Two types of coating

including pure Al and composite coating of Al-Zn were prepared using Cold Spray (CS) process. Microstructure of coatings was investigated to understand the properties of coating produced by CS and improve the CS technology parameters. Coating residual stress and microhardness were also characterized. The corrosion behaviour of two coatings was evaluated by electrochemical measurement and salt fog test. The results show that the coatings are very dense and no significant inherent defects. The coating/substrate interface exhibit excellent bonding without voids or areas of delamination. The surface residual stress of Al coating and Al-10%Zn coating exhibits compression stress. The salt fog test results were consistent with the result of electrochemical measurement

Al coating displays more anti-corrosion than Al-10%Zn coating

red rust covered the whole surface of Al-10%Zn coating

but only slight red rust on Al coating after suffering salt fog for 48h (48h salt fog test).