Electrochemical characterization and microstructure of cold sprayed AA5083/Al2O3 composite coatings

doi:10.1016/j.jmst.2020.04.041

摘要/Abstract

Abstract:

This work focused on the role of Al₂O₃ particles in the corrosion behavior of cold sprayed AA5083 aluminum alloy matrix composite (Al-MMC) coatings. The electrochemical characterization of the coatings was investigated in a 3.5 wt.% NaCl solution as a function of time. The results show that fragmentation of Al₂O₃ particles is not clearly observed in the case of AA5083/20 vol.% Al₂O₃ coating, while the broken Al₂O₃ particles can be seen clearly in AA5083/40 vol.% Al₂O₃ and AA5083/60 vol.% Al₂O₃ coatings. The addition of 20 vol.% Al₂O₃ particles yield the coating with the lowest porosity, and different volume fractions of Al₂O₃ in the feedstock have important effects on the electrochemical behavior of composite coatings. The Al-MMC coating reinforced with 20 vol.% Al₂O₃ particles exhibits the highest E_corr and the lowest i_corr compared with the other conditions. The order of current density is as follows: AA5083/20 vol.% Al₂O₃ < AA5083 < AA5083/40 vol.% Al₂O₃ < AA5083/60 vol.% Al₂O₃.

Key words: Cold spray, Aluminum alloy, Alumina particlesComposite coating, Electrochemical characterization

. [J]. 材料科学与技术, 2020, 59(0): 117-128.

Xiawei Yang, Wenya Li, Siqi Yu, Yaxin Xu, Kaiwei Hu, Yaobang Zhao. Electrochemical characterization and microstructure of cold sprayed AA5083/Al₂O₃ composite coatings[J]. J. Mater. Sci. Technol., 2020, 59(0): 117-128.

图/表 20

Fig. 1. OM microstructure of ZM 5 magnesium alloy.

Fig. 2. SEM images of the feedstock powders: (a) AA5083; (b) Al2O3.

Table 1 Chemical compositions of the AA5083 powder and ZM5 substrate (wt.%).

Element	Si	Fe	Cu	Mn	Mg	Zn	Al
AA5083	0.4	0.4	0.1	0.6	4.4	0.25	Bal.
ZM5	<0.25	<0.09	<0.1	0.35	Bal.	0.5	8.5

Fig. 3. Photos of the CS system (a) and spray gun (b).

Fig. 4. Schematic of microstructure observation of cold sprayed coating: (a) cold sprayed coating on a substrate; (b) cutting sample cross-sectionally; (c) sample for microstructure observation.

Table 2 Porosity and real fraction of Al2O3 in the composite coatings.

Coating	Porosity (%)	Al₂O₃ content (vol.%)
AA5083	0.78 ± 0.09	-
AA5083/20 vol.%Al₂O₃	0.67 ± 0.12	9.9 ± 0.2
AA5083/40 vol.%Al₂O₃	1.14 ± 0.18	32.3 ± 1.6
AA5083/60 vol.%Al₂O₃	1.32 ± 0.21	51.7 ± 3.2

Fig. 5. Microstructures of cross sections of AA5083 coating and Al-MMC coatings: (a, b) AA5083; (c)-(e) AA5083/20 vol.% Al2O3; (f, g) AA5083/40 vol.% Al2O3; (h, i) AA5083/60 vol.% Al2O3.

Fig. 6. Surface morphologies and elements maps of the AA5083/20 vol.% Al2O3 coating with different immersion time.

Table 3 Results from electron probe microanalysis of AA5083/20 vol.% Al2O3 composite coating with different immersion time.

Immersion time (h)	Cl (wt.%)	Al (wt.%)	Mg (wt.%)	O (wt.%)
0	0.00	71.89	3.34	24.23
1	2.18	57.08	2.86	36.32
5	5.56	37.12	1.78	41.28
12	7.25	35.56	1.21	46.76
24	9.55	32.32	0.96	52.23

Fig. 7. Surface morphologies of the corroded AA5083/20 vol.% Al2O3 coating after immersion for: (a) and (b) 1 h; (c) and (d) 5 h; (e) and (f) 12 h; (g) and (d) 24 h.

Fig. 8. Cross-sectional images of the corroded AA5083/20 vol.% Al2O3 coating with immersion for 24 h (Al2O3 particles marked in red circles): (a) corroded coating at low magnification; (b) and (c) removed Al2O3 particles at high magnification.

Fig. 9. Surface morphologies and elements maps of AA5083 coating and Al-MMC coatings with immersion for 1 h.

Table 4 Results from the electron probe microanalysis.

Specimen	Cl (wt.%)	Al (wt.%)	Mg (wt.%)	O (wt.%)
AA5083	0.00	93.85	4.41	0.12
Corroded AA5083	4.18	66.74	4.01	13.28
AA5083/20 vol.% Al₂O₃	0.00	71.89	3.34	24.23
Corroded AA5083/20 vol.% Al₂O₃	2.18	57.08	2.86	36.32
AA5083/40 vol.% Al₂O₃	0.00	59.28	2.76	36.97
Corroded AA5083/40 vol.% Al₂O₃	5.82	40.61	1.98	45.58
AA5083/60 vol.% Al₂O₃	0.00	55.88	1.47	41.02
Corroded AA5083/60 vol.% Al₂O₃	7.56	20.23	0.77	56.89

Fig. 10. SEM morphologies of the corroded coatings: (a) AA5083; (b) AA5083/20 vol.% Al2O3; (c) AA5083/40 vol.% Al2O3; (d) AA5083/60 vol.% Al2O3.

Fig. 11. SEM morphologies of the cross sections of corroded AA5083/Al2O3 composite coating after immersion for 1 h: (a) AA5083/20 vol.% Al2O3; (b) AA5083/40 vol.% Al2O3; (c) and (d) AA5083/60 vol.% Al2O3.

Fig. 12. Schematic of the corrosion process for Al-MMC coatings: (a) un-corroded coating; (b) dissolution of Al; (c) formation of corrosion products; (d) corroded coating.

Fig. 13. OCPs for AA5083 and AA5083/Al2O3 composite coatings with different immersion time.

Fig. 14. Polarization curves of the AA5083 coating and AA5083/Al2O3 composite coatings immersed in 3.5 wt.% NaCl solution for 1, 5, 12 and 24 h: (a) AA5083; (b) AA5083/20 vol.% Al2O3; (c) AA5083/40 vol.% Al2O3; (d) AA5083/60 vol.% Al2O3.

Fig. 15. EIS curves of the AA5083 coating and AA5083/Al2O3 composite coatings: (a) AA5083; (b) AA5083/20 vol.% Al2O3; (c) AA5083/40 vol.% Al2O3; (d) AA5083/60 vol.% Al2O3.

Fig. 16. Equivalent circuits for cold sprayed coatings: (a) AA5083/20 vol.% Al2O3 coating; (b) AA5083, AA5083/40 vol.% Al2O3 and AA5083/60 vol.% Al2O3 coatings.

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Electrochemical characterization and microstructure of cold sprayed AA5083/Al₂O₃ composite coatings

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