Low Distortion Repair of Thin Superalloy Components

Thin walled nickel alloys in exhaust sections of USAF propulsion systems are prone to cracking. Traditional repairs result in distortion and require post heat treatment. Needed is a method of repair that eliminates distortion and is mechanically, microstructurally, and chemically stable in engine exhaust environments. VRC Metal Systems (VRC) and the South Dakota School of Mines and Technology (SDSM&T) propose to develop a solid-state additive repair technology based on our existing advanced high-pressure cold spray (CS) and friction stir processing (FSP) technologies. The proposed hybrid approach provides a solution to mechanically remove contamination and replace using cold spray solid-state additive technology and friction stir processing, resulting in a solid-state repair with refined microstructure improved mechanical properties. In this Phase I effort, VRC and SDSM&T will characterize the state of the art in CS and FSP of Inconel 625, as well as demonstrate the feasibility and operational gaps that currently exist in the deployment of the solid-state repair process. The team will successfully demonstrate our approach to provide the USAF with a solid-state repair and joining technology to provide enhanced propulsion systems sustainment capability and reduce the total cost of ownership of aging weapons systems.