According to a report by the US Army Research Laboratory on May 17, 2015, the US Army Research Laboratory has teamed up with the University of South Dakota to develop a new generation of hybrid cold spray systems that will be transferred throughout the Department of Defense. Technology will save users millions of dollars in maintenance costs.
In the cold spray process, the powder is impacted on the surface of the damaged part at supersonic speed, and then a dense solid material adhered to the surface of the substrate is formed to restore the part to its original size. The cold spray process is mainly used to repair some expensive and difficult-to-access parts of military aircraft, vehicles and submarines, such as costing hundreds of thousands of dollars, or difficulty in acquisition due to long lead times or discontinued production.
The Army Research Laboratory has signed a joint ownership agreement with the University of South Dakota Mining University. According to Victor Champagne of the Army Research Laboratory Weapons and Equipment Research Division, the commercialization of this cold spray system is called "VRC third generation" and represents the world's most versatile high pressure cold spray system. Requirements of the Department of Defense and its contractors. The system covers an area of ​​only 0.91m x 1.52m and is wheeled for easy use during production, repair or on-site. It can be operated by hand or by a robotic arm, which is also a highlight of the system, especially for military purposes.
Champagne also said that the repair of damaged hydraulic pipe fittings is the most time-consuming on the B-1 bomber, and the accumulated repair time per year exceeds 5,000 man-hours. In March 2009, in the US Air Force-funded Aircraft Maintenance Feasibility Study Project, the Army Research Laboratory developed a hydraulic pipe/skin siding cold spray repair/preventive maintenance process for the B-1 bomber, in a damaged The flight test of the aircraft landing gear hydraulic accumulator was carried out for more than 6 years (3000 flight hours). In January 2011, additional cold spray hydraulic hoses (4 years, more than 4,000 combined flight hours) were installed on the wing spoiler and the two main landing gears. In June 2012, a front equipment panel was also repaired using the cold spray process. Global Coatings understands that these components have been selected for testing because they represent some of the most demanding application requirements and will deliver the highest expected results or benefits in terms of aircraft performance or cost savings. For example, only the cost savings of front equipment panel repairs exceeds $220,000. If applied to the entire aircraft, the cost savings will increase by two orders of magnitude.
It was the success of these flight tests and the need for combatants to improve aircraft availability that prompted the Air Force Combat Command to support the implementation of cold spray technology at Ellsworth Air Force Base, South Dakota, and Days Air Force Base, Texas.
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