LAUSR

Abstract Thermally sprayed coatings are one of the potential ways to increase corrosion performance of Mg alloys dedicated for aircraft applications. In our research, a novel thermal spray process called Warm Spraying (WS) was used to deposit Ti coatings onto AZ91E magnesium alloy. WS gives us the possibility to control the temperature of the sprayed particles by changing the nitrogen flow rate (NFR) what as a result determine the porosity of WS coatings. The microstructure, porosity and oxygen content of coatings deposited under three different NFR was determined. A relation between porosity, oxygen content and NFR was revealed. The corrosion testing in 3.5% NaCl solution of as-sprayed coatings revealed their poor corrosion resistance that led to fast degradation of the substrate. The following post-treatment with epoxy-based polymer resulted in a significant improvement of the corrosion performance of Ti warm sprayed coatings.