NCAME & 6K Additive Tackle Cold Spray Repair Data Gap

Researchers at Auburn University's National Center for Additive Manufacturing Excellence (NCAME) have initiated a study with metal powder producer 6K Additive. The project's primary objective is to evaluate the performance of cold spray feedstock materials under demanding conditions, addressing a critical lack of mechanical performance data that has hindered the technology's use in repair.

Mikyle Paul, NCAME research engineer leading the project, stated that the study aims to understand how cold spray materials behave during repair and sustainment operations in challenging environments. The team will assess the mechanical performance and strength of various feedstock materials to develop data that can inform future repair strategies for essential components in defense and industrial sectors.

The experimental work will utilize NCAME's VRC Gen IV Cold Spray System. The findings are expected to enhance the understanding of cold spray material behavior during field repairs, where structural reliability is paramount. Scot Carpenter, NCAME laboratories manager, noted that by clarifying the strengths and limitations of these materials, the project can accelerate their integration into real-world repair scenarios, considering factors like downtime, cost, and operational readiness.

Cold spray technology has long been recognized for its potential in defense and industrial repair due to its ability to deposit material without melting, thus preserving substrate integrity and allowing for field deployment. However, the consistent obstacle has been the absence of standardized mechanical performance benchmarks for specific materials and conditions, preventing procurement and maintenance engineers from confidently qualifying the process for critical component repairs. This NCAME project directly targets this bottleneck by generating the necessary evidence base for broader adoption.