CTMA Project #: 142152
Problem: Recent advances in commercial cold spray technologies and processes have shown to be very effective at protecting parts from corrosion and repairing damaged parts. However, it is challenging to apply these coatings to parts of intricate or complex geometry or to the inside of cylindrical bores. Using one orientation of a nozzle to apply the coating may not work in parts that are long and have confined spaces such as long pipes used in the oil industry. In prior work, it was recognized that process consistency needs to be improved and that coating inside cylindrical bores needs to be developed and productionized. Process variabilities affect the application of the coating, which in turn affect product performance. Upgrades to hardware for better powder feeding, better spraying, in-process monitoring, and gas reclamation are needed to improve coating quality and reduce process cost with reduced waste.
Benefit: The completion of these tasks will serve as an example to commercial industry on how new materials and processes can be used to better protect the environment while protecting complex machinery and parts from damage. This will reduce necessary maintenance, increase safety of the maintainers, and increase the lifespan of the parts.
Solution/Approach: Phase II will continue to develop the advanced manufacturing process and capability to apply a high temperature, wear resistant cold spray coating to the inner diameter of large caliber tubes and machine that coating to blueprint geometry and specifications using waterjet milling. The U.S. Army will use coupons and sub-scale sections for process development and materials screening, progressing to longer cannon tube sections and full-length tubes to demonstrate and validate the process. Combining current advanced manufacturing methods such as cold spray and waterjet technologies along with new materials, this initiative will assess possible replacements for chrome plated barrel liners. These new materials and techniques will result in longer lasting barrels that are easier to maintain and affordably sustain.
Impact on Warfighter:
- Reduce equipment and weapon system down time
- Enhance warfighter readiness
- Decrease maintenance and sustainment costs
DOD Participation:
- U.S. Army Combat Capabilities Development Command (DEVCOM) – Army Research Laboratory (ARL)
- U.S. Army DEVCOM Armaments Center – Benet Laboratories and Watervliet Arsenal
- Program Executive Office Ground Combat Systems (PEO GCS)
- Project Manager Main Battle Tank Systems (PM MBTS)
- Project Manager Self Propelled Howitzer Systems (PM SPHS)
- Product Manager Extended Range Cannon Artillery PdM (ERCA)
Industry Participation:
- Solvus Global
- VRC Metal Systems
- NCMS
Benefit Area(s):
- Cost savings
- Repair turn-around time
- Maintenance avoidance and reliability
- Obsolescence management and continued maintenance capability
- Positive environmental impact
- Safety
- Maintenance management improvement
- Improved readiness
- Survivability
- Durability
- Reliability improvement
Focus Area:
- Advanced/additive manufacturing
