Journal of Thermal Spray Technology

, Volume 26, Issue 4, pp 671–686 | Cite as

Effect of the Cold-Sprayed Aluminum Coating-Substrate Interface Morphology on Bond Strength for Aircraft Repair Application

  • Quentin Blochet
  • Francesco Delloro
  • Franck N’Guyen
  • Dominique Jeulin
  • François Borit
  • Michel Jeandin
Peer Reviewed


This article is dealing with the effects of surface preparation of the substrate on aluminum cold-sprayed coating bond strength. Different sets of AA2024-T3 specimens have been coated with pure Al 1050 feedstock powder, using a conventional cold spray coating technique. The sets were grit-blasted (GB) before coating. The study focuses on substrate surface topography evolution before coating and coating-substrate interface morphology after coating. To study coating adhesion by LASAT® technique for each set, specimens with and without preceding GB treatment were tested in load-controlled conditions. Then, several techniques were used to evaluate the effects of substrate surface treatment on the final coating mechanical properties. Irregularities induced by the GB treatment modify significantly the interface morphology. Results showed that particle anchoring was improved dramatically by the presence of craters. The substrate surface was characterized by numerous anchors. Numerical simulation results exhibited the increasing deformation of particle onto the grit-blasted surface. In addition, results showed a strong relationship between the coating-substrate bond strength on the deposited material and surface preparation.


aluminum alloys bond strength cold spray coating interface morphology random surface modification surface topography 



Aluminum Alloy 2024-T3




Cold Spray


X-Ray Diffraction


Scanning Electron Microscopy


LAser Shock Adhesion Testing




Equation of State


Finite Element Analysis


Additional Interface Length


Representative Profile Length

List of symbols


Arithmetic average of absolute values (µm)


Average distance between the highest peak and lowest valley in each sampling length (µm)


Particle velocity (m s−1)


Yield strength (MPa)


Young’s modulus (MPa)



This work was carried out within the “C-SAR” FUI program. The authors would like to thanks all the members of the program consortium, i.e., Airbus Industries Group, Safran Helicopter Engines, Lifco Industrie, APS Coating, UTBM, Dassault Aviation and Trochet, for valuable discussion, and OSEO, “Pôle ASTech Paris Région”, “Pôle des microtechniques” and “Pôle Pégase” for financial support. Many thanks also to Mrs. N. De Dave-Fabrègue from MINES ParisTech for its precious help in microscopic characterization and metallographic samples preparation.


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Copyright information

© ASM International 2017

Authors and Affiliations

  • Quentin Blochet
    • 1
  • Francesco Delloro
    • 1
  • Franck N’Guyen
    • 2
  • Dominique Jeulin
    • 2
  • François Borit
    • 1
  • Michel Jeandin
    • 1
  1. 1.Centre des Matériaux, CNRS UMR 7633, Competence Center for Spray Processing (C2P)MINES ParisTechEvryFrance
  2. 2.Centre de Morphologie Mathématique, Mathématique et SystèmesMINES ParisTechFontainebleauFrance

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