Microstructure and Corrosion Properties of Cold-sprayed Al/Ni-Al2O3 Composites

SHI Lei; QIN Yusheng; JI Lulu; HAN Yahui; JIANG Ailong; WANG Gaomin; WU Qihua; XIE Yingchun

doi:10.16490/j.cnki.issn.1001-3660.2026.01.021

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Surface Technology ›› 2026, Vol. 55 ›› Issue (1) : 240-249. DOI: 10.16490/j.cnki.issn.1001-3660.2026.01.021

Thermal Spraying and Cold Spraying Technology

Microstructure and Corrosion Properties of Cold-sprayed Al/Ni-Al₂O₃ Composites

SHI Lei^1,*, QIN Yusheng¹, JI Lulu¹, HAN Yahui¹, JIANG Ailong¹, WANG Gaomin², WU Qihua¹, XIE Yingchun²

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Abstract

Cold spray technology offers significant advantages in enhancing the wear resistance and corrosion resistance of critical cast iron components. However, the cold spray process is prone to issues such as porosity and low bond strength, which limits its engineering applications in critical structural components. Therefore, metal-ceramic composite corrosion-resistant coatings were prepared through cold spray technology, with different metals (Al/Ni) and Al₂O₃ content (10%-30%) selected to achieve synergistic control of microstructure and properties.
Pure aluminium powder (Al), nickel powder (Ni), and aluminium oxide powder with a purity greater than 99.9% were selected as the spray materials for preparing Al/Ni-Al₂O₃ composite coating. Cast iron was used as the substrate material, and Al/Ni powder with different Al₂O₃ contents was uniformly mixed. A PCS-1000 cold spray system was employed to prepare the corrosion-resistant coatings. During spraying process, nitrogen was used as the propellant gas at a pressure of 4-5 MPa and temperatures of 500 ℃ and 870 ℃. The microstructure and corrosion morphology of the Al/Ni-Al₂O₃ composite coating were observed through a scanning electron microscope (SEM, Sigma500, Zeiss) and energy dispersive spectrometer (EDS), and the elements on the corroded surfaces were analyzed. The bond strength of the coating was tested with an INSTRON-3382 universal testing machine. The porosity of different metal-ceramic composite coating cross-sections was measured with the image analysis software Image-J. The micro-hardness of the coating was measured with a FALCON-500 Vickers hardness tester. Electrochemical potential polarisation curves and electrochemical impedance spectroscopy (EIS) tests were conducted on a Zahner ZENNIUM XC electrochemical workstation. Salt spray corrosion tests were conducted with a Q-FOG CCT 1100-type salt spray corrosion test chamber, with the test conducted in accordance with GB/T 10125—2012.
The study showed that the Al/Ni-Al₂O₃ composite coating had a dense structure, with porosity values below 0.5%. Lower porosity indicated better corrosion resistance. The micro-hardness of the Al-Al₂O₃ composite coating fluctuated around 50HV0.3. The average micro-hardness of the Ni-Al₂O₃ composite coating was 262HV0.3. Both metal-ceramic composite coatings enhanced the corrosion resistance of the substrate. In the Al-Al₂O₃ composite coating, the corrosion current density and corrosion rate decreased in the order of A-1>A-3>A-2. A-2 exhibited the best corrosion resistance, reducing the corrosion rate by 76% compared to the substrate. In the Ni-Al₂O₃ composite coating, the N-2 coating had the lowest corrosion rate, decreasing it by 96% compared to the substrate. Salt spray test results indicated that after 456 hours of exposure, the surface of the Al/Ni-Al₂O₃ composite coating showed minor corrosion but no cracks or peeling. This demonstrated the significant advantage of the coating in resisting neutral salt spray corrosion.
Cold spraying technology can be used to produce high-density, corrosion-resistant coatings. The corrosion resistance of nickel and the high chemical stability of Al₂O₃ are the primary reasons for the significant improvement in the corrosion resistance of the coating. The extremely low porosity and high bond strength of the coating and the incorporation of Al₂O₃ into the metal effectively enhance chemical stability and reduce corrosion occurrence.

Key words

cold spraying / cast iron / porosity / corrosion resistance / neutral salt spray

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SHI Lei, QIN Yusheng, JI Lulu, HAN Yahui, JIANG Ailong, WANG Gaomin, WU Qihua, XIE Yingchun. Microstructure and Corrosion Properties of Cold-sprayed Al/Ni-Al₂O₃ Composites[J]. Surface Technology. 2026, 55(1): 240-249

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