Advanced Cold Spray Development for Aerospace Aluminum Alloys

Cold spray technology has been qualified for use in the aerospace industry as a repair technology for the restoration of aerospace materials, including; aluminum and magnesium alloys. The use of cold spray has been primarily limited to dimensional restoration of corroded, worn or damaged parts and for ‘nonstructural’ applications. The disadvantage of the use of cold spray has been a decrease of ductility in the as-sprayed condition but advancements in novel processing has resulted in unprecedented increases in strength and ductility. This paper will discuss the advancement of cold spray aluminum aerospace alloys by the US Army Research Laboratory in conjunction with a research team that includes industry and academia and the efforts underway to expand use their use for the repair of structural components. Data will be presented regarding the development of aluminum aerospace alloys with increased strength and ductility. Strength levels of 60ksi ultimate tensile strength with a corresponding ductility of over 15% elongation have been reported. An overview of the state-of-the-art of cold spray aluminum aerospace alloys will be discussed and their current use. Comparisons of materials properties will be made as well as applications in rotorcraft and fixed wing aircraft.