Cold spray blended Al + Mg17Al12 coating for corrosion protection of AZ91D magnesium alloy

► Fully dense Al + Mg17Al12 coatings were successfully prepared by CS process. ► 10% of the hard Mg17Al12 particles were retained in the composite coatings. ► Using hard particles, the cohesion strength of the Al coatings was improved. ► The coatings show high corrosion resistance, comparable to the Al bulk material.