Cold spray Aluminium 6061 coating samples were produced with variations of cold spray gas temperatures from 300°C, 400°C, 500°C, 600°C and 700°C, with all other spray parameters constant. The tensile adhesive strengths of the coatings were found to be decreasing with increasing spray temperature, with a marked 70% drop from 400°C to 500°C. A 72% increase in the average coating adhesive strength was observed after T6-heat treatment of non-grit blasted coating samples although the average coating adhesive strength decreased by 9% after stress-relief heat treatment. A 64% increase in the average coating adhesive strength was observed after T6-heat treatment of grit blasted coating samples although the average coating adhesive strength decreased by 20% after stress-relief heat treatment. Coatings were also sprayed at 40° and 60° and subjected to stress-relief and T6 heat treatment. However there were no significant variations in the coating adhesive strengths after heat treatment.

Deposition of amorphous aluminium powder using cold spray technology as a corrosion prevention measure was studied. Amorphous aluminium (Al-Ni-Ce) powder was successfully deposited on 7000-series aluminium substrates using cold spray parameters of 1.7 MPa under compressed air and temperature of 450°C. The coatings were subjected to tensile bond strength measurement and comparative studies with cold sprayed pure Al6061 coatings were conducted. The results obtained showed that the amorphous aluminium coatings exhibited better adhesive strength. In addition, salt-water immersion test was conducted. The Al-Ni-Ce coating not only demonstrated better corrosion resistance but also exhibited evidence of passivation of surface imperfections such as scratches in the coatings.