Novel Feedstock Powder for Cold Spray Coatings in Advanced Weapon Systems

The Defense Logistic Agency has requested a high-performance coating solution substantiated by marginal increases in thermal stability, corrosion and wear resistance, and low friction coefficient. The solution provided to DLA by Triton Systems targets these requirements by proposing a process for applying a self-lubricating, corrosion, and wear resistant coating for use on gun barrels, hypersonics, missile launchers, and other military equipment to improve fleet operations and reduce sustainment costs/burdens. Capitalizing on the inherent highly kinetic processing characteristics of cold spray (CS), there are two proposed material combinations comprising metal matrix composites (MMC’s) which are designed to meet the desired requirements. The primary MMC proposed is designed for light-weighted solutions for integration on aviation platforms. All proposed materials leverage domestic-based suppliers to ensure supply chain security. While these coatings are proposed for rail systems, successful demonstration of the proposed coating technology can be rapidly integrated into other platforms on multitude of applications including possible restoration of transmission and motor housings, landing gear, and drive gears. Integral to the success of this technology, processing strategies will focus on achieving optimal depositions without distortion or introduction of thermal gradients to underlying material being repaired. Furthermore, due to the deposition mechanics of cold spray, the proposed coating solutions can not only be applied to previously cast, forged, drawn, etc. parts but also offers the opportunity to be applied to additively manufactured parts as well.