Development of Small Scale, Portable AFSD Repair System for Aircraft Structures

Solvus Global will partner with Baylor University (STTR research institute), University of New Hampshire (UNH), and Bond Technologies to develop a portable AFSD repair system along with the tooling and process parameters needed to meet the required structural properties in aircraft repairs. The team will utilize round feedstock AFSD technology patented by Baylor co-PIs to repair damaged areas measuring less than 1’’. This process ensures dense dimensional restoration and a 1-to-1 chemical composition compared to wrought materials, without contamination from pre-sprayed graphite lubricant. Specific designs of AFSD tools, such as reduced shoulder area and concave shoulder surface, will be utilized. Smooth particle hydrodynamics (SPH) simulation will be adopted to develop process windows for sub-scale AFSD repair using feedstocks of AA7050-T7451, Ti6-4, and AerMet100. Reduction of the repair systems backing force will be achieved by augmenting the process using Electrically-Assisted Manufacturing, a technique patented by UNH co-PI   demonstrated to significantly reduce the forces required for friction-based processes. This multilayer softening technique should also improve the layer adhesion between the aircraft’s existing structure and the deposited material as well as layer-to-layer adhesion. Bond Technology as the AFSD machine OEM will provide technical and commercialization input to ensure design feasibility and facilitate technology transition.