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<p>Nickel–aluminum bronze (NAB) coatings are widely used in marine and industrial applications due to their excellent corrosion resistance, but their deposition on soft, low-melting substrates such as magnesium (Mg) remains challenging. This study investigates the cold spray deposition of as-received and heat-treated NAB (unsegregated) powders on Mg and NAB substrates, followed by post-processing using a fine-beam scanner-based laser remelting system. The as-deposited coatings improved the corrosion resistance of Mg substrates; however, they exhibited high porosity (5.2 ± 0.7%) and poor inter-splat bonding, as evidenced by the dislodgement of weakly bonded splats during polishing. Laser remelting with optimized parameters selectively fused layers to depths ranging from ~ 42&#xa0;µm to ~ 220&#xa0;µm. By remelting only the top surface layers (~63&#xa0;µm), surface porosity, and inter-splat defects were sealed effectively, while the underlying cold-sprayed microstructure remained unaltered. Phase analysis confirmed martensitic transformation in the remelted layer, with no detectable oxidation due to effective argon shielding. Electrochemical testing revealed a 52% reduction in corrosion current density after remelting. This study demonstrates the feasibility of utilizing scanner-based laser remelting as a post-processing method, offering a controllable approach for selectively refining cold-sprayed coatings made of hard and brittle materials on soft substrates.</p>

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Enhancing Cold-Sprayed Nickel–Aluminum Bronze Coatings on Magnesium via Scanner-Based Laser Remelting

  • 期刊论文

  • 发表日期：

    2026年1月6日

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  • Gidla Vinay,
  • Ravi Kant,
  • Aki Piiroinen,
  • Chinmayee Nayak,
  • Ashish Ganvir,
  • Harpreet Singh

摘要

Nickel–aluminum bronze (NAB) coatings are widely used in marine and industrial applications due to their excellent corrosion resistance, but their deposition on soft, low-melting substrates such as magnesium (Mg) remains challenging. This study investigates the cold spray deposition of as-received and heat-treated NAB (unsegregated) powders on Mg and NAB substrates, followed by post-processing using a fine-beam scanner-based laser remelting system. The as-deposited coatings improved the corrosion resistance of Mg substrates; however, they exhibited high porosity (5.2 ± 0.7%) and poor inter-splat bonding, as evidenced by the dislodgement of weakly bonded splats during polishing. Laser remelting with optimized parameters selectively fused layers to depths ranging from ~ 42 µm to ~ 220 µm. By remelting only the top surface layers (~63 µm), surface porosity, and inter-splat defects were sealed effectively, while the underlying cold-sprayed microstructure remained unaltered. Phase analysis confirmed martensitic transformation in the remelted layer, with no detectable oxidation due to effective argon shielding. Electrochemical testing revealed a 52% reduction in corrosion current density after remelting. This study demonstrates the feasibility of utilizing scanner-based laser remelting as a post-processing method, offering a controllable approach for selectively refining cold-sprayed coatings made of hard and brittle materials on soft substrates.