SBIR-STTR Award

The objective of this proposal is to develop a methodology for using the Cold Spray Process for in-service repair of magnesium, aluminum and high-strength steel. The process will focus on the development of corrosion resistant coatings and provide improved corrosion resistance with a minimal effect on the base materials properties. The performance of two portable systems will be evaluated. One system is a commercially available system that uses air and nitrogen as the carrier gas and the other system is a system that uses helium as the carrier gas. Evaluation criteria will include coating properties (density, adhesion, strength, and corrosion resistance), easy of use, cost and portability. The efforts will address coatings for magnesium, aluminum and high strength steels. The results of this effort will be used to establish the performance of the available portable systems and to define the requirements for a portable system that will meet the in-service requirements. The end result will be an environmentally friendly, economical, portable system that can be used to apply coatings for in-service repair of magnesium, aluminum and high strength steels used is aircraft.

Benefit:
The proposed solution will enable field repairs of aircraft components. Current repair methods require the removal of the component and return to a repair facility. A portable cold spray system will open the possibility of in-place repair, or at a minimum in-field repair for many different components. Additionally corrosion protective coatings can be applied to the component following the repair of the base metal. Cold spray techniques for in-field repair developed for military applications will be applicable to similar commercial aircraft components or any other commercial applications using aluminum, magnesium or high strength steel based components.

Keywords:
Magnesium Aluminum High-Strength Steel Repair, Magnesium Aluminum High-Strength Steel Repair, Field Portable Protective Coating Corrosion resistant coatings

The primary objectives of this proposal are to develop a methodology for a Cold Spray concerning in-service repair of magnesium, aluminum and high-strength steel, application of corrosion resistant coatings, develop specifications for a portable Cold Spray system and demonstrate repair processes on representative hardware. Emphasis will be placed on aluminum and magnesium alloys. This will include detailed process, coating and equipment specifications. Technology developed through this SBIR will make field repairs of aircraft components feasible. Cold Spray is an emerging technology being developed as a process to repair/restore the base metal for select components and/or to apply corrosion resistant coatings to various substrate materials including aluminum, magnesium and high strength steel alloys. A unique feature of Cold Spray is the relatively low process temperatures allowing the powder particles to remain in a solid state during the coating process. This avoids substrate melting and produces coatings with less oxide than thermal spray coatings of the same material. Cold Spray is an ideal process for applying coatings to heat sensitive alloys. This process is durable, economical, environmentally friendly, easy to implement and can be applied to complex-shaped aerospace components utilizing a portable spray system.

Benefit:
In this program, process and equipment specifications will be developed for a portable Cold Spray system. The system will be portable and capable of repairing components and/or applying corrosion coatings in the field. Current repair methods require the removal of the component and return to a repair facility. A portable Cold Spray system provides the possibility of in-place repair or, at a minimum, in-field repair of select components. The portable systems will be economical to procure and operate and can produce economical coatings. Cold spray techniques for in-field repair will have a wide range of application for aircraft, ground vehicles, and ships. The technology can easily be transitioned to several industries including auto and truck manufactures, private aircraft manufactures, and marine craft manufactures. The field repair could be used for other applications such as spot corrosion coating repair for structures.

Keywords:
Field Repair, Aluminum Repair, field portable, Protective Coating, cold spray, High-Strength Steel Repair, Magnesium Repair, Corrosion Resistance