High-strength aluminum alloys offer excellent strength-to-weight ratios making them attractive for use in aircraft and aerospace applications [1]. During use, these alloys are subjected to multiple environmental conditions that can lead to corrosive formations. Corrosion leads to reduced performance and can eventually lead to catastrophic failure. The type and extent of the corrosion is dependant on alloy composition, temper, type of loading, coupling with other materials and coating. In this proposal, Cold Spray is being developed to create a better means of corrosion-resistant coating to these alloys. Cold Spray which unlike thermal spray coatings, does not form oxide levels at the bond interface and does not use hazardous chemicals as seen in other corrosion-resistant applications. Coatings will be applied to 2xxx and 7xxx aluminum alloys in both robotically-controlled and manually-controlled environments. These coatings will be optimized by varying certain process variables, coating materials, and carrier gas. Once approved coating levels are achieved, an analysis will be conducted to verify corrosion resistance, coating durability and substrate-strength retention. Also a better understanding involved with property coating to process relationship and process costs will be investigated.
