Dimensional Restoration of Landing Gear Component Bores Using Kinetic Metallization

Hill Air Force Base is soliciting spray deposition processes for restoring dimensional tolerances of internal diameters (bores) of worn/damaged aluminum alloy aerospace components. Specifically, high-strength heat-treated 7000 series aluminum alloys used in landing gear parts. Kinetic Metallization is an innovative low temperature deposition process for depositing high-velocity powder particles by solid-state particle impact, while keeping the component temperature below 225 °F.  The unique design of the patented Kinetic Metallization process permits deposition of high density coatings using extremely short nozzles that are capable of spraying bore dimensions down to the three-four inch diameter and bore lengths of 36-inches consistent with land gear components. The overall objective of the Phase I research is to demonstrate the capability of the Kinetic Metallization process and equipment as a spray deposition tool for applying high performance coatings to restore bores of aluminum alloy landing gear components.  Additionally, the Phase I research will develop specific Kinetic Metallization powder alloy formulations that meet the restored coating material requirements for landing gear bores including dimensional, surface finish, density, cohesion, adhesion, permeability, corrosion resistance, and wear resistance. BENEFITS: The military benefit for successfully developing and commercializing the Kinetic Metallization process, equipment, and powder alloy formulations for this project would provide a low cost method for dimensionally restoring land gear bores with a wear and corrosion resistant coating that would extend the life of these aircraft components.  This same process and technique would be applicable for commercial airline land gear bores as well.  More importantly, this technology could lead to commercial processes for coating aluminum alloy automotive and engine bores to reduce wear of OEM engines and dimensionally restore worn bores during engine overhaul.