Corrosion-resistant metallic coatings for aluminum alloys by cold spray

An Al-V alloy powder produced by high-energy ball milling has been cold sprayed on an AA2024-T3 substrate. The corrosion resistance of cold sprayed alloy, represented by the corrosion current density and pitting potential, was significantly higher than the substrate. Furthermore, a zero-resistance ammeter test revealed that the coating was anodic to the substrate, which would provide cathodic protection in any event of coating breakdown. The wear resistance of the coating was almost four times higher than that of the substrate.