Abstract
Abstract A high-density, low-porosity Al-Co-Ce metallic coating has been applied successfully to an aluminum alloy (AA)2024-T351 (UNS A92024) substrate using a pulsed thermal spray (PTS) process in thicknesses ranging from 100 μm to 500 μm. The three proposed modes of corrosion protection brought about by the coating (i.e., a localized corrosion barrier, a sacrificial anode to supply cathodic protection of any exposed AA2024-T351, and active inhibitor release to facilitate chemical protection of AA2024-T351) have been verified to function simultaneously in dilute chloride solutions. The localized corrosion properties of the PTS-applied coating samples were not equal to the fully amorphous melt-spun ribbons even when ribbons were produced from feedstock powders. This inferior behavior in coatings was traced to various microstructural and physical defects. However, this inferior behavior cannot be attributed to feedstock powder composition since melt-spun ribbons made from feedstock powders had excellent lo...
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