In this paper, we report the application of zinc phosphate electrostatic-painting top coating on cold sprayed AA7075 leading to a significant improvement in corrosion-fatigue performance. High strength AA7075 powder was sprayed on AZ31B substrate, followed by the application of the top coating. The electrochemical corrosion and corrosion-fatigue tests of the coated and uncoated specimens were performed in 3.5% NaCl solution. Transmission electron microscopy (TEM) analysis showed that a continuous nanolayered mixture of Mg/Al was formed at the cold spray coating/substrate interface leading to high bonding strength. The results showed that the combined coatings improved the corrosion resistance remarkably, and significantly increased the fatigue life, with a fatigue strength of 80 MPa at 10⁷ cycles, as compared to the as-cast specimen. Surface topographic analysis of the corrosion-fatigue-tested specimens demonstrated the presence of deep macro-pits on the cold sprayed AA7075 coating after 3.7 million cycles, while there were no such pits on the top-coated specimens, even after 10⁷ cycles when tested at 30 Hz. The fractographic analysis of the fatigue-fractured specimens showed that the formation of pits allowed the NaCl solution to penetrate in the AZ31B substrate, creating localized corrosion pits resulting in premature failure, which eventually reduced the fatigue life.

The plastic deformation behaviour of the Al–Si–Cu–Mg alloy with micro-additions of Zr–V–Ti was measured in the temperature range of 298–673 K and the true stress–true strain compression curves were used to calculate the dislocation slip distance (DSD). A new constitutive equation for the temperature dependent DSD was developed, based on Mott's theory of strain hardening. The DSD predicted by the model was in good agreement not only with values achieved for the Al–Si–Cu–Mg alloy tested but also for other Al based and Pb–Sb alloys with deformation data available in the literature. A comparison of deformation and microstructure suggests that the grain refinement during hot compression deformation occurring due to continuous dynamic recrystallisation is responsible for a drastic growth of the DSD.

Tensile and stress controlled fatigue tests were performed to investigate the influence of forging at a temperature of 400°C at different rates, on the performance of extruded AZ31B magnesium alloy. The obtained microstructural analysis showed that the extruded AZ31B magnesium alloy possesses a bimodal grain structure with strong basal texture. In contrast, the forged samples showed refined grains and a weaker texture. During tensile testing, a maximum yield and ultimate tensile strength of about 163 MPa and 268 MPa were obtained for the forged samples showing an increase of 102% and 7%, respectively from the as-extruded material. At the same time, a significant improvement of fatigue life was also observed for the sample forged at the rate of 100 mm/min. The fractographic analysis of the fracture surfaces showed that ductile type fractures occurred in both as-extruded and forged samples. However, more dimples and plastic deformation were identified in the fracture surfaces of the forged specimens. It is believed that forging improved the fatigue life by a combination of grain refinement and texture modification resulting in improved yield and ductility. KEYWORDS. AZ31B; Forging; Fatigue Characterization; Fracture; Texture.

Supersonic impact of particles in their solid state with substrate at a low temperature creates a complex bonding mechanism and surface modification in cold spray coating. Here, we report the formation of a layer of 200 to 300 nm intermetallic at the interface of cold spray coated AZ31B-type Mg alloy with AA7075-type Al alloy powder. XRD, SAED, and FFT analysis confirmed the layer possessed BBC crystal structure of Mg₁₇Al₁₂ intermetallic. The HR-TEM image analysis at the interface identified the BBC crystal structure with interplanar spacing of 0.745 nm for (110) planes, suggesting the Mg₁₇Al₁₂ phase. The nanoindentation tests showed that the hardness at the interface was ~3 times higher than the substrate. It was also noticed that Young’s modulus at the interface was 117GPa. The combined action of impact energy and carrier gas temperature, along with the multiple passes during coating, caused the formation of intermetallic.