This video presentation provides a brief overview of the CORSAIR project’s concept, objectives, methodology and expected impact.
Cold Spray Radical Solutions for Aeronautic Improved Repairs (CORSAIR) held its kick-off meeting on June 24th at the Politecnico Di Milano facilities in Milan, Italy. During this one-day event, the partners had the opportunity to meet and decide upon the activities and interactions to be realized in the first months of the project.
Generic presentation of the project's challenges, objectives, methodologies and expected results.
Generic presentation of the project's challenges, objectives, methodologies and expected results.
Generic presentation of the project's challenges, objectives, methodologies and expected results.
An introductory overview of the CORSAIR project was realized on October 10th, during the 3rd EASN Workshop in Aerostructures. The workshop was held in Milan, Italy and was part of the celebratory activities of the 150th Anniversary of Politecnico di Milano.
The video shows the deposition of an Al alloy for repairing a section of a Mg-based fan case frame. The camera focuses into the TWI cold spray laboratory to show other equipment including the waste particle collection unit, the gas compound, the powder feeder and control unit, and finishes with some coated samples. This video is courtesy of TWI.
The 1rst Progress Meeting of CORSAIR took place on Wednesday, February 5th 2014, at the premises of Universidad Rey Juan Carlos(URJC) in Madrid, Spain. This was a very important assembly, being the first time after the project Kick-Off for partners to meet and discuss their technical progress, findings and dilemmas so far. CORSAIR’s first step was to match the industrial needs of MRO divisions with the experimental plan for cold spray characteristics and capabilities. A collection of components listing properties of each part, its damage and required feature repairs has been assembled with inputs from the industrial partners. An initial list of materials of interest includes Al2024, Ti64, WE43 and powder materials are being prepared accordingly. Experiments will include adhesion and cohesion tests, static and fatigue characterization as well as plans regarding the electrochemical and corrosion resistance of materials. Next steps focus on the design of new nozzles and powder feeders for an innovative portable plant.
The video presents adherence tests following ASTM 4541 performed onto cold sprayed AA2024 coatings using Automatic PosiTest® Pull-Off Adhesion Tester. This video is courtesy of URJC.
The following video presents adherence tests following ASTM 4541 performed onto cold sprayed Ti6Al4V coatings using Automatic PosiTest® Pull-Off Adhesion Tester. This video is courtesy of URJC.
Represented by the Politecnico di Milano, the CORSAIR project will be briefly presented in EUCOSS 2014, involving key actors in the field of Cold Spray. The symposium will take place on May 26th in Paris, and it is organized by MINES ParisTech Graduate School.
During the first year of development (01/06/2013-31/05/2014) activities included the collection and definition of industrial (end-user) requirements for the aeronautical parts to be repaired by Cold spray. Laboratory work also included the realization of simulation models to give the basis for technological developments, as well as the study of electro-chemical properties with respect to different alloys (Al, Mg, Ti). Finally, studies on the optimization of feedstock powders are being realized. An inner coating device has already been developed while work on the design of innovative nozzles and the mobile repairing system are progressing.
The details of more than 25 different Al, Ti and Mg alloys components coming from 4 large industries, and the related defects to be repaired within the project, have been collected, described and included in a summarizing “Component Chart”. Starting from this Chart, a complete set of materials, powders, experiments, specimens’ type and use, characterization and quality control plan, as well as the guidelines to develop new models to describe the deposition process and equipment have been defined. The image above presents a specific specimen studied and designed to perform fatigue tests on cold sprayed material (axial defect geometry). The image below presents a coating sheet defined in order to provide a quick tool to describe the main mechanical and microstructural characteristics of a specific coating related to a specific deposition process.
Two important parameters in cold spray deposition are the particle’s impact velocity, related to cold spray apparatus, deposition parameters and nozzle type, and the critical velocity, which is an intrinsic property of feedstock materials. No particle adhesion to the substrate occurs if the impact velocity is below the critical velocity. A computational fluid dynamic (CFD) model was used to estimate the particle impact velocity for given processing parameters. The model was also utilized as a tool for a new nozzle design based on optimum powder acceleration. A finite element simulation of powder particle impact onto the substrate was developed based on the CFD outputs. Furthermore, the critical velocity for Al2024 and Ti6Al4V was calculated using finite element simulation. The image presents a finite element simulation of Al2024 powder deformation onto the same substrate at impact velocity of 550 m/s. Severe deformation occurs at the rim of the powder with a material jet forming characteristic. Bonding in cold spray deposition begins in the same region.
The 2nd Progress Meeting of CORSAIR took place on July 3rd-4rth, 2014, at the premises of TWI Technology Center Yorkshire in Sheffield, UK. Having completed the first year of the project, the consortium presented and discussed the ongoing progress, achieved results and future actions. After the meeting, the partners had the opportunity to visit the TWI labarotory and its hosted technologies.
Poster focusing on the development of novel nozzle design. The poster was developed for the needs of the project’s exhibition at the 5th EASN Workshop on Aerostructures.
Poster presenting an overview of the activities realized by the end of the second year. The poster was developed for the needs of the project’s exhibition at the 5th EASN Workshop on Aerostructures.
An inner coating device (ID gun) was developed for the repair of bore holes with different diameters. The ID gun will be used for the repair of Aluminum housings, casing covers and other aircraft parts with high value. It can be used for a minimum diameter of 80mm. The image presents the developed inner coating device (ID gun) with nozzles.
A prototype of the new powder feeder, to be integrated into the mobile CG system, is manufactured and currently under the first tests. The image presents the developed KHAI-IMPACT powder feeder.
During the spraying tests performed in the cold spray facility at VN, it was observed that the adaptation and installation of a specific water cooling of the nozzle (developed within WP3) at the ID gun equipped with a SiC nozzle, allowed the achievement of gas temperature up to 600°C without causing nozzle clogging, even after more than 20 h operations (20 min operations is the limit without this improvement), thus enabling the realization of a fully reliable process. A2024 (wrought alloy) and A357 (cast alloy) alloys have been tested up to now as the two more representative alloys for the realization of aircraft parts and gearbox & housings respectively. Concerning the coatings properties the achievement of cohesive strength up to 400 MPa (100 % of the base material strength) and bond strength higher than 50 MPa in case of A2024 on A2024 as reported in the graph below with a more than 100 % increase with respect to the traditional state-of-art process carried out at 350°C. Moreover deposition efficiency has been more than doubled. Further experiments to define the optimized deposition protocol with A2024 and A357 as well the realization of a complete plan of tests also with 7xxx alloys and Mg alloys are both planned and they will be carried out soon. The image presents a SiC nozzle and water cooling device provided by IMPACT, un-mounted (left) and mounted on the CS gun (right).
The following video presents the deformation, material jet formation and temperature distribution of Al2024 particle at 650 m/s impact velocity. This video is courtesy of POLIMI.
Material jet formation in the particle acts as a crucial precursor of adhesion. An effective and novel finite element simulation was developed as a complementary model the previous simulations to provide better understanding of material jet formation and growth for Al2024 and Ti6Al4V particles. General deformation, induced plastic strain, temperature rise in the particle and in particular in the material jet and eventually a critical discussion on critical velocity of the two materials is given. The image presents general deformation, material jet formation and temperature distribution of Al2024 and Ti6Al4V powder particles beyond the critical impact velocity.
The 3nd Progress Meeting of CORSAIR took place on December 2nd-3rd, 2014, at the premises of the European Commission in Brussels, Belgium. During this two-day meeting, the consortium discussed its latest and planned actions realized during the last semester, but also reflected on the progress achieved during the first half of the project’s lifetime. This was also CORSAIR’s 1st Review meeting, where partners had the opportunity to discuss their work with the project officer, Dr. Andreas Wiesinger, and discuss upon future items.
ITSC, the world’s foremost international conference and exposition for thermal spray technologists, researchers, manufacturers and suppliers took place at Long Beach, California, USA on May 11th-14th, 2015. The program featured the latest advanced technology, research and development, and a wealth of resources on thermal and cold spray techniques. CORSAIR participated with multiple presentations.
During the second year of development (01/06/2014-31/05/2015), the partners are narrowing down on the key parameters and the definition of optimized designs and processes. The CORSAIR Portable Cold Spray Unit is being developed using novelty designs for optimized performance. The developed technologies (equipment and feedstock) are being tested by the partners, providing a very positive feedback on the overall performance.
The 4th CORSAIR meeting, marking the end of its second year, took place on June 23rd-24th, 2015, at Skiathos Island, Greece. Having completed more than half of the project, the partners had the opportunity to discuss in person their latest finding and progress. In particular, the work realized on the repairing samples was discussed in connection to the development of the Cold Spray Portable Unit, towards determining new requirements, solutions and techniques for the repair operations which will focus on the validation of the technology, during its last year. The overall progress is ongoing according to the scheduled tasks and milestones, and all partners have actively contributed to the generation of significant results so far.
Through a series of presentations, CORSAIR organized its participation at the 4th International Conference of Engineering Against Failure (ICEAF IV) , which took in Skiathos Island, Greece on June 24-26, 2015. The scope of the Conference is to attract interdisciplinary work dedicated to the design against, and prevention of, engineering failure. Works are expected to cover a number of different technological areas applied in Aeronautics, Construction, Automotive, Bioengineering, Recycling, and more. CORSAIR partners are participating in a dedicated cold-spray session organized within the event.
Over 90 Industrial Members and technical experts visited TWI for the company’s first open day in over eight years. It was a day to showcase the breadth of new and existing expertise, capabilities and services at the culmination of a £60m build project to establish technical facilities for a new era of research and education in materials joining and engineering. During this all-day event, both a poster and banner from the CORSAIR project (an FP7 project, using funding allocated by the European Union’s Seventh Framework Programme for research, technological development and demonstration. Grant Agreement no. ACS3-GA-2013-605207) were showcased, highlighting aerospace related research into the key technology of cold spray deposition.
Poster focusing on the development of FE damage models and nozzle optimization techniques. The poster was developed for the needs of the project’s exhibition at the AERODAYS 2015 Conference
Poster presenting the developed CORSAIR Portable Cold Spray Unit. The poster was developed for the needs of the project’s exhibition at the AERODAYS 2015 Conference
CORSAIR participated at one of the most important events for the European Aeronautics sector, the AERODAYS 2015 Conference, which took place on October 20-23, 2015 in London, UK. A presentation was given by the project coordinator, Prof. Mario Guagliano, while an exhibition booth showcasing repaired samples and application examples of the technology was also set up. A detailed video depicting the activities of the project was further displayed. This participation was an opportunity for the attending partners to discuss CORSAIR with similar research projects (e.g. REPAIR, ALAMSA) and interested stakeholders.
CORSAIR was represented by METALOGIC in the “Industrial Valorisation of Aviation research at KU Leuven – Association and development of a joint strategy for research and innovation” a workshop co-organized by the Leuven centre for Aero & Space Science Technology and Applications (LASA) and the Flemish Aerospace Group (FLAG). The objective of LASA was to bring together all relevant research efforts and to present this as a consolidated portfolio to the aviation industry sector in Flanders. To enable personal contacts, the organizing groups at KU Leuven initiated together with the Flemish Aerospace Group (FLAG) a workshop for facilitating contacts between academia and aviation industry. The target was a) to present research results and expertise, b) to report on running commercialisation activities, c) to inspire new opportunities as well as d) to enable a free debate about the general situation of aviation research in Flanders.
The 5th CORSAIR meeting took place on December 3rd-4th, 2015, at the European Commission Offices at Convent Garden, in Brussels, Belgium. Being at the mid-term of the third year, the meeting was an important opportunity to elaborate on the repairing efficiency of the CORSAIR technology, with regards to the novel equipment (powder feeder, nozzles) and the novel feed-stock developed. Engaging dialogues focused on the performances of different feed-stock and varying alloys, as well as on possible post-treatment processes to be examined. The meeting was also a good opportunity to discuss important issues with regards to the management of the remaining activities and the collaboration of the partners on future topics. Finally, the project officer Andreas Wiesinger, attended the meeting and provided his feedback on the ongoing and planned activities, while remarking the overall good progress of the project.
We'd love to hear from you. Please send questions or feedback to the below email addresses.
Before contacting us, you may wish to visit our FAQs page which has lots of useful info on Tiki-Toki.
We can be contacted by email at: hello@tiki-toki.com.
You can also follow us on twitter at twitter.com/tiki_toki.
If you are having any problems with Tiki-Toki, please contact us as at: help@tiki-toki.com
Close