Restoration of Damaged Aircraft Skin by Cold Spray Technique: The Advantages and the Challenges

Unlike thermal spray process, the recent development of cold spray technology has made possible the deposition of low porosity and oxide-free coatings; with good adhesion and with almost no change on the microstructure of the coated parts.  This work will focus on the performance of using low pressure cold gas dynamic spray system (LP-CGDS) to repair damaged Al-based thin aircraft skin.  The effect of the spraying process parameters on the quality of the coating has been investigated.  The optimal parameters’ of spraying commercially pure aluminum have been determined.  Microstructures, microhardness, adhesion strength, surface finish and corrosion resistance were performed using different ASTM & Boeing standards.