Effect of Asymmetric Deformation of Particles on the Properties of Copper-Zinc Coatings on Magnesium Substrate
SHI Qifeng1, QI Liang1, WU Huishu1,*, ZHOU Fei2, SHAO Long3, JIE Xiaohua3,*
1 College of Mechanical Engineering, Tongling University, Tongling 244000, Anhui, China 2 Zhongrui Plastic Industry Company Limited, Tongling 244000, Anhui, China 3 School of Materials and Energy, Guangdong University of Technology, Guangzhou 510006, China
Abstract: Cold-sprayed Cu-based composite coatings on magnesium alloys can significantly enhance the corrosion resistance and friction performance of magnesium alloys, where coating densification plays a critical role. This work investigates the influence of asymmetric deformation of metallic powders on the microstructure, corrosion resistance, and friction performance of the coatings deposited via cold spraying using pre-alloyed CuZn powders and Cu/Zn mixed powders. Results demonstrate that when Cu and Zn are deposited as a mixed powder, their dissimilar hardness induces asymmetric deformation during deposition. The softer Zn phase fills the Cu matrix and acts as a binder, leading to superior densification and interfacial adhesion in the Cu-Zn mixed coating (porosity is 1.67%, and bonding strength is 30.39 MPa) compared to the pre-alloyed CuZn coating (porosity is 2.56%, and bonding strength is 23.39 MPa). Corrosion resistance test results reveal that in the Cu-Zn mixed coating, the independently distributed Zn phase serves as a large anode, promoting rapid formation of corrosion products that uniformly cover the surface, resulting in generalized corrosion. In contrast, the Zn phase in the pre-alloyed CuZn coating, confined within the alloy lattice, acts as a small anode, leading to localized pitting. During friction tests, the detached Zn phase in the Cu-Zn mixed coating undergoes thermal oxidation to form ZnO lubricants, thereby improving the coating’s tribological performance.
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2026, Vol. 40 
