Development of Repair Strategies of Aluminum-Alumina Metal Matrix Composite using Cold-spraying Additive Manufacturing and Friction Stir Processing

This project aims to enhance the surface durability of aluminum components used in industries such as aerospace, defense, automotive, and renewable energy, while maintaining aluminum’s lightweight and corrosion-resistant qualities. The research will employ a cost-effective coating method, low-pressure cold spray, to apply aluminum–alumina composite coatings, followed by friction stir processing to further improve their quality. By investigating how processing parameters and particle properties affect the bonding between the coating and the substrate, as well as hardness, wear, and erosion resistance, the project will develop stronger, more reliable surface coatings. The expected outcomes include a better understanding of coating behavior, improved performance characteristics, and practical guidelines for scalable industrial applications. Participating institutions will benefit from new scientific insights, advanced processing capabilities, high-impact publications, and stronger industry connections focused on durable, energy-efficient materials for demanding applications. The project will also support the training of highly skilled researchers and generate transferable expertise in advanced surface engineering. Ultimately, it will enhance institutional leadership in sustainable materials innovation and facilitate real-world impact through industry-ready coating solutions.

Faculty Supervisor:

André McDonald

Student:

Partner:

University West

Discipline:

Engineering

Sector:

Education

University:

University of Alberta

Program: