Cold Spray Repaired Aluminium Research Impresses at MS&T23

NSIRC Research into Cold Spray Repaired AA7075 Could Reduce Costs, Maintenance Time, and Environmental Impact for the Aerospace Industry.

Columbus, Ohio - NSIRC PhD student Ali Alperen Bakır presented his latest research on “Structural Integrity Assessment of Cold Spray Repaired High-Strength Aluminium 7075 Specimens" at Materials Science & Technology (MS&T) 23 in Columbus, Ohio. The conference provided Ali with an opportunity to share his insights and collaborate with fellow material scientists.

The MS&T technical meeting and exhibition series is a long-standing, recognised forum for fostering technical innovation at the intersection of materials science, engineering, and application. At MS&T conferences, participants can learn from those who are on the cutting edge of their disciplines, share their work with the leading minds in their field, and build valuable cross-disciplinary collaborations unique to this conference series.

Ali's research is significant in the aerospace industry, where the repair of high-strength aluminium components is a crucial requirement. The use of cold spray (CS) as a repair technique has the potential to reduce costs, minimise maintenance time, and have a positive environmental impact. Ali's research aims to address the concerns regarding the mechanical performance of cold spray repaired specimens, thereby making it a viable solution for the aerospace industry.

Aluminium Alloy AA7075 is a popular material used in the aerospace industry, especially for wing skins, due to its high strength-to-weight ratio and durability. However, these components get damaged over time due to cyclic loading and corrosion.

Repairing these components is challenging due to the temperature sensitivity of the material. High-temperature repair processes are not viable due to the temperature and oxidation sensitivity of this material.

CS, on the other hand, offers solid-state deposition to repair these components. It uses microscopic metal particles accelerated to supersonic velocity, and is used for the deposition of functional coatings that can improve properties such as wear and corrosion resistance.

However, since CS is a new technology, using it in industry is still a concern. Little is known about the mechanical performance of CS-repaired specimens, particularly due to porosity, interface defects, and lack of ductility.

Ali's project aims to assess the structural integrity of these repaired parts in order to understand if the repaired components are structurally safe under mechanical loading.

A third-year PhD student, Ali completed his BSc in mechanical engineering at Middle East Technical University. He then gained his MSc from Nottingham University, where he worked on the creep behaviour of additively manufactured Inconel 718.

"I would like to thank the National Structural Integrity Research Centre, Coventry University, and Lloyd's Register Foundation for their support," said Ali. "Let's keep pushing the boundaries of innovation!"

Ali's research demonstrates the potential of CS as a repair technique for high-strength aluminium components. His work can have a significant impact on the aerospace industry by providing an effective and environmentally friendly alternative to traditional repair techniques.