Cold Spray Aluminum: A Cutting-Edge Solution for the Restoration of Gas Turbine LPC Components

The restoration of gas turbine Low-Pressure Compressor (LPC) components is critical for maintaining operational efficiency and prolonging the lifespan of turbine systems. This paper explores the innovative application of cold spray aluminum technology as a cutting-edge solution for repairing LPC components subjected to wear and erosion corrosion. Cold spray, a solid-state deposition process, offers significant advantages over traditional repair methods, including minimal thermal distortion, enhanced adhesion, and the ability to apply coatings with tailored microstructures. We present a comprehensive analysis of the cold spray process, detailing its mechanics, material properties, and the resulting performance enhancements in restored components. Experimental results demonstrate the efficacy of cold spray aluminum in improving wear resistance and operating performance, alongside case studies illustrating successful restorations in operational settings. The findings highlight cold spray aluminum as a viable and effective strategy for the maintenance of gas turbine LPC components, promoting operational reliability and cost-effectiveness in aerospace and industrial applications.