A Novel System for On-Site Structural Restoration Methods for Aircraft Components

Navy aircraft components require constant repair due to damage from field operations. In most cases, the damage is due to maintenance occurrences or service, due to Foreign Object Debris (FOD). Although the damage appears to be minor, the components need to be sent back to a Navy depot for disposition and repair, which is usually comprised of blending away the damage and substantially reducing the material thickness in the repaired region. Our Compact Repair System (CRS) will provide a robust repair of the nicks, dings, and dents in Navy rotorcraft as a result of field operations. We have adapted conventional friction stir welding and miniaturized the technology using compact, high speed spindles and additive tools to facilitate the repair of such damage and to return the component at or above its original strength. We clearly demonstrated the feasibility of our Compact Repair System (CRS) during the Phase I SBIR project. During the Phase II project, we will complete activities and tasks that are focused on the transition of our technology to safely and effectively produce high-quality repairs for Navy helicopters and will include the design, testing, and pre-certification of a prototype CRS.