Magnesium alloys have characteristics that make them ideal for aerospace applications, but are also very susceptible to corrosion.  Traditional coatings are used to establish corrosion resistance, but after time still fail in the field.  Cold spray is an emerging technology that can be used to reclaim the corroded areas.  Together with such advanced corrosion resistant coatings as Tagnite and Rockhard sealant, cold spray can return these salvaged parts to service. 

This paper details the interaction between cold sprayed materials, Tagnite coatings, and magnesium substrates. Results from the examination of different cold spray coatings and the reaction with the magnesium substrate will be shown. Results will be presented on corrosion resistance testing of Tagnite and different protective coatings on magnesium substrates repaired by cold spray. The research will include electrochemical, salt fog and mechanical testing of the repaired areas. Finally, an overview of the current status of development of a complete repair process for magnesium will be delivered.