Tribological and Corrosion Behavior of Cold Sprayed Fe-Based Bulk Metallic Glass Coating on Aluminum Alloy

Aluminum alloys are vital to the aerospace, marine and automobile industries due to their lightweight, high specific strength, and good corrosion resistance. However, despite these favorable characteristics, they suffer rapid deterioration under severe friction and wear conditions, making surface engineering and coating imperative for use in several industrial applications where high wear resistance is a design requirement. This thesis investigates the tribological and corrosion behavior of cold sprayed Fe-based bulk metallic glass (BMG) coatings on aluminum alloys. Through a series of experiments including pin-on-disc tribological tests and corrosion assessments, the performance of the coatings was evaluated under various loading conditions and environments. The results demonstrate that the Fe-BMG coatings significantly enhance the wear resistance and corrosion performance of aluminum alloys compared to uncoated samples. The findings highlight the potential of cold spray technology in producing durable coating solutions for aluminum components subjected to harsh operational conditions. This work contributes to the understanding of how efficient surface modifications can prolong the life of aluminum alloys in critical applications.