Abstract:
Magnesium alloy aerospace components often fail due to dimensional deviations caused by stress, wear and extrusion during service. Using high-pressure cold spray(HPCS) technology with nitrogen gas as the carrier, 6061 coating and 6061+20 wt%Al
2 O
3 composite coatings with different spraying angles were conducted under gas pressure of 5 MPa and gas heat temperature of 500 ℃ on the ZM6-T6 magnesium alloy substrate surface. Multi-scale characterization methods were employed to analyze the metallographic structure, microhardness, interfacial bonding strength and static tensile strength of the coatings. The results show that the composite coatings exhibit good interface bonding with the substrate, have uniform and dense microstructure, without obvious defects such as cracks and pores. The addition of Al
2 O
3 hard phases improve the coating's compactness, microhardness and interfacial bonding strength. With the variation of spraying angles(0°-40°), the metallographic structure and microhardness of composite coatings show no significant changes. However, the interfacial bonding strength significantly increases due to enhanced compaction effect of hard phases. This study provides important theoretical basis for engineering applications of HPCS technology in repairing ZM6-T6magnesium alloy aerospace components.