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

Navy aircraft components require constant repair of minor nicks, dings, and dents due to damage from field operations. Although the damage appears to be minor, these components may no longer meet design specifications and need to be scrapped, increasing downtime of the asset. Thus, there is a critical need to develop a repair technology that will restore both the dimensions and the pre-damage strength of the component, particularly for Ti-6Al-4V components on the H-1 and other Light/Attack Helicopters. Our novel solution is our handheld Compact Repair System (CRS). We have adapted a conventional solid state welding process currently used for large-scale manufacturing (conventional friction stir welding) and miniaturized the technology to facilitate the repair of minor damage. Our CRS is ideally suited to portable systems for the repair of minor damage. During the Phase I project, we will assemble the CRS, complete repair testing on relevant materials, design the prototype for aircraft repair, and demonstrate that the strength of the repaired parts (mechanical and fatigue) meet or exceed the baseline. During Phase II, we will complete the system design, fabrication, and testing and transition the technology to the Navy fleet.