Seems to me that thermal spraying might work for this. Using pure aluminum powder and Argon as the propellant onto a clean aluminum substrate seems very possible. I know that when conventional milling aluminum the waste chips easily re-attach themselves back onto the parent metal. This has always puzzled me. My best guess is that the freshly exposed surface and the chips are thrown back together with enough force to get them to stick together on a molecular level because there hasn't been enough time for the aluminum to re-oxidize.
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Bob
Don't believe everything you think.
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