Kinetic Metallization Process for Dimensional Restoration of Aluminum Alloys and High Strength Steels Ph II.5

The NAVAIR Fleet Readiness Centers (FRC) have a critical need to repair high-value assets on NAVAIR aircraft. Due to lack of off-the-shelf OEM replacement parts, these operational centers are experiencing service challenges to meet the Fleet demand. The FRCs do not currently have a technically viable or environmental sustainable method for repairing aluminum and steel aircraft components. Developing a low temperature metallic repair technology that closely matches or enhances the parent material properties would greatly reduce cost and increase operational readiness by repairing select aircraft components. The objective of Phase II.5 SBIR project is to successfully transition the Kinetic Metallization (KM) technology into the NAVAIR FRCSW for repairing damaged high-cost and low-inventory parts. The results of the Phase II work successfully demonstrated the viability of repairing Aircraft Mounted Accessory Drive (AMAD) gearbox housings. The 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. Demonstration and validation testing necessary to ensure that these repairs meet the restoration requirements of specific aircraft parts will also be conducted in the Phase II.5 project.