WP1: Roadmap and selection of materials and components

Lead by: VN
Participating partners: POLIMI, TWI, NAU KHAI, URJC, METALOGIC, AVIO, EADS, EADS-CASA, IMPACT, IBERIA
Duration: June 2013 – November 2013 (M01-M06)

 

Overview: Challenges and current SoA

Nowadays Cold Spray Technology is emerging from Laboratory scale and becoming a real opportunity for several applications especially in aviation. However, the current SoA scenario still depicts the presence of some spot applications only, a know-how dispersed among several Universities and Enterprises and spread on a wide range of materials and industrial fields. The Challenge of CORSAIR and WP1 in particular is to collect all information already available, plan the further development of the technology and processes focusing the target on aviation needs as well extending the effort on the definition of protocols and guidelines for an optimized technological transfer to aviation industry.

Main Objectives

WP1 represent the first step of the project and it would like to analytically summarize all resources, equipment and targets of the project. The whole consortium capabilities will be listed and scanned; the WP1 will seek to define components, materials and a detailed background of the aeronautical industry requirements. Additionally, this research will explore the different procedures and protocols to completely characterize coatings and repairs in order to provide laboratory validation.

Related Activities

Considering that we are talking about the first step of the CORSAIR, the activities planned in WP1 are very intuitive and related to the accurate assessment of the SoA and industrial needs.

A Component ID CARD will be defined and will include all information about each component to be studied and considered in CORSAIR, describing the current technology readiness level (TRL) or manufacturing capability readiness level (MCRL) in the context of aircraft and engine components. The constituting materials, the defects and object of the repair and of course target properties of the repair to be performed by Cold Spray will be also included in these cards. A preliminary list of components and materials to be scanned is the following:

Alloys Type of Alloy Components Main alloys of interest
Aluminium Accessory gearboxes, Oil tanks, Covers, Casings, Adapters, etc. Aluminium Silicon alloys: A357, C355, A356; Aluminium Copper alloys: 2024, 2014, 2618
Magnesium Accessory gearboxes, Covers, Carters, Main Housings, Adapters, etc. ZE41A, QE22A, WE43
Titanium Structural and aerodynamic components. Complex shapes obtained by machining, sheet metal forming, die forging, etc. (Fittings, panels, joint parts, frames, stringers, brackets, covers, skins) Ti Alloys IMI 550 (Ti-4Al-4Mo-2Sn-0.5Si) IMI 834
(Ti-5.8%Al-4%Sn-3.5%Zr-0.7%Nb-0.5%Mo-0.3%Si); Titanium TiAl6V4 ; Ti-P99002;
Other Components Tooling Steel, Invar

 

A Characterization Set-Up Chart will complete the activities planned in WP1. A complete setup and procedure to fully characterize coating and repaired parts will be defined by the whole RTD partners of the consortium and planned taking into account the different requirements of aeronautical components. These will be studied in terms of mechanical, metallurgical and chemical-physical properties. All the RTD partners will contribute to define the set-up of overall characterisation and further validation of the deposited materials.

Expected Results beyond the SoA

WP1 research will deliver the basic definitions regarding to the materials, processes and characterization of the Cold Spray technology in the industry. A set of charts will be delivered describing:

  • base Materials and Components devoted to the repair interventions, different Type and Objectives of Repairs as well Expected results
  • a preliminary definition of features beyond the state of art, to be developed during the project
  • the characterisation set-up (metallurgical, mechanical, chemical properties) required for repairs and materials defined by this research
Progress

June 2013-May 2014 (M01-M12)

The aim of WP1 was the collection of all the information regarding components and end-user requirements (aeronautic industries), which are necessary for defining the work plan of the project. The details of more than 25 different components in Al, Ti and Mg alloys coming from 4 large industries and the related defects to be repaired within the project have been collected, described and included in a summarizing “Component Chart”.

Starting from this Chart, the work-plan has been adapted to achieve the industrial objectives; a complete set of materials, powders, experiments, specimens’ type and use, characterization and quality control plan, as well as the guidelines to develop new models to describe the deposition process and equipment have been defined. All data collected have been discussed within the consortium, agreed and summarized in three charts representing the heart of the WP1 deliverables.

WP1 has been successfully concluded. The main part of data collected are confidential or must be restricted within the consortium due to the significant presence of engineering details about proprietary components and mechanical parts. By the point of view of impact, the meaning of WP1 is to put the basis to direct the project versus a fruitful goal, and this result has been achieved.


 

The activities related to the CORSAIR research are being organized in the following Work Packages (WPs):