Integrated process-structure–property–performance optimization of cold-sprayed zinc coatings on AZ91 magnesium alloy

Niverty, Sridhar; Kalsar, Rajib; Li, Lei; Overman, Nicole R.; Jun, Jiheon; Haag, James V.; Ajantiwalay, Tanvi A.; Pole, Mayur; Joshi, Vineet V.

doi:10.1016/j.jma.2025.09.005

Integrated process-structure–property–performance optimization of cold-sprayed zinc coatings on AZ91 magnesium alloy

Journal Article · Fri Oct 24 04:00:00 EDT 2025 · Journal of Magnesium and Alloys

DOI:https://doi.org/10.1016/j.jma.2025.09.005· OSTI ID:3002142

^[1]; ^[1]; ^[1]; Overman, Nicole R. ^[1]; ^[2]; Haag, James V. ^[1]; ^[1]; Pole, Mayur ^[1]; ^[1]

Pacific Northwest National Laboratory (PNNL), Richland, WA (United States)
Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States). Materials Science & Technology Division

High-pressure die cast (HPDC) AZ91 magnesium alloy is widely used in automotive components such as transmission housings and brackets for its excellent strength-to-weight ratio. Zinc-based cold spray coatings can be applied selectively to vulnerable areas to enhance corrosion resistance, minimize galvanic coupling with dissimilar metals, and eliminate the need for full-surface oxide coatings, making the process more efficient and targeted. A comprehensive evaluation of 16 combinations of nitrogen carrier gas temperatures and pressures led to the identification of an optimal range of process parameters, yielding Zn coatings with porosity <0.5 % by area, wear rates reduced by a factor of two compared to uncoated AZ91, and adhesion strengths up to 35 MPa. The enhanced mechanical performance of the coating is attributed to the low porosity and the formation of a metallurgical bond at the coating-substrate interface. Corrosion studies using macroscale potentiodynamic polarization (PDP) and electrochemical impedance spectroscopy (EIS) revealed a significant decrease in corrosion rate and a shift to more noble corrosion potentials (ZCP) for coated substrates. Furthermore, the Zn cold-sprayed samples exhibited significantly lower corrosion-induced evolved hydrogen content compared to the base AZ91 substrate and AZ91 coated with industrial coatings, demonstrating that the Zn layer effectively protects the substrate from the corrosive environment. Overall, cold spray Zn coatings significantly improve the mechanical and corrosion performance of AZ91 Mg alloys, addressing key material challenges and enabling their broader use in automotive applications.

View Accepted Manuscript (DOE)

Research Organization:: Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)

Sponsoring Organization:: USDOE Office of Energy Efficiency and Renewable Energy (EERE), Office of Sustainable Transportation. Vehicle Technologies Office (VTO)

Grant/Contract Number:: AC05-00OR22725

OSTI ID:: 3002142

Journal Information:: Journal of Magnesium and Alloys, Journal Name: Journal of Magnesium and Alloys; ISSN 2213-9567

Publisher:: National Engineering Research Center for Magnesium Alloys of ChinaCopyright Statement

Country of Publication:: United States

Language:: English

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