Hard anodize of cold spray aluminum layer

Abstract

A process for repairing components includes the steps of providing a component having an affected area on a surface of a component to be repaired; depositing a repair material over the affected area on the surface of the component so that the repair material plastically deforms without melting and bonds to the affected area upon impact with the affected area and thereby covers the affected area; providing a sulfuric acid based anodizing solution; anodizing a deposited repair material on the surface of said component in the sulfuric acid based anodizing solution; consuming only a portion of the deposited repair material to form a hard anodized coating layer upon the deposited repair material to form a hard anodized coated component; providing a corrosion resistant sealant solution; and contacting a hard anodized coated component with the corrosion resistant sealant solution to form a corrosion resistant sealant coating on the hard anodized coated component.

1 . A process for repairing components, comprising the steps of:
 providing a component having an affected area on a surface of a component to be repaired;   depositing a repair material over said affected area on said surface of said component so that said repair material plastically deforms without melting and bonds to said affected area upon impact with said affected area and thereby covers said affected area;   providing a sulfuric acid based anodizing solution;   anodizing a deposited repair material on said surface of said component in said sulfuric acid based anodizing solution;   consuming only a portion of said deposited repair material to form a hard anodized coating layer upon said deposited repair material to form a hard anodized coated component;   providing a corrosion resistant sealant solution; and   contacting a hard anodized coated component with the corrosion resistant sealant solution to form a corrosion resistant sealant coating on the hard anodized coated component.   
   
   
       2 . The process of  claim 1 , wherein said repair material comprises any one of the following: pure aluminum, aluminum alloy 6061, aluminum alloy 2219, aluminum alloy 5056, Al-12Si alloy, Al—Sc alloy, and aluminum alloy 6061/B4C. 
   
   
       3 . The process of  claim 1 , wherein depositing said repair material comprises cold spraying said repair material. 
   
   
       4 . The process of  claim 1 , wherein said depositing step comprises providing said repair material in powder form having a particle size in the range of from 5 microns to 50 microns. 
   
   
       5 . The process of  claim 1 , wherein said depositing step further comprises accelerating said powder particles to a speed in the range of from 825 m/s to 1400 m/s. 
   
   
       6 . The process of  claim 1 , further comprising mechanically removing at least one of corrosion pits and damaged areas from said affected area on said component prior to performing said depositing step. 
   
   
       7 . The process of  claim 6 , further comprising chemically cleaning said affected area on said component after said removal step. 
   
   
       8 . The process of  claim 7 , further comprising grit blasting a chemically cleaned affected area of said component after said cleaning step. 
   
   
       9 . The process of  claim 1 , further comprising stress relieving said component with said deposited repair material at a temperature and for a time sufficient to recover ductility for said deposited aluminum containing repair material prior to performing said anodizing step. 
   
   
       10 . The process of  claim 1 , further comprising determining a wear resistance of said deposited repair material on said surface of said component prior to performing said anodizing step. 
   
   
       11 . The process of  claim 10 , further comprising performing a final inspection of said component. 
   
   
       12 . The process of  claim 10 , further comprising determining a corrosion resistance of said anodized component prior to providing said chromate conversion solution. 
   
   
       13 . The process of  claim 1 , wherein providing said corrosion resistant sealant solution comprises providing a chromate conversion solution or a molybdenum conversion solution. 
   
   
       14 . A repaired component, comprising:
 a component including a surface having a cold sprayed layer of repair material disposed thereupon, said component further includes an original thickness and said surface includes a restored thickness; and   an anodized, hard coat disposed upon said cold sprayed layer,   wherein said original thickness is a thickness of said component prior to applying said cold sprayed layer and said restored thickness is said original thickness combined with a thickness of said cold sprayed layer.   
   
   
       15 . The repaired component of  claim 14 , wherein said component comprises any one of the following: aluminum alloy, a magnesium alloy, conductive alloy and combinations thereof.