Aerospace Al alloy cold spray coating performance under fatigue and corrosion environments

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Cold spray is a repair process that can be considered an additive repair process, whereby metal powder particles are impacted at high speed in a carrier gas, at relatively low temperatures, so the repaired surface layer is formed by extreme deformation rather than melting and solidification. The evolving microstructures and the residual stress states between the substrate and new coating layer mean CS structures are not currently used in highly stressed locations as their mechanical performance is not well understood. A better understanding of how the micromechanical processes in this layered system controlling fatigue and corrosion interactions is needed. This is part of a larger research project supported by Airbus Operations, in collaboration with Coventry UniversityThis project will use advanced microstructural characterization techniques (SEM, EBSD, EDX, TEM and X-ray CT) to analyse the evolution of the CS microstructure and defect distributions, and will also investigate full field experimental mechanics approaches (e.g. DIC and EC-AFM) to evaluate strain evolution and corrosion processes under fatigue loading and in the presence of corrosion service conditions.