Dimensional Restoration of Aircraft Components Damaged by Corrosion

The U.S. Air Force (USAF) typically requires restoration of damaged aircraft components. These aircraft structure and components are typically manufactured from aluminum substrates, as well as other alloys like magnesium, titanium, and low alloy, PH and Cres steels.Current repair techniques will inspect, clean, and then apply Corrosion Preventative Compounds to prevent/reduce corrosion.Additionally, these traditional repair techniques may utilize and/or produce hazardous materials and waste.Consequently, ES3 will develop cold spray repair technique(s) designed to be portable and provide dimensional restoration using an environmentally-friendly, corrosion resistant coating application.While the Phase II technical objectives more thoroughly evaluated the successful Phase I powder(s) and addressed validation testing for cold spray coating on 2XXX, 7XXX, and 6XXX aluminum alloys; and ZE41A (or similar) Magnesium Alloy; the Phase II modification technical objectives will focus on the validation of handheld coating properties with metallurgical coupon testing as compared to robotic test results from Phase I and phase II efforts; operator training, and development of cold spray repair process on actual aircraft components utilizing the cold spray coating(s) developed under the Phase II effort.Subject cold spray development will focus on portable repair techniques that can be used at depot and field level activities.