Abstract
The recently developed thermal spray technique was used to deposit different composition of totally dense aluminium-based (Al) coating on AZ31B magnesium (Mg) alloy. The microstructure, adhesive coating, and corrosion behaviour of the materials were all thoroughly examined. The Al-coated AZ31B alloy has enhanced surface morphology and mechanical characteristics. This exceptional corrosion resistance is due to its disordered structure, consistent material composition, and the creation of a uniform passive coating on the surface, which prevents chloride ions from invading and causing additional corrosion. The high defined corrosion tests also show that the Al-based coatings are not aqueous solution permeable for the certain period immersions, indicating that the AZ31B Mg alloy substrate was protected against corrosion for a long time. Furthermore, the differences in corrosion resistances of Al-based coating was detected and explained using their distinct microstructures created during the coating deposition process. The current thermal spray technique has a lot of potential for cost-efficient and effective magnesium alloy corrosion protection, and it gives industries greater freedom in designing and using magnesium alloy products.
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