Application of High-Pressure Cold Spray for an Internal Bore Repair of a Navy Valve Actuator

Cold spray is a reduced temperature, supersonic thermal spray process that is increasingly being used to perform repairs on high-value components. In this case, a valve actuator internal bore sealing surface was repaired on an aluminum 6061 hydraulic valve body using high-pressure cold spray. Corrosion damage to non-critical surfaces was also repaired, allowing the part to be returned to service. A high-pressure cold spray system was used to deposit gas-atomized 6061 aluminum powder using helium. The internal bore surfaces were approximately 100 mm in diameter with a depth of nearly 200 mm, and were sprayed using a 45° nozzle 65 mm in length. Modeling predictions validated the approach, and were used to identify a favorable nozzle geometry and process window combination. The minimum required adhesion strength on critical surfaces was 69 MPa. The average adhesion strength was 71.4 MPa, with glue failures on ASTM C633 bond test specimens. The actuator subsequently passed all bench top service related testing, was qualified as an approved repair, and is now in service. This was a first of its kind repair for cold spray, and demonstrates that it is a viable repair technology and is ready for broader implementation.