Effect of substrate surface roughening and cold spray coating on the fatigue life of AA2024 specimens

C. W. Ziemian, M. M. Sharma, B. D. Bouffard, T. Nissley, T. J. Eden

Research output: Contribution to journalArticlepeer-review

85 Scopus citations


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.

Original languageEnglish (US)
Pages (from-to)212-221
Number of pages10
JournalMaterials and Design
StatePublished - Feb 2014

All Science Journal Classification (ASJC) codes

  • General Materials Science
  • Mechanics of Materials
  • Mechanical Engineering


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