Effect of heat treatment on the intermetallic layer of cold sprayed aluminum coatings on magnesium alloy

► Successful deposition large Al particles on AZ91D Mg substrate. ► Al coatings have a low porosity content and good bonding with the substrate. ► Uniform intermetallic compounds were formed at the Al/Mg interface. ► Intermetallics growth rates obey the parabolic law. ► Dense coating and T4 substrate lead to the formation of thicker intermetallics.