Surface modification of WE43 Mg alloy via combination of cold spray and micro-arc oxidation for wear related applications at high temperatures

This study investigates the high temperature wear behaviour of a WE43 Mg alloy after covering it with single and dual layer coatings. For this purpose, cold spray and micro-arc oxidation processes were employed individually and sequentially. Single-layer coatings fabricated by cold spray and micro-arc oxidation processes were Al/Al₂O₃ composite and MgO-based ceramic, respectively. Sequential application of cold spray and micro arc oxidation processes induced dual layer coating upon synthesizing an external Al₂O₃–based layer over the Al/Al₂O₃ composite layer. Results of the wear tests conducted under the load of 2 N revealed the superior resistance of the dual layer coated sample against the rubbing action of the counterface compared to single layer coatings. Thus, the presence of a relatively hard and tough external Al₂O₃-based layer over the Al/Al₂O₃ composite layer sustained protection up to the temperature of 320 °C, where the dominant wear mechanism was fatigue wear. However, the increase in the test temperature to 350 °C caused detachment of the external Al₂O₃-based layer. Reduction of the wear test load from 2 to 1 N resulted in the remaining of external Al₂O₃-based layer intact with the underlying Al/Al₂O₃ composite layer even at a test temperature of 350 °C. It is therefore concluded that the combination of cold spray and micro-arc oxidation processes is promising to broaden the reliable use of WE43 and other Mg alloys in wear related applications at high service temperatures.