In-Situ Solid State Repair and Refurbishment of AM-2 Aluminum Mats

Expeditionary airfields are in need of an efficient in-situ repair method to reduce operation downtime while being serviced. Cold spray offers effective in-situ repair capabilities while remaining sufficiently portable for use in remote locations. Repairs done through cold spray can be further improved via friction stir processing to provide even higher quality refurbishment potential on site.   Cold spray additive manufacturing technology is capable of depositing layers of metal onto a surface while friction stir processing enhances cold spray deposits and increases their mechanical properties comparable to the original base material. While smaller repairs may be achievable with only a single method, a combined in-situ solid state approach will ensure high quality repairs to maximize airfield uptime.   By the conclusion of the Phase I effort, an ideal aluminum recipe for repairing AM-2 mats will be selected. Additionally, comparison testing between repairs using only cold spray and cold spray followed by friction stir processing will be completed. The Phase I Option will include the development of a cold spray applied anti-skid coating for expeditionary airfield repairs to restore the surface finish after refurbishing. Finally, a demonstration sample will be restored using cold spray and friction stir processing.