Developing a Qualification and Testing Framework for Cold Spray Repairs in Aerospace Applications

Abstract

Cold spray is a solid-state deposition technology with great potential for coating and repair applications. This study examines the compliance of the cold spray repair process with a qualification and testing framework based on the requirements set by the European Union Aviation Safety Agency (EASA). As part of this effort, the case study of a repair of a Main Landing Gear (MLG) aluminium component is investigated to demonstrate the applicability of the proposed framework. This framework integrates mechanical and microstructural evaluations, including bond strength, hardness profiling and microstructural characterisation according to relevant ASTM and ISO standards. Experimental results from post-repair testing indicated promising performance, while ongoing testing is aligning reasonably with expected benchmarks and showing compliance with the EASA requirements.