Year 1 Progress – Project Summary
Year 1 Progress – Project Summary

After the Kick-off meeting (Politecnico di Milano, June 24th, 2013) the activities of CORSAIR started with the definiton of the roadmap and the selection of the materials and components of interest. All industrial partners were asked to express the materials they were interested to and to propose a series of damaged components suitable to be cold sprayed. The results of this activity was the «Map of Materials and Components», approved by the consortium during the M6 meeting (Universidad Rey Juan Carlos, Madrid, February, 5-6 2014): priority of the Map was to explore the opportunities of cold spray in a wide range of materials and applications including alloys (both as base material and repair material) Al2024, Ti64, A357, C355, Scalmalloy and WE43 as well more than 25 different aeronautic components among castings, housings, airframes, landing gears, slats, etc. Finally, the realization of repairs in zone hard to reach, such as inner diameters and out-if-view areas, represent a further topic of great interest by the industry and forward the development of cold spray technology (spray nozzles, equipment, deposition process) beyond the state of art.

The mechanical characterization of the cold sprayed feedstock (LPW) and coating materials have been launched and process parameters combinations have been assessed with the aim to find the process able to guarantee the best corrosion, adhesion and cohesion properties. These have been selected for further investigations (residual stresses, fatigue, etc.) The Laboratory deposition experiments have started at VN and TWI with A2024, A357 and Ti64 coatings and a first set of coatings exhibiting microstructural and mechanical properties according to the state of art have already been reached.

At the same time the simulation activity aimed at the fluid dynamics of the process and the condition to obtain adhesion were initiated by KHAI and POLIMI respectively. These were used to assess the most favorable cold spray conditions for the cases of interest in CORSAIR. The results received so far are satisfactory and were used for the design of the new nozzle equipment.

New technological development for pushing the technology beyond the state of art has been discussed and was available close to the end of the first year of CORSAIR. In particular, adapted cooling device to deposit Al alloy coatings at high temperature has been provided by IMPACT, as well a first prototype of 90deg nozzle to enable coating of inner diameters up to 50 cm depth. An innovative feeding system to enable the use of fine and low-flowability powders has been further developed and supplied to Veneto Nanotech and TWI. Furthermore IMPACT is fully involved in the design and development of the new cold spray system that will be completed within the project.

At the end of the first year, the consortium has finally reached the heart of the project with continuous advancements in process optimization, sample production and characterization. The first repair trials are expected to be presented during the next meeting (M18), slightly in advance with respect to the expectation of the project’s Gantt chart.

At this stage, once the mechanical characterization at high strain rate of the materials will be completed, the next step is refinement in order to introduce more accurate material parameters as inputs for the simulation.

All these activities were discussed and approved at the M12 meeting (TWI, July 2-3, 2014).

To learn more about the progress developed within each project WP, please refer to their dedicated pages.