Dimensional Restoration of Aircraft Components Damaged by Hidden Corrosion

ABSTRACT: Corrosion damage in hidden and/or hard to access locations within aircraft structures and components can be difficult to detect and even more difficult to repair. The Air Force is seeking innovative technologies for dimensionally restoring aircraft aluminum components damaged by corrosion using commercial-off-the-shelf (COTS) equipment which can be operated through small inspection access ports. Inovati"s proposed solution to meet this objective is an innovative spray deposition process that can be used to apply metallic and polymer-based materials to aircraft component surfaces at low temperatures. This COTS process is call Kinetic Metallization, which allows small nozzles with commensurate form factors to be inserted through small access ports to be used for application of these materials. The Phase I work will survey the Air Force Logistics Complex to identify corrosion damage in hidden and hard to access locations of aircraft structures and components. This information will be used to refine the proposed solution to develop repair tool kits that can be used to perform dimensional restoration of corrosion damaged aircraft components. Aluminum based repair compounds will also be identified, developed, and tested for performing these restorations with improved corrosion resistant materials. BENEFIT: The anticipated benefit to the US Air Force and the Dept. of Defense is the deployment of Kinetic Metallization repair tool kits at maintenance depots that can be used to dimensionally restore aircraft components damaged by hidden corrosion in hard to access locations. Development of repair tool kits and suitable aluminum-based repair compounds is expected to significantly reduce the maintenance cost for military aircraft and extend the mission life of these assets. The commercial potential for the Kinetic Metallization process and equipment is augmented by the capability of performing dimensional restoration and coating treatments through small access ports in hard to access locations of buildings, infrastructures, and commercial vehicles including aircraft, automobiles, trucks, trailers, and buses.