J. Mater. Sci. Technol. ›› 2020, Vol. 59: 117-128.DOI: 10.1016/j.jmst.2020.04.041
• Research Article • Previous Articles Next Articles
Xiawei Yanga, Wenya Lia,*(), Siqi Yua, Yaxin Xua, Kaiwei Hua, Yaobang Zhaob
Received:
2020-01-22
Revised:
2020-03-31
Accepted:
2020-04-19
Published:
2020-12-15
Online:
2020-12-18
Contact:
Wenya Li
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: 117-128.
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 |
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. 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.
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 |
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.
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 |
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.
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 |
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. 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. 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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