Analysis of Aluminum Aerospace Parts and Coatings Restored Using Cold Gas Dynamic Spray

Aluminum and its alloys are used on countless aerospace parts; from simple secondary structures (such as brackets), to primary structures (such as landing gears), and protective coatings. These parts cannot currently be repaired when damaged during regular operation, or during initial machining, due to a lack of existing economical/ practical repair technologies. Currently, when these intricate and expensive aluminum parts are damaged, they are removed and new parts must be machined from bulk material. Damaged coatings, such as IVD coated steel, must be completely stripped and recoated. This is an extremely costly and time consuming process.

The primary objective of this study is to develop an economical and practical technique for the repair/ restoration of damaged aluminum aerospace parts and coatings using commercially available cold spray technology.  Secondly, this study investigates the corrosion properties, density, bond strength, wear resistance, and hardness of these reparations, and their effect on the substrate material. Cold gas dynamic spray has shown to be a promising technique for the deposition of pure aluminum and its harder alloys for this application.