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Cold-Spray Application For In-Field Corrosion And Damage Repair

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The need for corrosion mitigation and repair is a perennial concern for a wide array of industries. An attractive evolution in coatings application for mitigating the effects of environmental/operational degradation is cold spray of metallic replacement layers. As cold spray technologies continue to become more commonplace, portable, low-pressure cold spray systems presents an opportunity to bring metallic repair to the field for heavily damaged or corroded assets.

Product Number: 51323-19086-SG
Author: Joshua P. James
Publication Date: 2023
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The ability to repair corroded assets in situ or at least prior to full-scale teardown (without decommissioning) ultimately improves productivity, readiness, and reliability. This research seeks to understand the applicability of cold spray to in-field repair of damaged assets, specifically those structures that have suffered deleterious corrosion. Patch repair via cold spray presents an opportunity to avoid expensive tear down and rehabilitation. However, the differing metallic compositions of cold spray powders and the formation of discontinuous interfaces at the edges of the applied patch may serve to simply change the corrosion mechanism affecting the asset. This work details the characterization of aluminum cold spray patches applied on structural substrates for general corrosion resistance, adverse galvanic interactions, and the nature of the bond at the diffuse edges of repair patch borders.

The ability to repair corroded assets in situ or at least prior to full-scale teardown (without decommissioning) ultimately improves productivity, readiness, and reliability. This research seeks to understand the applicability of cold spray to in-field repair of damaged assets, specifically those structures that have suffered deleterious corrosion. Patch repair via cold spray presents an opportunity to avoid expensive tear down and rehabilitation. However, the differing metallic compositions of cold spray powders and the formation of discontinuous interfaces at the edges of the applied patch may serve to simply change the corrosion mechanism affecting the asset. This work details the characterization of aluminum cold spray patches applied on structural substrates for general corrosion resistance, adverse galvanic interactions, and the nature of the bond at the diffuse edges of repair patch borders.

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