Abstract
Abstract The joining of arc sprayed Al-Zn coating and AZ91D substrate was achieved by solid-liquid compound casting. The microstructure evolution and formation mechanism of the interface were investigated in this study. A scanning electron microscopy (SEM), an energy dispersive spectroscopy (EDS), and an X-ray diffraction (XRD) were used to analyze the microstructure of the Al-Zn/AZ91D interface, whose results showed that the interface could be divided into three different intermetallic compound layers, which confirmed that the bonding between arc sprayed Al-Zn coating and AZ91D substrate was metallurgical. Among the three layers, the layer adjacent to the AZ91D substrate was mainly composed of δ-Mg, Mg 17 (Al, Zn) 12 and a small amount of lamellar Φ-Mg 21 (Al, Zn) 17 intermetallic compounds. The layer which was close to the Al-Zn pseudo-alloy coating mainly consisted of δ-Al, Al 2 Mg 3 Zn 3 and a small amount of oxides. The intermediate layer was mainly comprised of τ-Mg 32 (Al, Zn) 49 intermetallic compound. Furthermore, the microhardness values of interface zone were much higher than that of AZ91D substrate.
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