Improved Hardware Sustainment Through Solid State Additive Manufacturing Development – Phase II

NCMS Project #: 142020

Problem: A new technologies are rolled out into new products, the ability to upgrade previous generations of hardware becomes more critical.  This could be the addition of corrosion barriers or protection layers, the addition of wear surfaces, or even the addition of features like bosses, brackets, etc.  This project aims to advance the understanding of the Cold Spray process for repair and modification of aerospace and ground vehicle systems in both commercial and DoD applications. 

Benefit: The results will be to greatly enhance DoD maintenance for aerospace and ground vehicles while at the same time developing the materials and systems which can be leveraged by private industry to enable repair of the commercial fleets of aerospace and ground vehicles.

Solution/Approach: The project has matured and undergone some initial technology evaluations and testing, exposing the need to more fully define and develop some tasks and deliverables.  Phase II will build upon the technical discoveries and additional research requirements exposed during the Phase I effort, utilizing an approach that improves communication and collaboration to coordinate, integrate and consolidate the research and results enabling new cold spray powders, materials, processes and hardware for rapid transition

Impact on Warfighter:

  • Fabricate/coat critical parts reliably, repeatedly, safely and quickly
  • Expand the materials, systems and processes available
  • Secure streamlined supply chain
  • Reduce overall maintenance and sustainment costs and equipment downtime
  • Increase warfighter readiness and lethality

DOD Participation:

  • U.S. Army Research Labs
  • U.S. Air Force
  • U.S. Army
  • U.S. Navy Air Command

Industry Participation:

  • VRC Metal Systems
  • University of Massachusetts Amherst
  • Mississippi State University
  • NCMS

Benefit Area(s):

  • Repair turn-around time
  • Maintenance avoidance and reliability
  • Energy efficiency
  • Durability
  • Lightweighting

Focus Area:

  • Advanced/additive manufacturing