Kinetic Metallization Process and Equipment for Dimensionally Restoring Bores of Aircraft Components

The NAVAIR Fleet Readiness Centers have a critical need to repair high-value and low-inventory parts on military aircraft. Due to lack of off-the-shelf OEM replacement parts, these operational centers are experiencing service challenges to meet the Fleet demand. The maintenance centers do not currently have technically viable or environmental sustainable methods for repairing many of the bore structures associated with aluminum alloy, magnesium alloy and steel aircraft parts. The objective of Phase II.5 SBIR project is to successfully expand the capabilities of the Kinetic Metallization (KM) technology for repairing bore structures of damaged high-cost and low-inventory parts. This Ph II.5 work will further expand powder development and application parameters for the KM process to perform dimensional restoration of non-structural aluminum alloy components and non-structural dimensional restoration of high-strength steel parts. The research activity required to meet the objective of the project is the development, qualification testing of repairs, and manufacture of rotary KM Bore ID Guns to accommodate dimensional restoration repairs of key aircraft bore structures and actuators using the proven KM technology.