Kinetic Spray Metal Deposition

NCMS Project #: 140382

Problem: Restoration of metallic surfaces plays a significant role in maintenance activities.  Application of a corrosion-protection package to metallic surfaces (e.g. galvanizing, priming, painting) is a routine maintenance activity.  DoD spends $10-20 billion annually on corrosion prevention and mitigation.  National Association of Corrosion Engineers (NACE) suggests that the National corrosion bill has an annual value exceeding $270 billion.


  • Supports the Oklahoma City Air Logistics Center Lean Cell concepts
  • Reduces the incidence of corrosion that impacts number and frequency of secondary repairs that fail by corrosive failure
  • Supports Albany’s execution of the emerging Depot Support in Theatre (DSIT) which require flexible deposition technologies that may be transported directly into the field.

Solution/Approach: Deliver a suitable technology “ensemble” (including hardware specifications, materials, operating parameters, and validation methods) for the application of kinetic-spray technology to the implementation of galvanic and barrier metallizations for improved corrosion resistance of ferrous and non-ferrous metals as specified by the participating depots.  Implement a kinetic-spray deposition of aluminum, aluminum alloys, zinc, and zinc alloys to provide corrosion protection of ferrous structures, as well as novel protection and restoration schemes for materials of construction including aluminum and magnesium.

Impact on Warfighter: Repair and corrosion protection of most iron, aluminum and magnesium articles for decreased downtime and significant readiness improvement.

DOD Participation:

  • U.S. Air Force (OC-ALC)
  • U.S. Marines (Albany)
  • U.S. Navy (NADEP Cherry Point)

Industry Participation:

  • U.S. Army Research Lab
  • Boeing (defense)
  • Boeing (commercial)
  • Centerline
  • Delphi Research Lab
  • Ford Motor Company
  • Solidica
  • NCMS

Final Report