Ford Global Technolgoies, LLC

University of Michigan

Vikram Varadarrajan

Matthew John Zaluzec

Timothy Jay Potter

James Maurice Boileau

Pravansu Sekhar Mohanty

Paul George Sanders

An alloy composite material comprising an aluminum alloy layer and a thermal spray alloy layer of 20 to 40% Mn and 47 to 76% Fe by weight in overlaying contact with the aluminum alloy layer. An alloy composite material comprising an aluminum alloy layer or base layer and a thermal spray alloy layer of 20 to 40% Mn and 47 to 76% Fe by weight in overlaying contact with the aluminum alloy layer or base layer. The aluminum alloy layer or base layer and the thermal spray alloy layer have a mechanical compatibility to each other of 20-60 MPa as determined using tests specified by ASTM-C633 test. A process of thermal spraying comprising providing a base layer and a feed stock alloy of 20 to 40% Mn and 47 to 76% Fe and thermally spraying the feed stock alloy onto the base layer to form an alloy composite material.

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Westland, MI, United States of America

Vikram Varadarrajan