Elaboration of sacrificial Zinc coating on carbon steel via High pressure cold spray technique

For corrosion protection, sacrificial coatings are one solution to limit the degradation of metallic structures in aggressive environment. Among metallic material, Zinc (Zn) can be deposited by cold spray. This technique is suitable to deposit thick coating and for local restoration of damaged surfaces. Unlike thermal spray techniques, the cold spray avoids particle melting and phase transformations since the propellant gas temperature is below the melting point of feedstock materials. For anti-corrosion applications, high-density coating combine with a good adhesion on substrate are required. Since the cold spray is a semi-empirical method, deposition parameters have to be optimized experimentally regarding to the coating quality and the deposition efficiency. In this work, the porosity and the deposition efficiency have been used as relevant parameters for Zn coating optimization by high-pressure cold spray (HPCS). These parameters have been optimized to guaranty high corrosion resistance of the Zn layers. Therefore, this paper proposes a description of the optimized projection parameters and to study coating's morphology, adhesion and anticorrosion properties.