1. NAVAIR Cold Spray Initiative Update
Cold Spray Action TEAM
CSAT 2014 TIM; Worcester Polytechnic Institute
Frederick A. Lancaster AIR S&T Lead
June 2014

2. Platform Affordability √
Objective
The US Navy has the need to perform dimensional restoration of metallic components caused by corrosion, restoration of material due to wear or damage, and the ability to easily and rapidly repair structures in place on Naval Aircraft.
The objective is to develop a metallization process that can be used to facilitate repairs on naval aviation assets at all levels of maintenance.
Naval S&T Focus Areas:
Affordability √
Maintainability √
Reliability
Naval S&T Objectives:
Platform Affordability √
Availability √

3. NAVAIR Workforce Development
Engineer 1 Ground Support
Engineer 8,
Tech 1; Low Pressure unit
Engineer 4
Tech 1; Low/High Pressure units
Engineer 3
Tech 1; Low Pressure, 2 Robotic High pressure units
Engineer 4
Tech 1; Low Pressure
4/16/2017

4. NAVAIR Cold Spray Timeline
Pre-Section 219 Timeframe (5 Years)
FY-05
FY-06
FY-07
FY-08
FY-09
FY-10
FY-11
FY-12+
Section 219 S&T Investment
8 F-18 parts back in service
3 H-1 parts back in service
2 approved repair processes
2 new process pending/local approval
5 parts OEM approved (SAC) for rework
Gearbox CS Repaired
Part Repair Approval
Initiate Army Contact
Army Collaboration (Demval, Testing, Information Exchange, Project Teaming, DOD Vision)
SME
Trained
SME
Pax River
Modeling
SME
SME
Trained
FRC-East
4 Low pressure CS units Operational
All FRC’s w/ full repair capability
Technical staff all sites
2 sites high pressure capable
SME
FRC-SE
Trained
SME
FRC-SW
Trained
MIL-STD-3021
Cold Spray Spec
Cold spray specifications for process Approved
Aerospace Powder Spec Developing
MIL-PRF-XXXX
Aerospace Powder Spec
Specifications
TRL Level

5. Current Navy Cold Spray Capabilities
NAVAIR Facilities
FRC-East. 2 high & 1 low pressure
Pax River, low pressure portable
FRC Southeast (Jax), low pressure portable
FRC Southwest (NI), low pressure portable, 2 high pressure robotic units (fy 14)
NAVSEA
- NSWCCD Inovati since 2004
- Keyport?
NPS
- Low Pressure cabinet

6. Technology Assessment
Target Material Applications Air Vehicles
Aluminum alloys used for naval aviation applications
7075-T73651 Plate,
7075-T76511 Extruded,
7075-T6 sheet/clad skin,
2024-T3 – sheet/cladskin,
A356-T61 Cast,
Steel alloys used for naval aviation applications
AISI 4130 & AISI 4340,
Stainless Steel PH13-8Mo,
High Strength Steels (landing gear, arresting hooks),
300M,
Aermet 100,
AF1410
Magnesium alloys (AZ-91, ZE41A)
Titanium (Ti6-4)

7. Partnerships / Collaborations
Direct collaboration with
AIR Power & Propulsion
AIR Structures
AIR NDI (Pax & FRC-SW)
Penn State ARL (REPTECH)
PMA 265, PMA 299
FRC East, Southeast, Southwest
Sikorsky Aircraft, Boeing Aircraft
Australian DSTO
NSWC Carderock & US Naval Postgrad
Partnerships with
USMC Corrosion Program
NSWC Carderock Materials
Engineer/Scientist Rotation
NRL Code 35
US Naval Postgrad School, Monterey
Army Research Lab
AMRDEC
TIPS: H-1 Combining Gearbox Repair
DLA: IVD Aluminum Repair, Cad Alternative, Hard Chrome Alternative
SBIR: Low pressure repairs, two small businesses & academia
AERMIP: Low Pressure Portable Metallization FRC-SE, Hole restoration F-18
OSD Corrosion: Portable Robotic System
REPTECH- PSU ARL Portable Repair and Restoration of Aluminum and Magnesium Components
OSD Mantech-2012 Cold Spray Repair & Rebuild Technology (automated)
ONR SBA (NSWC Carderock/NPS) Single Particle Impact Study

8. FY12 Progress FY13 Progress
Key Milestones Achieved
All depots operational & workforce trained
DT/OT for AMAD Fretting Corrosion Repair
Parts released back into fleet
DT for AMAD internal damage rebuild repair
FRC-East System Upgrade
Auxiliary heater installed on CGT Unit.
FY13 Progress
Key Milestones Achieved
Continued flight time for AMAD repairs
Upgrade of FRC-E w/ 47kW heater
OSD Corrosion Office sponsorship for continued working relation with Australian DSTO.
(overall, slow due to sequestration)

9. FY14 Expectations Future: H-60 H-1
Radar Racks, AMAD Gear Hard Chrome Alt, Wing/spar fastener hole repair (ie bushing repair)
20 F-18 Radar Racks est $220K each tot $4.4M
IVD Repair:
H-60
Canted bulkhead repair (bushing alternative)
Gearbox repair (SAC & Australian DSTO)
V-22
V-22 Sills est $80K+ each sending back to CP.
H-1
Cobox O-Level Repairs
FRC independent teams can now perform repairs
Continue S&T work at Pax River with FRC’s to expand applications
Refine portable repair process (field and depot – roll up to the airframe)
Further Navy & Marine Corps Collaborative projects
Collaborative engineer rotation set-up with NSWC Carderock

10. Change Authorizations to Date
Local Process Specifications: Authority granted by the cognizant engineering authority at the Fleet Readiness Center (With local Materials & involved competencies concurrence) Engineering Orders from Sikorsky (ORI/(MEO Army)): OEM approval. For Cold Spray the parts to date are for using cold spray aluminum as an alternative to flame spray aluminum, mainly for wear areas, 5 applications.

11. FRC-SW Cold Spray Apps & Repairs
F/A-18E/F AMAD Main Housing (hydraulic pad restoration) LPS
F/A-18E/F AMAD Main Housing (gear failure repair) LPS
F/A-18E/F AMAD Hydraulic Gearshaft (seal surface repair) LPS
F/A-18E/F Main Landing Gear Brake Carrier
F/A-18A-D AMAD Housing PTS Axis (fretting repair)
F/A-18E/F Radar Rack Assembly (dimensional restoration)
F/A-18A-D GCU Tube Flange (pitted repair)
F/A-18E/F GCU PMG Shaft (dimensional restoration)
F/A-18E/F Wing Panel Fastener Holes (dimensional restore)
F/A-18A-D Center Pylon (dimensional restoration)
10. F/A-18E/F Steering Collar Cover (HSS dimensional restore)
11. F/A-18E/F Arresting Hook Pivot (HSS dimensional restore)
AMAD = Aircraft Mounted Accessory Drive GCU = Generator Control Unit PTS = Power Take-Off Shaft PMG = Permanent Magnet Group HSS = High-Strength Steel LPS = Local Process Specification
Mature
In-Process
Recently Identified

12. FRC-E Cold Spray Apps & Repairs
H-60 Sump (wear restoration, dimensional repair) SAC ORI
H-53 – Five SAC ORI’s for various drivetrain parts. (detail coming)
H-1 Combining Gearbox Chafing repair (dimensional) LPS *
First Operational Level Repair
V-22 Window Sill Corrosion Repair (dimensional) LPS
H-60 Gearbox Pad Restoration;
Intermediate,
Tail,
Combining, &
Main
AMAD = Aircraft Mounted Accessory Drive GCU = Generator Control Unit PTS = Power Take-Off Shaft PMG = Permanent Magnet Group HSS = High-Strength Steel
LPS = Local Process Specification
Mature
In-Process

13. FRC-SE Cold Spray Apps & Repairs
F-18 Bomb Rack Repair (coating repair) LPS
GSE Spotting Dolly Pin Coating Repair (coating repair) Engineering Test
IVD Aluminum repair
AMAD = Aircraft Mounted Accessory Drive GCU = Generator Control Unit PTS = Power Take-Off Shaft PMG = Permanent Magnet Group HSS = High-Strength Steel\
GSE= Ground Support Equipment
LPS= Local Process Specification
Mature
In-Process

14. Current & Future Projects
Yr-13
Yr-10
Yr-11
Yr-12
Aircraft Component &Transition(s) Timeline
H-60 Gearbox repairs – Australian Navy/USN/US Army/SAC
Repair of Cad & Al Coatings (OSD)
UH-1N/AH-1W COMBINING GEARBOX HOUSING REPAIR – PORTABLE (TIPS) FRC-E
Dimensional Repair/Aerospace Powder Spec(DLA)
UH-1N/AH-1W RING GEAR High Pressure (Section 219) FRC-E
F-18 EMI REPAIR – PORTABLE (TBD)
UH-1N/AH-1W SUPPORT CASE PAD MOUNT – PORTABLE (TBD)
UH-1N/AH-1W CAD ALTERNATIVE ELECTTRICAL CONNECTORS – PORTABLE (TBD)
Repair of IVD(DLA)
Repair of Cad Alt to Brush Plate (DLA)
F-18 E/F/G AMAD Transmission Housing High Pressure Fretting/Dim Rep(Section 219) FRC-SW
PSU-ARL Repairability, F-18 (REPTECH)
Key
H-53 MGB Pad Mounts ( POM15)
Corrosion
Dimensional/Non-structural
Future
Structural (Repair within struct limits)

15. Current & Future Projects
Yr-17
Yr-14
Yr-15
Yr-16
Aircraft Component &Transition(s) Timeline
Portable Robotic CS - H-60 Intermediate Gearbox repairs – Australian Navy DSTO/USN NAVAIR (OSD Corrosion)
UH-1N/AH-1W COMBINING GEARBOX HOUSING REPAIR – PORTABLE (TIPS) FRC-E (Deployment to O-Level)
Aerospace Powder Spec(DLA)
F-18 EMI REPAIR – PORTABLE (TBD)
UH-1N/AH-1W CAD ALTERNATIVE ELECTTRICAL CONNECTORS – PORTABLE (TBD)
Repair of Cad Alt to Brush Plate (DLA)
Repair of IVD(DLA)
Repair of Cad Alt to Brush Plate (DLA)
F-18 Wing Spar Fastener Hole Elongation Repair(AERMIP)
PSU-ARL Repairability, F-18 (REPTECH)
Key
Portable Robotic Cold Spray Application
Corrosion/Coat
Dimensional/Non-structural
Structural (Repair within struct limits)
To Be Proposed (wish list)

16. Future: Field/FRC Deployable Robotic Systems
Example: Australian DSTO has adapted a robotic cold spray metallization system for Mobile Repair
Advantage: Ability to apply CS portably at High Pressures for structural applications or precise repair.
Goal: A system that artisan teams can deploy and repair aircraft in the field, operational level, or at the aircraft at the Intermediate level.
Worked with RAN under a Coalition Warfare project to further develop this technology for structural applications. Currently awarded an OSD Corrosion effort to further collaboration & demonstration of portable repairs.
*Rosebank Engineering presentation “TSS Cold Spray Conference 2010-Cold Spray application in Australian Aerospace Industries-Neil Matthews” DSTO Project

17. S&T Analysis Issues for all materials of interest to the Navy/NAVAIR
Process parameters
Repair limitations
Coating optimization
Powder
Surface preparation
Spray parameters
Coating bond strength
Coating cohesion
Post-coating preparation
Sealing
Welding
Machining
Microstructural characterization
Metallurgical bond
Dislocation density
Coating formation
Mechanical properties (comparison to existing technology)
Residual stress
Fatigue
Corrosion
Evaluation/Development of NDT
Significance of Flaws
Specifications and Requirements
Fitness for service acceptance criteria & logistics
In-service repair
Safety/Environmental concerns
Application based cost benefit analysis
Modeling, process & materials
Logistics constraints
Material
Equipment
Need to tie fundamental understanding of process parameters/operating envelope to coating properties

18. Hierarchy of Cold Spray Application Projects
$COST$
CAPABILITIES
RISK/COMPLEXITY
Advanced Powder/Alloy Development
Structural
Corrosion & Dimensional Non-Structural

19. Approach Develop Qualify Check Assure Establish Procedure(s)
Develop Process(es) & Equipment
NRL, ARL, NSWC-Carderock, Industry, Academia
Certify Testing & Results (laboratory)
Physical Tests
Corrosion Tests
Non-destructive
Develop Process Certification Procedures/Methods
System/Process Functional Tests
Apply to aircraft
Flight Test

20. Take-Aways
All Fleet Readiness Centers are capable of Cold Spray repairs
Hardware in place
Personnel trained, SME’s in place
Active S&T portfolio to support new process applications
Still a significant amount of applications & repairs to develop
New alloy development still an open technology area.
Continue process development, verification & validation, and qualification of applications
Next Step: Portable Systems for Depot & Field Use
Develop portable repair processes for field and depot – roll up to the airframe in place.

21. Summary
Responsive to fleet needs with solutions that keep fleet assets affordable & maintainable
Establishing for NAVAIR a solid base to grow from
Material & Process Protocols
Capabilities
Processes
Manpower
Logistics