Improving corrosion and corrosion-fatigue resistance of AZ31B cast Mg alloy using combined cold spray and top coatings

Hypothesis: combined cold spray and e-paint top coatings improve corrosion and corrosion-fatigue of Mg alloys

Results:The combined coatings improved the corrosion resistance by a factor of 135, and significantly increased the fatigue life, with a fatigue strength of 80 MPa at 107 cycles, as compared to the as-cast sample. Surface topographic analysis of the corrosion-fatigue-tested samples demonstrated the presence of deep macro-pits on the cold sprayed AA7075 coating after 3.7 million cycles, while there were no such pits on the top coated samples, even after 107 cycles.