Deposition of Commercially Pure Titanium Powder Using Low Pressure Cold Spray and Pulsed Gas Dynamic Spray for Aerospace Repairs

The objective of this study is to investigate the feasibility of depositing 1.5 mm thick titanium coatings, as a repair method for aerospace Ti-6Al-4V substrates, using two new commercially available processes: Low Pressure Cold Spray (LPCS) and Pulsed Gas Dynamic Spray (PGDS). The coatings produced were examined and characterized by their porosity level, microhardness, adhesion strength, particle flattening ratio, wipe tests, fracture surface type and wear tests. Phases and chemical composition were determined using X-Ray diffraction analysis and energy dispersive spectroscopy, respectively. It was found that both spraying processes are capable of producing dense, hard and oxide-free coatings using specific parameters. Finally, as a first step towards repair implementation of these processes, damages were simulated on Ti-6Al-4V samples, which were successfully repaired with low porosity and high hardness levels. The feasibility of repairs was confirmed, the next step will consist in qualification testing to assess coating performances under real life application