Research Progress on Cold-Sprayed Protective Coatings for Magnesium Alloy Surfaces

As the lightest engineering metallic material， magnesium alloys exhibit broad application prospects in fields such as aerospace and transportation. However， issues including their poor corrosion resistance and insufficient wear resistance severely restrict their practical applications. As a solid-state surface modification method， cold spray technology achieves coating deposition via high-velocity particle impact， which can effectively improve the surface performance of magnesium alloys while avoiding the thermal damage to the substrate induced by conventional thermal spray processes. Studies have shown that different powder systems possess respective advantages in terms of interfacial bonding mechanisms， corrosion resistance， and functional properties， yet they all face common challenges such as controlling coating uniformity and establishing long-term durability mechanisms. Future efforts should focus on optimizing process parameters， developing novel post-treatment techniques， and exploring low-cost spraying gases to promote further application. This paper systematically reviews the research progress in cold spray technology for magnesium alloys， with a focus on in-depth discussions on the coating characteristics， process optimization， and performance enhancement of different powder systems （including aluminum， zinc， copper， nickel， and other composite powders）. It offers valuable references for the development and application of cold-sprayed magnesium matrix composites.