In the construction of naval aircraft magnesium is used for the excellent strength to weight ratio, especially for large items such as power and drive-train components. Aluminum alloys are also widely used for structural components of naval aircraft.  Magnesium and aluminum components are found in both rotary wing and fixed wing aircraft. Both metals are highly susceptible to corrosion or damage, especially in the caustic environment that naval aircraft operate. As well aluminum components are damaged due to handling of components during repair processes. The downtime and expense to replace parts that have either been damaged due to corrosion or wear is significant. Corrosion damage to such items as magnesium gearboxes and drive-train components can cost over a quarter of a million dollars each, and have to be replaced. Currently we do not have a process to perform structural and corrosion repair to power and drive-train components or for other structural components on aircraft.
A new application for Cold Spray kinetic metallization is to use it for structural repair and corrosion repair of magnesium and aluminum aircraft components. Other DOD functions such as the Army have shown the merits of cold spray metallization for repairing ground vehicle components or to enhance corrosion resistance of parts. NAVAIR has initiated both research and production programs to implement Cold Spray kinetic metallization for the repair of aircraft components both at the depot and in the field. This presentation will summarize NAVAIR efforts to this date in developing and implementing the manufacturing rework capability. This includes alloy development, part and coating performance, to process equipment and field implementation.