Effect of Substrate Surface Roughening and Cold Spray Coating on the Fatigue Life of AA2024 Specimens

Constance W. Ziemian, Bucknell University
Mala M. Sharma, Bucknell University
Benjamin D. Bouffard, Naval Surface Warfare Center, W. Bethesda, MD
Travis Nissley, Johns Hopkins University, Applied Physics Lab
Timothy J. Eden, Applied Research Lab, Penn State University


The effects of cold spray coating and substrate surface preparation on crack initiation under cyclic loading have been studied on Al2024 alloy specimens. Commercially pure (CP) aluminum feedstock powder has been deposited on Al2024-T351 samples using a cold-spray coating technique known as high velocity particle consolidation. Substrate specimens were prepared by surface grit blasting or shot peening prior to coating. The fatigue behavior of both coated and uncoated specimens was then tested under rotating bend conditions at two stress levels, 180 MPa and 210 MPa. Scanning electron microscopy was used to analyze failure surfaces and identify failure mechanisms. The results indicate that the fatigue strength was significantly improved on average, up to 50% at 180 MPa and up to 38% at 210 MPa, by the deposition of the cold-sprayed CP-Al coatings. Coated specimens first prepared by glass bead grit blasting experienced the largest average increase in fatigue life over bare specimens. The results display a strong dependency of the fatigue strength on the surface preparation and cold spray parameters.