This work describes recent progress in Cold Spray of 2618 (Al-Cu-Mg-Fe-Ni) aluminum alloy with Sc addition. Atomized 2618+Sc aluminum powder was sprayed onto aluminum substrates. 2618Al alloy is used for intermediate to high temperature applications in aerospace and automotive industry. The addition of Sc provides higher thermal stability to this alloy by the formation of fine Al 3 Sc particles. The Cold Spray process allows the fabrication of refined microstructure when compared to conventional manufacturing techniques such as casting. The microstructure of the powder and the resulting coating was analyzed using scanning electron microscopy. The mechanical behavior of the powder and the coating was studied using micro indentation measurements. The influence of different heat treatment conditions on the coating was also analyzed. This work shows that Al-Cu alloys with a refined grain structure microstructure can be successfully produced by the Cold Spray process.

The effect of high frequency pulse detonation (HFPD) and HVOF thermally sprayed WC-Co coatings on the high cycle fatigue (HCF) behavior of 2024-T4 aluminum was investigated. The fatigue life distributions of specimens in the polished and coated conditions are presented as a function of the probability of failure. The monotonic and cyclic deformation behaviors of the as-received and as-coated specimens were investigated. The conclusions show that, (i) the HFPD sprayed specimens exhibited slightly higher fatigue lives compared to the uncoated specimens, (ii) the HVOF sprayed specimens exhibited significantly higher fatigue lives compared to the uncoated specimens, and (iii) the as-coated specimen was cyclically stable.