Ultrasonic Vibration-Assisted Mechanical Coating of Cr Powders on 45 Steel for Superior Corrosion Resistance
Conventional surface coating technologies for 45 steel are constrained by high processing temperatures, limited material compatibility, and insufficient interfacial bonding. This study introduces ultrasonic vibration-assisted mechanical coating (UVAMC) as a low-temperature deposition route that mitigates these limitations. The process yields a chromium coating on 45 steel with a nanoscale elemental interdiffusion transition layer at the interface, achieving a bonding strength of 66.0 MPa. The coating delivers improved corrosion resistance in aggressive environments while preserving the substrate's original compressive and tensile strength. The method also demonstrates broad process adaptability, successfully depositing copper, aluminum, and 316 stainless steel powders, and forming complex shapes such as the "SZU" pattern. These results establish UVAMC as a viable surface functionalization strategy for metallic materials, combining efficient deposition with operational flexibility.