Enhancing anti-wear and anti-corrosion performance of cold spraying aluminum coating by high current pulsed electron beam irradiation

High current pulsed electron beam (HCPEB) was employed to irradiate cold spraying aluminum coating. The microstructures, tribological and corrosion behaviors of the untreated and irradiated samples were investigated by the X-ray diffraction (XRD), scanning electron microscope (SEM), ball-disc wear and electrochemical tests. HCPEB irradiation significantly triggered the surface remelting and densification of the coating texture. Compared with the original coating, the irradiated coating showed a higher hardness of up to 88 HV, a higher compressive stress value of 31 MPa and a lower wear rate of 1.06 × 10⁻⁴ mm³ N⁻¹ m⁻¹, but also exhibited an outstanding anti-corrosion performance, reflected by a higher polarization resistance and a smaller corrosion current density of 4.45 μA/cm². These current findings confirmed that HCPEB irradiation shows a huge potential for enhancing the anti-corrosion and anti-wear properties of cold spray coatings.