road Transport Polytechnic College, Krishnagiri 635104, India

Department of Mechanical Engineering, Government Polytechnic College, Thiruvarur 612804, India

Department of Mechanical Engineering, Alagappa Chettiar Government College of Engineering and Technology, Karaikudi 630003, India

Department of Mechanical Engineering, Mohandas College of Engineering and Technology, Trivandrum 695544, India

Funding

Department of Science & Technology

References (58)

Show source-provided references
1. Aluminium based in-situ composite fabrication through friction stir processing: A review10.1016/j.jallcom.2017.04.309 ↗
2. Influences of Mechanical, Corrosion, erosion and tribological performance of cold sprayed Coatings A review10.1016/j.matpr.2021.01.664 ↗
3. Fabrication of 5052Al/Al2O3 nanoceramic particle reinforced composite via friction stir processing route10.1016/j.matdes.2011.04.048 ↗
4. Microstructural study of the interface reaction between whiskers and aluminium10.1016/S0266-3538(96)00127-3 ↗
5. A study on microstructure and mechanical properties of Al 6061–TiB2 in-situ composites10.1016/j.msea.2011.02.024 ↗
6. Method of stir casting of aluminum metal matrix composites: A review
7. Microstructural features and mechanical properties of Al-Al3Ti composite fabricated by in-situ powder metallurgy route10.1016/j.jallcom.2008.05.068 ↗
8. In situ composite coatings prepared by complex reactive plasma spraying of Fe2O3-Al-Cr2O3 composite powders10.1016/j.surfcoat.2017.08.040 ↗
9. Study on thermal, mechanical, microstructural properties and failure analyses of lanthanum zirconate based thermal barrier coatings: A review10.1016/j.matpr.2021.02.672 ↗
10. Cold spraying—A materials perspective10.1016/j.actamat.2016.06.034 ↗
11. Microstructure of Kinetic Spray Coatings: A Review10.1007/s11666-015-0223-5 ↗
12. Investigation on relationship between mechanical properties and mi-crostructural characteristics of metal matrix composites fabricated by cold spraying technique10.1016/j.apsusc.2012.12.166 ↗
13. Advanced diamond- reinforced metal matrix com-posites via cold spray: Properties and deposition mechanism10.1016/j.compositesb.2017.01.009 ↗
14. Plasma electrolytic oxidation of cold spray kinetically metallized CNT-Al coating on AZ91-Mg alloy: Evaluation of mechanical and surficial characteristics10.1016/j.jallcom.2021.162094 ↗
15. Microstructure, mechanical property and wear performance of cold sprayed Al5056/SiCp composite coatings: Effect of reinforcement content10.1016/j.apsusc.2013.10.132 ↗
16. Cold sprayed AA2024/Al2O3 metal matrix composites improved by friction stir processing: Microstructure characterization, mechanical performance and strengthening mechanisms10.1016/j.jallcom.2017.11.132 ↗
17. Critical review of corrosion protection by cold spray coatings10.1179/1743294415Y.0000000018 ↗
18. Corrosion characteristics of cold gas spray coatings of reinforced aluminum deposited onto carbon steel10.1016/j.corsci.2016.10.019 ↗
19. The use of Al-Al2O3 cold spray coatings to improve the surface properties of magnesium alloys10.1016/j.surfcoat.2009.07.032 ↗
20. Effect of α-Al2O3 on the properties of cold sprayed Al/α-Al2O3 composite coatings on AZ91D magnesium alloy10.1016/j.apsusc.2009.08.012 ↗
21. Effect of Ceramic Particles on Properties of Cold-Sprayed Ni-20Cr+Al2O3 Coatings10.1007/s11666-009-9345-y ↗
22. Microstructure and corrosion behavior of cold sprayed SiCp/Al 5056 composite coatings10.1016/j.surfcoat.2014.04.036 ↗
23. Microstructure, mechanical properties and corrosion performance of 7075 Al matrix ceramic particle reinforced composite coatings produced by the cold gas dynamic spraying process10.1016/j.surfcoat.2013.07.020 ↗
24. Investigation of Al-Al2O3 Cold Spray Coating Formation and Properties10.1007/s11666-007-9086-8 ↗
25. On the PEO treatment of cold sprayed 7075 aluminum alloy and its effects on mechanical, corrosion and dry sliding wear performances thereof10.1016/j.surfcoat.2019.125271 ↗
26. Abrasion, sliding wear, corrosion, and cavitation erosion characteristics of a duplex coating formed on AZ31 Mg alloy by sequential application of cold spray and plasma electrolytic oxidation techniques10.1016/j.mtcomm.2020.101978 ↗
27. Mechanical, tribological and corrosion physiognomies of CNT-Al metal matrix composite (MMC) coatings deposited by cold gas dynamic spray (CGDS) process10.1016/j.surfcoat.2020.126380 ↗
28. Luo, X., Chidambaram-Seshadri, R., and Yang, G.J. (2019). Micro-nanostructured cermet coatings. Advanced Nanomaterials and Coatings by Thermal Spray, Elsevier.10.1016/B978-0-12-813870-0.00004-8 ↗
29. The effects of heat treatment on the mechanical properties of cold-sprayed coatings10.1016/j.surfcoat.2014.11.017 ↗
30. Characterizations and anisotropy of cold-spraying additive-manufactured copper bulk10.1016/j.jmst.2018.01.002 ↗
31. Optimization of cold-sprayed AA2024/Al2O3 metal matrix composites via friction stir processing: Effect of rotation speeds10.1016/j.jmst.2018.03.016 ↗
32. Friction Stir Processing Technology: A Review10.1007/s11661-007-9459-0 ↗
33. Friction stir processing: A novel technique for fabrication of surface composite10.1016/S0921-5093(02)00199-5 ↗
34. Friction-stir processing of a cold sprayed AA7075 coating layer on the AZ31B substrate: Structural homogeneity, microstructures and hardness10.1016/j.surfcoat.2017.10.060 ↗
35. A novel uncertainty-oriented regularization method for load identification10.1016/j.ymssp.2021.107774 ↗
36. A synchronous placement and size-based multi-objective optimization method for heat dissipation design on antenna module of space solar power satellite. Sustain
37. Iterative two-layer thermal design strategy for step sandwich antenna of space solar power satellite using modified constrained multi-objective optimization10.1016/j.ast.2021.106987 ↗
38. Fabrication of aluminum–alumina metal matrix composites via cold gas dynamic spraying at low pressure followed by friction stir processing10.1016/j.msea.2012.06.066 ↗
39. Microstructural evolution and mechanical properties enhancement of a cold-sprayed Cu Zn alloy coating with friction stir processing10.1016/j.matchar.2017.01.027 ↗
40. Modification of a cold sprayed SiCp/Al5056 composite coating by friction stir processing10.1016/j.surfcoat.2016.04.016 ↗
41. Enhanced erosion performance of cold spray co-deposited AISI316 MMCs modified by friction stir processing10.1016/j.matdes.2017.01.099 ↗
42. The erosion performance of cold spray deposited metal matrix composite coatings with subsequent friction stir processing10.1016/j.apsusc.2016.10.156 ↗
43. Friction stir processing of aluminium alloy AA7075: Microstructure, surface chemistry and corrosion resistance10.1016/j.corsci.2016.02.006 ↗
44. The effect of artificial ageing heat treatments on the corro-sion-induced hydrogen embrittlement of 2024 (Al-Cu) aluminium alloy10.1016/j.corsci.2015.10.034 ↗
45. Influence of annealing on mechanical and electrochemical properties of cold sprayed niobium coatings10.1016/j.surfcoat.2016.04.027 ↗
46. Pitting corrosion of friction stir welded aluminum alloy thick plate in alkaline chloride solution10.1016/j.electacta.2009.12.083 ↗
47. Microstructure and corrosion performance of a cold sprayed aluminium coating on AZ91D magnesium alloy10.1016/j.corsci.2010.05.023 ↗
48. Corrosion behavior of low pressure cold sprayed Zn-Ni composite coatings10.1016/j.jallcom.2017.05.134 ↗
49. Saltwater corrosion behavior of cold sprayed AA7075 aluminum alloy coatings10.1016/j.corsci.2017.10.033 ↗
50. Fabrication of in situ Cu/SiC composites using multipass friction stir processing: Evaluation of microstructural, porosity, mechanical and electrical behaviour10.1016/j.compositesa.2011.06.010 ↗
51. X-ray line broadening from filed aluminium and wolfram10.1016/0001-6160(53)90006-6 ↗
52. Parmar, V., Changela, K., Srinivas, B., Sankar, M.M., Mohanty, S., Panigrahi, S.K., Hariharan, K., and Kalyanasundaram, D. (2019). Relationship between Dislocation Density and Antibacterial Activity of Cryo-Rolled and Cold-Rolled Copper. Materials, 12.10.3390/ma12020200 ↗
53. Global anisotropic response of friction stir welded 2024 aluminum sheets10.1016/j.actamat.2015.03.054 ↗
54. Microstructural evolution of 6063 aluminum during friction-stir welding10.1007/s11661-999-0251-1 ↗
55. The influence of multipass friction stir processing on the corrosion behavior and mechanical properties of zircon-reinforced Al metal matrix composites10.1016/j.msea.2016.05.056 ↗
56. Influence of ultrasonic shot peening on corrosion behavior of 7075 aluminum alloy10.1016/j.jallcom.2017.06.310 ↗
57. Effect of number of passes on the corrosion behavior of Fe/Al surface composites produced by plasma spraying and friction stir processing10.1016/j.jmatprotec.2017.06.018 ↗
58. Significant effect of oxide on mechanical properties of friction-stir-welded AA2024 joints10.1080/13621718.2016.1188514 ↗