The surfaces of damaged aluminum alloy components repaired by cold spray (CS) form chemically homogeneous but microstructurally heterogeneous interfaces. To enhance the corrosion and wear resistance of such conjunct materials, this study employed CS technology to fabricate a high-thickness 2024Al-CS deposit on rolled 2024Al-T3 substrate, followed by micro-arc oxidation (MAO) treatment to prepare carbon nanotubes (CNTs)-doped ceramic composite coatings on the 2024Al-T3/2024Al-CS conjunct material, with subsequent brush-applied polymer sealant modification. Comprehensive characterizations including X-ray diffraction (XRD), Raman spectroscopy, scanning electron microscopy (SEM), potentiodynamic polarization, electrochemical impedance spectroscopy (EIS), and sliding friction wear tests were conducted to systematically evaluate surface/sectional characteristics, mechanical properties, corrosion resistance, and tribological performance of the conjunct substrate, unsealed (U-MAO), and sealed (S-MAO) samples, accompanied by thorough mechanistic analyses of coating formation, corrosion behavior, and wear mechanisms. The results demonstrate successful preparation of integral MAO coatings with uniform hardness, thickness, porosity, and surface roughness through CNTs-modified silicate electrolytes. In terms of corrosion resistance, U-MAO exhibited corrosion current density (3.50 × 10 −7 A/cm 2) over one order of magnitude lower than the substrate (6.06 × 10 −6 A/cm 2), while S-MAO achieved two orders of magnitude suppression (4.88 × 10 −8 A/cm 2) along with maximal impedance modulus in EIS measurements, indicating optimal corrosion protection. Tribologically, U-MAO achieved wear rate (3.371 × 10 4 μm 3/(N·m)) significantly lower than the substrate (4.977 × 10 5 μm 3/(N·m)) and maintained low average friction coefficient (0.37). S-MAO outperformed with minimal wear rate (3.521 × 10 3 μm 3/(N·m)) and average friction coefficient (0.19). The synergistic combination of CNTs-doped MAO and sealant treatment shows promising potential for dual corrosion-wear protection in CS-repaired aluminum alloy components.
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