Cold Spray Process Development for the Reclamation of the Apache Helicopter Mast Support

Report No. ARL-TR-4922
Authors: P. F. Leyman and V. K. Champagne
Date/Pages: August 2009; 32 pages
Abstract: The U.S. Army Research Laboratory at Aberdeen Proving Ground, MD, has developed a novel process for repairing and rebuilding damaged aluminum components using Supersonic Particle Deposition, commonly referred to as cold spray. A Centerline Model No. SSM-P3300 Portable Cold Spray Deposition System was used to deposit a highly adherent, dense aluminum composite material to repair corrosion damage pits and rebuild the snap ring groove and gear teeth on the mast support on an Army helicopter. ARL performed microstructural analysis as well as adhesion, fatigue, and corrosion tests to evaluate the characteristics of the cold spray aluminum composite coatings. The cold spray deposited material was subsequently machined using conventional machining tools to dimensionally restore the component to its original condition. Final testing and approval for implementation of this repair procedure is in progress.
Distribution: Approved for public release
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Last Update / Reviewed: August 1, 2009