Patent ID: 8137755

Claim:
A method for making a pre-coated ultra-fine, submicron grain aluminum or aluminum-alloy component comprising the steps of: providing a coarse grain aluminum or aluminum-alloy powder material having a first grain size, wherein said aluminum-alloy material is composed of at least 50 percent aluminum by weight; cryogenically milling the coarse grain aluminum or aluminum-alloy powder material into an ultra-fine, submicron grain material having a second grain size less than the first grain size; densifying the ultra-fine, submicron grain material; forming an article from said densified ultra-fine, submicron grain aluminum or aluminum-alloy material by a forming technique selected from the group consisting of cold forming the article, hot forming the article, cold working the article and hot working the article; and, coating the article with an organic coating containing phenolic resin prior to installation, wherein making the component is performed from fabrication of the article to the installation of the article without any thermal treatment of the article other than that provided by the forming technique and that occasioned during curing of the coating, wherein making the component without any thermal treatment of the article comprises making the component without any associated thermal treatment subsequent to the forming technique to maintain the grain size.