Effect of Spraying Parameters on the Microstructure and Bond Strength of Cold Spray Aluminum Alloy Coatings

Aluminum alloy powders of different compositions and phases, Al/B₄C, Al-Co-Ce, and Al 5083, were sprayed using the Cold Spray deposition process. The resulting coatings and the effects of several process parameters were evaluated using scanning electron microscopy and bond strength tests. The results show that the bond strengths depend on the powder composition but do not vary significantly with the powder feed rate. Adhesion strength values were obtained for Al/B₄C and Al 5083 coatings. The Al-Co-Ce coatings failed at the coating-adhesive interface, indicating a superior adhesion strength than what was achieved in the bond strength tests.