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A high Al 2 O 3  content (40 wt.%) reinforced Al coating was deposited on AZ91D magnesium alloy through the low-pressure cold spraying technique. It was found that the low-pressure cold spraying method could deposit a high quality aluminium coating on AZ91D magnesium alloy with bonding strength ranging from 17.7 MPa to 25.2 MPa. The average porosity in this case is about 2.6 %, and the alumina particles are distributed uniformly. Electrochemical tests revealed that the low-pressure cold sprayed Al + 40 % Al 2 O 3  coating has better corrosion resistance than magnesium in neutral 3.5 wt.% sodium chloride solution. Low-pressure cold sprayed aluminium coating can separate the magnesium substrate from a corrosive electrolyte, which can significantly improve the anticorrosion performance of the AZ91D magnesium alloy.

Physical and electrochemical characteristics of low pressure cold sprayed aluminium composite coating on magnesium substrate