Cold Spray Action Team Workshop – June 2014


We are pleased to announce that The CSAT 2014 Meeting has been scheduled for June 18-19, 2014 and will take place at Worcester Polytechnic Institute (WPI), Worcester, MA.   We are planning to maintain a well rounded agenda whose emphasis will be ‘Cold Spray Structural Repair and Additive Manufacturing’.

CSAT meeting  over  200 registered: Over 200 registrants are expected to attend the CSAT 2014 Meeting scheduled for June 18-19, 2014 at Worcester Polytechnic Institute (WPI).  This breaks previous records for the CSAT meeting!

Exhibitors and On-Site Early Check-in: The CSAT will be held in the Odeum Conference Center at WPI.   Check-in early to receive your CSAT badges and visit our exhibitors from 6-9 pm on Tuesday, June 17, 2014 at the Odeum Center.  Please plan your travels accordingly.

CSAT Early Registration has been extended through Tuesday, June 10.

 CSAT Late Registration is open from June 11- June 18. However, meals will no longer be included in the $50.00 registration fee. You will be responsible for paying for your own food.  The campus food court is located in the lower level of the Odeum Campus Center for your convenience. (Late registration will continue through the morning of Wednesday, June 18 at the Odeum Center).

The CSAT has resulted in collaborations between many companies, the Government and academia. It is estimated based upon estimations of program funding that over $14M has been allocated toward the development of cold spray technology from 2011 and there continues to be opportunities for further research and development.

CSAT and JTEG Announce New Partnership: The Joint Technology Exchange Group (JTEG) and the Cold Spray Action Team (CSAT) have entered into a new Partnership agreement that enhance the effectiveness of both organizations from now on. The JTEG is working with CSAT to form an Integrated Product Team (WIPT) to improve cold spray repair coordination involving the introduction of new or improved technology, new processes, or new equipment into DoD depot maintenance activities.  The Cold Spray Repair WIPT will work with CSAT to seek ways to better leverage technology and process improvements in cold spray repair through collaboration to support the higher DoD goals of improving effectiveness and efficiency that will have widespread applicability across all sectors of industry. Further information about the JTEG can be found at:

Workshop: This year the CSAT schedule of events will include a workshop to be held the second day after 12:00 noon. Those who wish to participate are welcome to do so. Workgroup Organization: The idea is to run the 3 groups concurrently with each group having about 3 facilitators/leaders. Ideally, each group would have a leader from Government, industry, and academia. The intent is to take advantage of the experience and knowledge at the meeting and to brainstorm ideas and develop a plan to accomplish each workgroup’s objectives. The intent is not to assign a myriad of tasks to the meeting attendees. Each workgroup will provide a 10 minute summary to the entire meeting group. The group envisions the workgroup efforts being tracked through quarterly teleconferences, and results being briefed at the 2015 CSAT Meeting.

It is anticipated that there will be three workgroups at the meeting:

  • Body of Knowledge:  An online database where information and data on new and existing cold spray repair technology developments can be posted and accessed. This group will identify what type of information and data (and appropriate sources) should be posted. Examples include process development, powders, equipment, test results, and lessons learned.
  •  Process Qualification, Certification, Specifications, and Standards
  • Cold Spray Equipment: Provide an educational awareness on the different systems and their capabilities/limitations. Also discuss performance criteria.

Notification Requirements: This year we will require that all attendees notify us by May 30th 2014 whether they are planning to attend CSAT, as the response has been overwhelming for past meetings, and we need to order healthy snacks, drinks and boxed lunches for everyone in advance. Folks who show up at the door at the day of the CSAT will still be responsible for payment of the $50.00 but will have to eat at the Campus Center Food Court. The WPI Food court is right downstairs from the CSAT meeting location and there is a variety of foods including; Gompei’s Pizza, Coyote Jack’s Grill, Quiznos Subs, Chartwell’s catering and banquet services, and vending. Dunkin’ Donuts is also located on the main entrance level of the Campus Center and offers coffee, donuts, and breakfast sandwiches.

Registration:  The cost for the 2014 CSAT meeting will remain minimal and be only $50.00–just enough to cover the cost of snacks, breakfast, and a box lunch.  The CSAT meeting registration fee of $50.00 is electronically paid by credit card by using the link on the CSAT meeting registration page

All CSAT meeting participants will be able to access up to date information on the meeting agenda and logistics via

To pay by check or purchase order, the cut-off day to mail is MAY 30, 2014.  The payment should be made payable to VRC Metal Systems, and the address is 525 University Loop, Suite 211, Rapid City, SD  57701.   If you plan to pay by check, a 2014 CSAT meeting registration form is available for printing on the CSAT registration page (noted above) and at

Location: The CSAT will be held at Worcester Polytechnic Institute at the Odeum Conference Center. It is a modern spacious facility that is equipped with the latest state-of-the-art audio and visual communications systems and can accommodate 250 attendees comfortably. Attendees will be seated 6-8 around tables, as opposed to an auditorium seating arrangement (like last year). A complete cafeteria and bar are adjoined with an elevated window view of the campus so snacks and meals can be enjoyed in comfort. Last year there were over 160 attendees and we will need to limit the attendance to 250 this year. We have already received many positive responses and I will provide regular updates to that list.

Accommodations: The Worcester, the Hilton Garden Inn, 35 Major Taylor Blvd. (formerly Worcester Center Blvd.) is a new very nice hotel close to WPI. Their phone number is (508) 753-5700 and their website:

Agenda: The theme at CSAT this year is “Cold Spray Structural Repair and Additive Manufacturing”. In addition to the invited speakers there will be a tour scheduled at the end of Wednesday before the reception at Mid-America, which is a subsidiary of MOOG, located in Webster, MA. I am pleased to announce that Mid-America has also been selected as the Demonstration Site for the world’s most sophisticated cold spray repair facility, developed under an OSD (Office of Secretary of Defense) Manufacturing Technology Program managed by ARL. The facility is built around a totally automated modular concept and operates within a Flexible Robot Environment (FRE) incorporating a gantry robot that will control all of the operations associated with the repair and additive manufacturing of components. The system will have the capability of performing all of the following functions in sequence including; dimensional analysis, nondestructive inspection, surface preparation/blending, cold spray, final machining and final inspection. Other key core members of the OSD Mantech Program include; PEDCO, HF Webster, Cybernet, Sikorsky, South Dakota School of Mines, WPI, Flame Spray Industries, Bicommerce, NAVAIR, Tinker AFB, Corpus Christi Army Depot and the Army Aviation and Missile Command.


CSAT Mission: The Cold Spray Action Team (CSAT) serves as a forum to exchange ideas amongst the Department of Defense (DoD), private industry and academia and to collaborate for the purpose of implementing and transitioning cold spray technology. The practical uses of Cold Spray are growing to the point where the technology has entered and number of industries including; the Aerospace and Defense market as a solution distinct from thermal spray.  The MIL Spec (MIL-STD-2031 DOD Manufacturing Process Standard, Materials Deposition, Cold Spray) has been adopted throughout the world and the number of aerospace-qualified repair procedures are growing.  For example, cold spray has been qualified for use by the Army through Maintenance Engineering Order T-7631 by the Program Office UH-60 Blackhawk for the repair of magnesium aerospace components. It is also being used for landing gear hydraulics for the B1 Bomber, and it has been demonstrated by ARL in collaboration with private industry for applications for additive manufacturing as diverse as near-net forming of shape charge liners, donor tubes for explosive cladding and sputter targets.

There are a number of ongoing RDT&E programs under way in laboratories across the world, and service providers are beginning to offer Cold Spray processes for production and overhaul.  As we found with thermal spray, Cold Spray technology will move into the marketplace much more quickly and smoothly if users, spray shops and equipment and powder supplier’s work together to share information, develop the engineering data and match the technology to the best applications.

Questions, comments and ideas are encouraged.  We want to ensure that we incorporate different ideas, needs and viewpoints to make the team as useful and successful as possible. There are many ARL industry partners who are willing to share cold spray materials data with the CSAT and include Magnesium Elektron, Rosebank Engineering, Westinghouse, Mid America, Sikorsky Aircraft Company, VRC, FTG Corporation, and the United Technologies Research Center. These collaborations continue to make CSAT a great success.

For questions, contact:

Cold Spray Action Team

CONTACT for meeting logistics:
Faye Kann
VRC Metal Systems
525 University Loop, Suite 211
Rapid City, SD 57701

During the second day of the CSAT meeting, the CSAT-JTEG WIPT will facilitate a workshop to collaboratively form workgroups in three areas: the development of a CSAT body of knowledge where information and data on new and existing cold spray repair technology developments can be posted and accessed online; a process qualification, certification, specifications, and standards workgroup; and a systems workgroup to provide an educational awareness on the different cold spray systems and their capabilities.  The agenda is as follows:

1300 – 1320 JTEG/CSAT Collaboration Overview – Greg Kilchenstein, OSD-MPP & Vic Champagne, ARL
1320 – 1340 Cold Spray Technology Gaps in DoD and Transition Enablers  – Greg Kilchenstein, OSD-MPP & Vic Champagne, ARL
1340 – 1500 Meeting attendees will divide into the three workgroups below and collaborate/brainstorm to develop the requested plan or design.

  1. “Body of Knowledge”. Develop a plan of action and timeline to establish an online database where information and data on new and existing cold spray repair technology developments can be organized, posted, and accessed.
    1. Determine what data should be collected and shared (e.g.  process development, test results, powders, equipment, and lessons learned), and what mechanisms should be put in place to assist in the data collection.
    2. Identify a format to organize the data and information.
    3. Identify a process to submit data to include approvals if needed.
  2. “Process Qualification, Certification, Specifications, and Standards”. This group will discuss what currently exists, and what gaps needs to be addressed.
  3. “Cold Spray Repair Systems”. This group will discuss cold spray repair system performance criteria and the different cold spray repair systems in use and their respective capabilities. The group will also identify the information sources available to provide an educational awareness on each of these systems.

Workgroup Organization: The idea is to run the 3 groups concurrently with each group having a leader and several facilitators. Ideally, each group would be composed of members from government, industry, and academia. The intent is to take advantage of the experience and knowledge at the meeting and to brainstorm ideas and develop a working plan to accomplish each workgroup’s objectives.

1500 – 1545 Groups present their teams, plans, timelines and/or designs
1545 – 1600 Wrap-up – Greg Kilchenstein, OSD-MPP & Vic Champagne, ARL
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