Advanced Coating Tool for ID Surfaces

The Air Force currently spends millions of dollars replacing cylindrical hydraulics components that are worn or scratched on the ID surfaces.  These components may be otherwise salvageable, but there is currently no practical method for restoring the ID tolerances of the sealing surfaces.  Such repairs require adding a thick, highly dense, highly adherent ID metal coating and then machining the coated surface to tolerance.  Typical methods for producing dense coatings, such as physical vapor deposition and electroplating, are too slow and cumbersome or unable to produce coatings of desired compositions (e.g., aluminum alloys).  Conventional methods for producing thick coatings, such as thermal spray, typically cannot produce the desired coating density or adhesion strength in small ID geometries.  In this project, Creare will develop an advanced tool and coating process for ID surfaces that produces thick, essentially 100% dense alloy coatings with very high adhesion strength.  The technology will enable practical additive repair of cylindrical aluminum aircraft landing gear components and other cylindrical machinery components.  The coating technology will also enable application of advanced coatings for resistance to wear, corrosion, and high temperatures for aerospace, military, and industrial applications. BENEFIT: Creares advanced coating tool and coating process for ID surfaces has immediate application in dimensional restoration of worn or damaged parts, such as hydraulics components.  The technology will also enable a variety of engineered ID coatings for enhanced resistance to wear, corrosion, elevated temperatures, or oxidizing conditions for components in industrial and military machinery and aerospace vehicles.  These advances provide performance enhancements and reduce maintenance costs.