Investigation of deposition behavior of cold-sprayed magnesium coating

Two types of magnesium powders with different particle size distributions were deposited by cold spraying at different main gas temperatures. The effects of gas temperature and particle size distribution on the deposition efficiency of particles were studied. The microstructure of coatings was observed, and the porosity of coatings was evaluated. The deposition efficiency of particles increased, and the porosity of coatings decreased with the increase of gas temperature. The deposition efficiency of particles increased when using the powder with a smaller particle size distribution. Stainless steel and aluminum plates were used as substrates. The bonding strength and mechanism between the coating and substrate were studied. The commercial finite element software ABAQUS was used to help us better understand the deformation behavior of particles and substrates. The mean bonding strength slightly increased when aluminum plates were used as substrates. The bonding mechanism of Mg coatings on stainless steel and aluminum substrates was discussed.