Patent ID: 8486249

Claim:
A method for repairing an aluminum part having a worn portion, the method comprising: producing a first substantially non-porous coating over the worn portion utilizing a cold spray process wherein a powder mixture is propelled against the worn portion of the aluminum part, the powder mixture containing at least one of pure aluminum and an aluminum alloy and further containing about 5% to about 40% aluminum oxide, by weight of the powder mixture, such that the first substantially non-porous coating produced pursuant to the cold spray process has aluminum oxide particles embedded therein; depositing a second substantially non-porous coating over the first substantially non-porous coating by cold spraying an aluminum powder thereon, the aluminum powder cold sprayed onto the first substantially non-porous coating substantially free of aluminum oxide; and hard anodizing the aluminum part to grow an aluminum oxide layer overlaying the second substantially non-porous coating.