Abstract
This study investigated the microstructure and corrosion behavior of the cold-sprayed Zn11Al3Mg zinc alloy coating through analysis of phase composition, microstructures, and electrochemical behaviors. The results demonstrate that the CS-Zn11Al3Mg coating primarily consists of a finely structured ternary eutectic phase of Zn/Mg2Zn11/Al, with uniformly distributed submicron-sized Al phases. Additionally, a small amount of coarse Zn/Mg2Zn11 eutectic phase coexisted with MgZn2 was also observed. The enhanced corrosion resistance of the coating was obtained when compared with cold sprayed Zn coating. The rapid sacrificial dissolution of MgZn intermetallic compounds was observed in saline solution, leading to localized corrosion in the coating layer. Fortunately, the cooperative interaction of dissolved Mg2+ and Al3+ promotes the formation of protective corrosion products, namely Zn5(OH)8Cl2·H2O and Zn/Mg-Al layered double hydroxides, provided long-term corrosion protection for mild steel.
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