Research Progress on Cold-Sprayed Protective Coatings for Magnesium Alloy Surfaces

doi:10.19894/j.issn.1000-0518.250384

Chinese Journal of Applied Chemistry ›› 2026, Vol. 43 ›› Issue (3): 317-326.DOI: 10.19894/j.issn.1000-0518.250384

• Review •

Research Progress on Cold-Sprayed Protective Coatings for Magnesium Alloy Surfaces

Xiao FU¹^,²^,³, Li-Ren CHENG¹^,²(), Chao-Jie CHE¹^,², Xin-Lin LI³, Marina-Anatolyevna KRAVCHUK¹^,⁴, Valery-Konstantinovich SHELEG¹^,⁴, Hong-Jie ZHANG¹^,²^,⁵

^1.China-Belarus Belt and Road Joint Laboratory for Advanced Materials and Manufacturing，Changchun Institute of Applied Chemistry，Chinese Academy of Sciences，Changchun 130022，China
^2.Key Laboratory of Rare Earth Resource Utilization，Changchun Institute of Applied Chemistry，Chinese Academy of Sciences，Changchun 130022，China
^3.College of Materials Science and Chemical Engineering，Harbin Engineering University，Harbin 150001，China
^4.Department of Engineering Technology，Belarusian National Technical University，Minsk 220013，Belarus
^5.Department of Chemistry，Tsinghua University，Beijing 100084，China

Received:2025-10-09 Accepted:2025-12-12 Published:2026-03-01 Online:2026-03-26
Contact: Li-Ren CHENG
About author:lrcheng@ciac.ac.cn
Supported by:
Jilin Provincial Science and Technology Development Plan Project(20250201062GX);the National Key R&D Program of China(2020YFE0204500)

Abstract

Abstract:

As the lightest engineering metallic material， magnesium alloys exhibit broad application prospects in fields such as aerospace and transportation. However， issues including their poor corrosion resistance and insufficient wear resistance severely restrict their practical applications. As a solid-state surface modification method， cold spray technology achieves coating deposition via high-velocity particle impact， which can effectively improve the surface performance of magnesium alloys while avoiding the thermal damage to the substrate induced by conventional thermal spray processes. Studies have shown that different powder systems possess respective advantages in terms of interfacial bonding mechanisms， corrosion resistance， and functional properties， yet they all face common challenges such as controlling coating uniformity and establishing long-term durability mechanisms. Future efforts should focus on optimizing process parameters， developing novel post-treatment techniques， and exploring low-cost spraying gases to promote further application. This paper systematically reviews the research progress in cold spray technology for magnesium alloys， with a focus on in-depth discussions on the coating characteristics， process optimization， and performance enhancement of different powder systems （including aluminum， zinc， copper， nickel， and other composite powders）. It offers valuable references for the development and application of cold-sprayed magnesium matrix composites.

Key words: Cold spray, Magnesium alloy, Surface protection, Corrosion, Wear

CLC Number:

O614

Xiao FU, Li-Ren CHENG, Chao-Jie CHE, Xin-Lin LI, Marina-Anatolyevna KRAVCHUK, Valery-Konstantinovich SHELEG, Hong-Jie ZHANG. Research Progress on Cold-Sprayed Protective Coatings for Magnesium Alloy Surfaces[J]. Chinese Journal of Applied Chemistry, 2026, 43(3): 317-326.

Figures/Tables 4

References 46

[1]	HSIN C L， LEE T C， FU Y C， et al. Formation of porous Mg₂（SiSn） by nanoparticle alloying and its thermoelectric properties［J］. Mater Res Bull， 2023， 161： 112156.
[2]	HUANG H， LI D， HOU L， et al. Advanced protective layer design on the surface of Mg-based metal and application in batteries： challenges and progress［J］. J Power Sources， 2022， 542： 231755.
[3]	LI Z Y， SUN Y J， ZHANG C C， et al. Optimizing hydrogen ad/desorption of Mg-based hydrides for energy-storage applications［J］. J Mater Sci Technol， 2023， 141： 221-235.
[4]	HASHEMI M， ALIZADEH R， LANGDON T G. Recent advances using equal-channel angular pressing to improve the properties of biodegradable Mg-Zn alloys［J］. J Magnesium Alloys， 2023， 11（7）： 2260-2284.
[5]	KIM J D， JUN H U， CHEON J， et al. Effect of additional side shielding on the wire arc additive manufacturing of AZ31 magnesium alloy［J］. J Mater Res Technol， 2023， 25： 6567-6577.
[6]	BAHMANI A， LOTFPOUR M， TAGHIZADEH M， et al. Corrosion behavior of severely plastically deformed Mg and Mg alloys［J］. J Magnes Alloy， 2022， 10（10）： 2607-2648.
[7]	ZHU Q， LI Y， CAO F， et al. Towards development of a high-strength stainless Mg alloy with Al-assisted growth of passive film［J］. Nat Commun， 2022， 13（1）： 5838.
[8]	KLU E E， JIANG J， WANG G， et al. Achieving ultrahigh specific strength of an ultrafine grained Mg-9Li-1Al alloy via the combined processing of ECAP with repeated annealing and rolling［J］. J Mater Res Technol， 2023， 25： 3228-3242.
[9]	JI Q， ZHANG S， WU R， et al. High strength BCC magnesium-lithium alloy processed by cryogenic rolling and room temperature rolling and its strengthening mechanisms［J］. Mater Charact， 2022， 187： 111869.
[10]	王华，刘艳艳. 镁合金表面防腐蚀超疏水涂层制备研究进展［J］. 表面技术， 2023， 52（11）： 1-22， 127.
	WANG H， LIU Y Y. Research progress in the preparation of anti-corrosion superhydrophobic coatings on magnesium alloys［J］. Surf Technol， 2023， 52（11）： 1-22， 127.
[11]	郑黎，王美婷，于宝义. 镁合金表面冷喷涂技术研究进展［J］. 中国腐蚀与防护学报， 2021， 41（1）： 22-28.
	ZHENG L， WANG M T， YU B Y. Research progress of cold spraying coating technology for Mg-alloy［J］. J Chin Soc Corros Prot， 2021， 41（1）： 22-28.
[12]	肖雯心，王叶，马凯，等. 镁合金表面化学转化涂层研究进展［J］. 材料导报， 2024， 38（12）： 192-203.
	XIAO W X， WANG Y， MA K， et al. Research progress on chemical conversion coatings on magnesium alloys［J］. Mater Rep， 2024， 38（12）： 192-203.
[13]	YANG B， XIA L， LI R， et al. Superior plating/stripping performance through constructing an artificial interphase layer on metallic Mg anode［J］. J Mater Sci Technol， 2023， 157： 154-162.
[14]	王洺浩. 汽车轻量化材料镁合金的腐蚀防护技术应用现状与发展趋势［J］. 汽车实用技术， 2025， 50（9）： 93-98.
	WANG M H. Application status and development trends of corrosion protection technology for automobile lightweight material magnesium alloy［J］. Automobile Appl Technol， 2025， 50（9）： 93-98.
[15]	张祥，周亮，贾宏耀，等. 镁合金微弧氧化膜层性能优化研究进展［J］. 表面技术， 2023， 52（3）： 122-133.
	ZHANG X， ZHOU L， JIA H Y， et al. Research progress on performance optimization of micro-arc oxidation films on magnesium alloys［J］. Surf Technol， 2023， 52（3）： 122-133.
[16]	NUGROHO A， DAUD S， PURANTO P， et al. Next-generation thermal spray coatings for military use： innovations， challenges， and applications （bibliometric review 2015-2025）［J］. Digit Chem Eng， 2025， 17： 100259.
[17]	刘海飞，侯玉柏，夏春阳，等. 冷喷涂技术［J］. 热喷涂技术， 2025， 17（2）： 65-86.
	LIU H F， HOU Y B， XIA C Y， et al. Cold spray［J］. Therm Spray Technol， 2025， 17（2）： 65-86.
[18]	LUO Y， HUANG J， YU X， et al. Surface microstructure and corrosion characterization of AZ31 magnesium alloys fabricated by laser surface-modification［J］. J Alloys Compd， 2024， 994： 174708.
[19]	DAROONPARVAR M， BAKHSHESHI-RAD H R， SABERI A， et al. Surface modification of magnesium alloys using thermal and solid-state cold spray processes： challenges and latest progresses［J］. J Magnesium Alloys， 2022， 10（8）： 2025-2061.
[20]	苏贤涌，周香林，崔华，等. 冷喷涂技术的研究进展［J］. 表面技术， 2007（5）： 71-74.
	SU X Y， ZHOU X L， CUI H， et al. Research progress in cold gas dynamic spray technology［J］. Surf Technol， 2007（5）： 71-74.
[21]	MONETTE Z， KASAR A K， DAROONPARVAR M， et al. Supersonic particle deposition as an additive technology： methods， challenges， and applications［J］. Int J Adv Manuf Technol， 2020， 106（5/6）： 2079-2099.
[22]	ZHU J， ZHANG Y， XU M， et al. Development of low-cost high entropy alloys composite coating with gradient structures on Mg alloys manufactured by supersonic solid-state cold spray［J］. J Alloys Compd， 2025， 1021： 179699.
[23]	ASSADI H， KREYE H， GÄRTNER F， et al. Cold spraying-a materials perspective［J］. Acta Mater， 2016， 116： 382-407.
[24]	虞思琦，杨夏炜，王非凡，等. 镁合金表面冷喷涂层防护研究进展［J］. 表面技术， 2018， 47（5）： 43-56.
	YU S Q， YANG X W， WANG F F， et al. Protection for cold sprayed coatings on magnesium alloy［J］. Surf Technol， 2018， 47（5）： 43-56.
[25]	SUN W， CHU X， LAN H， et al. Cold spray additive manufacturing （CSAM）［M］//KAR A， ALAM Z. Solid State Additive Manufacturing. 1st ed. Boca Raton： CRC Press， 2023： 96-126.
[26]	ULLAH N， TARIQ N U H， DHAKAL M， et al. Ultrafine grain stabilization and corrosion studies on supersonic cold-sprayed Al-5Si/Al₂O₃ coating via thermal annealing［J］. J Alloys Compd， 2025， 1024： 180129.
[27]	ZHANG L， YANG S， LV X， et al. Wear and corrosion resistance of cold-sprayed cu-based composite coatings on magnesium substrate［J］. J Therm Spray Technol， 2019， 28（6）： 1212-1224.
[28]	ASSADI H， GÄRTNER F， STOLTENHOFF T， et al. Bonding mechanism in cold gas spraying［J］. Acta Mater， 2003， 51（15）： 4379-4394.
[29]	DEFORCE B S， EDEN T J， POTTER J K. Cold spray Al-5% Mg coatings for the corrosion protection of magnesium alloys［J］. J Therm Spray Technol， 2011， 20（6）： 1352-1358.
[30]	MOHANKUMAR A， DURAISAMY T， CHIDAMBARAMSESHADRI R， et al. Enhancing the corrosion resistance of low pressure cold sprayed metal matrix composite coatings on AZ31B Mg alloy through friction stir processing［J］. Coatings， 2022， 12（2）： 135.
[31]	WANG Q， NIU W， LI X， et al. Tuning the microstructure and mechanical properties of additive manufactured aluminum matrix composites by cold spray［J］. Surf Coat Technol， 2021， 428： 127847.
[32]	JI G， LIU H， YANG G J， et al. Formation of intermetallic compounds in a cold-sprayed aluminum coating on magnesium alloy substrate after friction stir-spot-processing［J］. J Therm Spray Technol， 2021， 30（6）： 1464-1481.
[33]	MARZBANRAD B， TOYSERKANI E， JAHED H. Characterization of single- and multilayer cold-spray coating of Zn on AZ31B［J］. Surf Coat Technol， 2021， 416： 127155.
[34]	杨水梅，张留艳，詹浩芝，等. 掺杂镍对镁合金表面冷喷涂锌基涂层性能的影响［J］. 表面技术， 2019， 48（5）： 217-224.
	YANG S M， ZHANG L Y， ZHAN H Z， et al. Effect of mixing Ni on properties of cold sprayed Zn-based coating on Mg alloy［J］. Surf Technol， 2019， 48（5）： 217-224.
[35]	LI W， ZHANG J， CUI S， et al. Influence of Al contents on the long-term corrosion behaviors of cold-sprayed Zn-xAl coatings［J］.Surf Coat Technol， 2024， 476： 130201.
[36]	CONG S， ZHOU H， LI W， et al. The corrosion behavior of novel cold-sprayed Zn-xTa coating［J］. Surf Coat Technol， 2025， 512： 132389.
[37]	邵龙，吴惠舒，张留艳，等. 冷喷涂铜锌合金复合涂层的腐蚀行为研究［J］. 热加工工艺， 2022， 51（14）： 99-102.
	SHAO L， WU H S， ZHANG L Y， et al. Study on corrosion behavior of copper zinc alloy composite coating prepared by cold spraying［J］. Hot Work Technol， 2022， 51（14）： 99-102.
[38]	贾平平，马捷，王晓光，等. 镁合金表面沉积铜钨复合涂层工艺及涂层性能研究［J］. 表面技术， 2015， 44（5）： 43-47.
	JIA P P， MA J， WANG X G， et al. Process preparation and properties of Cu/W composite coatings on the surface of Mg alloy［J］. Surf Technol， 2015， 44（5）： 43-47.
[39]	XUE N， LI W， SHAO L， et al. Comparison of cold-sprayed coatings of copper-based composite deposited on AZ31B magnesium alloy and 6061 T6 aluminum alloy substrates［J］. Materials， 2023， 16（14）： 5120.
[40]	LI W Y， ZHANG C， LIAO H， et al. Characterizations of cold-sprayed nickel-alumina composite coating with relatively large nickel-coated alumina powder［J］. Surf Coat Technol， 2008， 202（19）： 4855-4860.
[41]	TAN C， KRISHNAN K， ELUMALAI N K. Corrosion behaviourof heat-treated cold spray nickel chromium/chromium carbides［J］. Metals， 2024， 14（10）： 1153.
[42]	WEI Y K， LUO X T， CHU X， et al. Ni coatings for corrosion protection of Mg alloys prepared by an in-situ micro-forging assisted cold spray： effect of powder feedstock characteristics［J］. Corros Sci， 2021， 184： 109397.
[43]	DAROONPARVAR M， KASAR A K， KHAN M U F， et al. Improvement of wear， pitting corrosion resistance and repassivationability of Mg-based alloys using high pressure cold sprayed （HPCS） commercially pure-titanium coatings［J］. Coatings， 2021， 11（1）： 57.
[44]	DAROONPARVAR M， KHAN M U F， SAADEH Y， et al. Modification of surface hardness， wear resistance and corrosion resistance of cold spray Al coated AZ31B Mg alloy using cold spray double layered Ta/Ti coating in 3.5wt% NaCl solution［J］. Corros Sci， 2020， 176： 109029.
[45]	戴宇，马冰，陈杰，等. 镁合金表面冷喷涂420不锈钢涂层及其摩擦磨损性能研究［J］. 兵器材料科学与工程， 2017， 40（2）： 118-121.
	DAI Y， MA B， CHEN J， et al. Tribological properties of cold sprayed 420 stainless steel coating on inagnesium alloy［J］. Ordnance Mater Sci Eng， 2017， 40（2）： 118-121.
[46]	陈杰，宋惠，戴宇，等. 镁合金表面冷喷涂420不锈钢/WC-17Co涂层及其耐磨耐蚀性能［J］. 航空材料学报， 2018， 38（4）： 82-86.
	CHEN J， SONG H， DAI Y， et al. Wear and corrosion properties of cold sprayed 420 stainless steel/WC-17Co coating on magnesium alloy［J］. J Aeronaut Mater， 2018， 38（4）： 82-86.

Type of technology	Processing features	Primary applications	Advantages	Disadvantages
Chemical conversion^［11-12］	Operation at room temperature， forming a thin conversion coating	Substrate for temporary protection/coating	Simple to implement and economical	Thin film layer with limited corrosion resistance
Electroplating^［13］	Metallic coating by electrodeposition	Conductive components for 3C product housings	Broad substrate compatibility and high throughput	Difficult process control， poor coating adhesion and heavy metal pollution
Anodic oxidation^［14］	Anodizing to form a dense oxide film	Aerospace/automotive/3C electronics	Excellent corrosion resistance， wear resistance and insulation	High process requirements， limited dimensional capacity and high cost
Micro-arc oxidation^［15］	Micro-arc oxidation （MAO） forming a ceramic layer	Aerospace/automotive/3C electronics	Excellent corrosion resistance， wear resistance and insulation	High energy consumption and porous coating requiring sealing
Thermal spraying^［16-17］	Thermal spray deposition	On-site repair of large components	Fast forming and excellent substrate compatibility	Weak adhesion， high porosity and high parameter sensitivity
Laser surface-modification^［18］	Surface modification by high-energy laser beam	Aerospace and medical implants	Enhancing wear resistance， corrosion resistance and biocompatibility	High cost， complex equipment， limited shape adaptability and difficult heat-affected zonecontrol
Cold spraying^［19-20］	Low-temperature solid-phase deposition（＜600 ℃）	Component repair and equipment protection	Oxidation prevention， high adhesion， and material property retention	Moderately weak coating adhesion and galvanic corrosion of certain materials

Type of technology	Processing features	Primary applications	Advantages	Disadvantages
Chemical conversion^［11-12］	Operation at room temperature， forming a thin conversion coating	Substrate for temporary protection/coating	Simple to implement and economical	Thin film layer with limited corrosion resistance
Electroplating^［13］	Metallic coating by electrodeposition	Conductive components for 3C product housings	Broad substrate compatibility and high throughput	Difficult process control， poor coating adhesion and heavy metal pollution
Anodic oxidation^［14］	Anodizing to form a dense oxide film	Aerospace/automotive/3C electronics	Excellent corrosion resistance， wear resistance and insulation	High process requirements， limited dimensional capacity and high cost
Micro-arc oxidation^［15］	Micro-arc oxidation （MAO） forming a ceramic layer	Aerospace/automotive/3C electronics	Excellent corrosion resistance， wear resistance and insulation	High energy consumption and porous coating requiring sealing
Thermal spraying^［16-17］	Thermal spray deposition	On-site repair of large components	Fast forming and excellent substrate compatibility	Weak adhesion， high porosity and high parameter sensitivity
Laser surface-modification^［18］	Surface modification by high-energy laser beam	Aerospace and medical implants	Enhancing wear resistance， corrosion resistance and biocompatibility	High cost， complex equipment， limited shape adaptability and difficult heat-affected zonecontrol
Cold spraying^［19-20］	Low-temperature solid-phase deposition（＜600 ℃）	Component repair and equipment protection	Oxidation prevention， high adhesion， and material property retention	Moderately weak coating adhesion and galvanic corrosion of certain materials

Research Progress on Cold-Sprayed Protective Coatings for Magnesium Alloy Surfaces

RichHTML

PDF

Knowledge

Abstract

Cite this article

share this article

Figures/Tables 4

References 46

Related Articles 15

Recommended Articles

Metrics

Comments

[1]	Run-Ze LI, Li-Ren CHENG, Chao-Jie CHE, Xin-Lin LI, VIACHASLAU-A TAMILA, Hong-Jie ZHANG. Research Progress on Synergistic Regulation of Strain Rate， Temperature， and Composition in High-Speed Extruded Magnesium Alloys [J]. Chinese Journal of Applied Chemistry, 2026, 43(2): 157-166.
[2]	Xue-Qiang CAO, Jia-Min ZENG, Yao SHI, Ying-Jing YUAN, Xiang FANG, Guang DU, Long-Hui DENG, Jia-Ning JIANG. Corrosion of Thermal Barrier Coatings in Atmospheric Environment [J]. Chinese Journal of Applied Chemistry, 2025, 42(7): 930-944.
[3]	Yuan WEN, Yan-Ru ZHUANG, Hui-Quan HONG. Preparation of Nitrate Intercalated Hydrotalcite and Its Anti-Rust Behavior on Steel Bars [J]. Chinese Journal of Applied Chemistry, 2025, 42(12): 1691-1700.
[4]	He LI, Gong LI, Xue GONG, Ming-Bo RUAN, Ce HAN, Ping SONG, Wei-Lin XU. Research on Performance Decay Mechanism of Pt/C Catalyst in Long‑Term ORR Test [J]. Chinese Journal of Applied Chemistry, 2022, 39(10): 1564-1571.
[5]	WANG Jianghui. Solving the Shutdown Corrosion Problem of Metal-Air Batteries via Kipp′s Apparatus Principle [J]. Chinese Journal of Applied Chemistry, 2020, 37(9): 1093-1098.
[6]	ZHANG Ping, ZHANG Guoqiang, TANG Yining, GUO Yanni. Corrosion Behavior of Typical Materials of Energy Tower in Different Coolants [J]. Chinese Journal of Applied Chemistry, 2019, 36(3): 349-357.
[7]	DING Hongxia, WU Ying, LIU Zhengping. Preparation of Cationic Polymerizable Imdazolium Ionic Liquid-Acrylamide Copolymers and Their Inhibition Behaviors for Carbon Steel Corrosion in Hydrochloric Acid [J]. Chinese Journal of Applied Chemistry, 2017, 34(8): 877-884.
[8]	ZHENG Xingwen, GONG Min, CHEN Shilin. Corrosion Inhibition of Q235 Steel by Moxifloxacin in Hydrochloric Acid Solution [J]. Chinese Journal of Applied Chemistry, 2017, 34(8): 955-964.
[9]	DING Hongxia, WU Ying, LIU Zhengping. Preparation of Cationic Polymerizable Imdazolium Ionic Liquid-Acrylamide Copolymers and Their Inhibition Behaviors for Carbon Steel Corrosion in Hydrochloric Acid [J]. Chinese Journal of Applied Chemistry, 2017, 34(8): 0-0.
[10]	SUN Yang, ZHANG Hongming, LYU Jinlong, WANG Xianhong, WANG Fosong. Ultraviolet-Thermal Double Cured Anti-corrosion Coating Based on Nano-dispersed Conducting Polyaniline [J]. Chinese Journal of Applied Chemistry, 2016, 33(5): 524-532.
[11]	XUE Shouqing, LIU Qinghua. Preparation of Polythiophene/Polypyrrole/TiO₂Composite Conductive Polymers by Solid-state Method and Its Anti-corrosion Properties for Stainless Steel [J]. Chinese Journal of Applied Chemistry, 2016, 33(1): 98-102.
[12]	YANG Jian, CHEN Buming, WANG Shuai, GUO Zhongcheng. Effects of Chloride Ion on the Properties of Al/Pb Alloy/β-PbO₂ Composite Anode During Zinc Electrowinning [J]. Chinese Journal of Applied Chemistry, 2015, 32(8): 955-962.
[13]	ZHANG Honghong, XIE Yan, LIU Yuanwei, YANG Zhongnian. Inhibition of Mild Steel Corrosion in Hydrochloric Acid Solution by Salicylaldehyde Thiosemicarbazone [J]. Chinese Journal of Applied Chemistry, 2015, 32(6): 720-725.
[14]	SU Tiejuna, , LI Kehuab, LUO Yunbaic. Inhibition Behavior of 1-Phenylaminomethylbenzimidazole for Mild Steel in Hydrochloric Acid [J]. Chinese Journal of Applied Chemistry, 2015, 32(4): 464-471.
[15]	CAO Zhiyong, LU Chen, QU June, ZHEN Guohui, CHENG Cong, WANG Hairen. Corrosion Resistance of Dodecyltriethoxysilane/Graphene Oxide Composite Film on 430 Stainless Steel [J]. Chinese Journal of Applied Chemistry, 2015, 32(1): 93-98.