Faculty Advisor or Committee Member

Brajendra Mishra, Advisor

Faculty Advisor or Committee Member

Danielle Cote, Committee Member

Faculty Advisor or Committee Member

Yu (Michael) Zhong, Committee Member

Faculty Advisor or Committee Member

Richard D. Sisson, Jr., Department Head




Alloys with good toughness and elevated temperature properties like A201 are expensive and can be more difficult to process. This results in the use of heavier but less expensive alternatives in many applications where toughness is of concern, such as steels. Common alloys such as A356 and E357 are relatively cheap and easy to work with. However, these alloys have considerably lower toughness than premium alloys. This research aims to investigate surface modification treatments that could yield better toughness at a low cost in a common aluminum alloy. The process must show significant improvement in said properties, be cost effective, and easily adaptable in a common foundry. Diffusion of coating material into the substrate was investigated with a variety of coating metals. The diffusion process was facilitated in the solutionizing step for the given substrate aluminum in order to strengthen the sub-surface region of the parts. This research aims to provide a platform for further research into the practical effects of the coating and tempering on impact and toughness properties. These samples were characterized by optical and scanning electron microscopy, EDS, impact testing, and tensile testing.


Worcester Polytechnic Institute

Degree Name



Materials Science & Engineering

Project Type


Date Accepted



Restricted-WPI community only


aluminum, Cold spray, copper, intermetallics, nickel, silicon, titanium

Available for download on Sunday, December 12, 2021