Method and Device for In-Service Repair of Magnesium, Aluminum and High-Strength Steel

The primary objectives of this proposal are to develop a methodology for a Cold Spray concerning in-service repair of magnesium, aluminum and high-strength steel, application of corrosion resistant coatings, develop specifications for a portable Cold Spray system and demonstrate repair processes on representative hardware. Emphasis will be placed on aluminum and magnesium alloys. This will include detailed process, coating and equipment specifications. Technology developed through this SBIR will make field repairs of aircraft components feasible. Cold Spray is an emerging technology being developed as a process to repair/restore the base metal for select components and/or to apply corrosion resistant coatings to various substrate materials including aluminum, magnesium and high strength steel alloys. A unique feature of Cold Spray is the relatively low process temperatures allowing the powder particles to remain in a solid state during the coating process. This avoids substrate melting and produces coatings with less oxide than thermal spray coatings of the same material. Cold Spray is an ideal process for applying coatings to heat sensitive alloys. This process is durable, economical, environmentally friendly, easy to implement and can be applied to complex-shaped aerospace components utilizing a portable spray system.