A Novel Approach to Helium Free Cold Spray

Triton Systems Incorporated will develop a cold spray system that does not use helium gas to produce low porosity components, <1%. The approach will reduce the overall cold spray repair costs, as well as the dependence on foreign supplies of helium. The goal is to develop cold spray processing equipment that can deposit aluminum, titanium, and high-strength steel with low porosity and without the use of helium. During Phase I, a conceptual design of a cold system that can process aluminum, titanium, and high strength steel to yield coatings with low porosity (<1%) without the use of helium will be constructed. Initial feasibility demonstration of the system will be performed. Sprayed material will be examined for mechanical and microstructural performance. A Phase II test plan will be prepared and provided. In Phase II, deposition parameters will be further evaluated and studied, and refinement of the deposition equipment will be performed. Material testing and evaluation will be expanded to other aluminum alloys. A Phase III plan and prototype system will be provided to NAWCAD for evaluation.