Abstract
This study employed a high-pressure cold spray to apply a Zn30Al alloy coating to Q235 steel substrates to provide corrosion protection for steel in marine environments. The corrosion resistance of the coatings was investigated through full immersion tests, and the corrosion mechanisms were further analyzed using electrochemical experiments. The results were compared with those of traditional flame-sprayed Zn30Al alloy coating. The findings indicate that the high-pressure cold-sprayed Zn30Al alloy coating possesses a dense microstructure with a porosity of only 0.32%, providing effective cathodic protection to the substrate during the immersion tests. The cold-sprayed Zn30Al alloy coating maintained good integrity after 720 h immersion in 3.5 wt.% NaCl solution, whereas the flame-sprayed Zn30Al alloy coating exhibited significant pitting corrosion.
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