A600438 - Cold Spray Al MIL 83488

Qualification of Cold Spray for
Repair of MIL-DTL-83488 Aluminum

Coatings
Stephen Gaydos
ASETSDefense Workshop
9 February 2011
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1. REPORT DATE 3. DATES COVERED

2. REPORT TYPE
09 FEB 2011 00-00-2011 to 00-00-2011
4. TITLE AND SUBTITLE 5a. CONTRACT NUMBER
Qualification of Cold Spray for Repair of MIL-DTL-83488 Aluminum 5b. GRANT NUMBER
Coatings
5c. PROGRAM ELEMENT NUMBER
6. AUTHOR(S) 5d. PROJECT NUMBER
5e. TASK NUMBER
5f. WORK UNIT NUMBER
7. PERFORMING ORGANIZATION NAME(S) AND ADDRESS(ES) 8. PERFORMING ORGANIZATION

REPORT NUMBER
Boeing,P. O. Box 516,St. Louis,MO,63166
9. SPONSORING/MONITORING AGENCY NAME(S) AND ADDRESS(ES) 10. SPONSOR/MONITOR’S ACRONYM(S)
11. SPONSOR/MONITOR’S REPORT

NUMBER(S)
12. DISTRIBUTION/AVAILABILITY STATEMENT

Approved for public release; distribution unlimited
13. SUPPLEMENTARY NOTES
ASETSDefense 2011: Sustainable Surface Engineering for Aerospace and Defense Workshop, February 7 -
10, 2011, New Orleans, LA. Sponsored by SERDP/ESTCP.
14. ABSTRACT
15. SUBJECT TERMS
16. SECURITY CLASSIFICATION OF: 17. LIMITATION OF 18. NUMBER 19a. NAME OF
ABSTRACT OF PAGES RESPONSIBLE PERSON
a. REPORT b. ABSTRACT c. THIS PAGE Same as 47
unclassified unclassified unclassified Report (SAR)
Standard Form 298 (Rev. 8-98)

Prescribed by ANSI Std Z39-18
ASC/ENVV Project Information
Engineering, Operations & Technology | Boeing Research & Technology Chemical Technology
• POP - 24 month project

• 7-31-2007 to 9-30-2009
• Final Report 10-30-2009
• Objectives
• Identify Portable Cold Spray Equipment
• Develop Procedures to Repair Damaged IVD Aluminum
Coatings
• Certify Cold Spray Process to Meet Requirements in
MIL-DTL-83488
– Cold Spray Process Can Also be Used to Repair any Damaged
Aluminum Coating
– Aluminplate, Sputter Aluminum, or CVD Aluminum
• Program Manager – Brian Tobin ASC/ENVV

Copyright © 2010 Boeing. All rights reserved. EOT_TE_Sub_Template.ppt | 2
Cold Spray Equipment Selection Criteria
• Equipment Requirements
• Portable
• Easy to operate
• Safe to operate
• Low cost to operate
• Apply aluminum coatings (1 to 3 mil thick)
• Cold Spray Al coating meets MIL-DTL-83488
• Readily available and easy to maintain
– Off the shelf technology

Cold Spray Equipment Suppliers
• Dymet
• CGT
• K-Tech
• Delphi
• Inovati
• Centerline (Dymet)
• ARL

Previous Cold Spray Studies Conducted
• Boeing – Moscow
• Dymet Equipment
• CTMA/NCMS
• ARL, Delphi, Centerline Equipment
• ARL
• ARL and Centerline Equipment
• ASB Industries
• CGT Kinetics
• Centerline
• SST Equipment

Portable Cold Spray Equipment Selected
• Centerline SST • Low cost

• Low Pressure • Easy to operate and
– Air @ 80 to 110 psig maintain
• Portable • Has potential to apply MIL-
• Off the shelf DTL-83488 Aluminum
coatings

Centerline SST Cold Spray Equipment

Installation of SST
• PO Placed February 2008

• Equipment Received May 2008
• Equipment Installed July 2008
• No Problems with Installation
• Cold Spray Equipment Performed Flawlessly
– Programming of Robot was Difficult
– Required Learning a Programming Language
• P-SEL
– Centerline Provided Hands-On Training

Aluminum Powder Selection

440-00239 (KSF-A017-1) – Blended Aluminum

SST-A0017 Particle Size Distribution

Optimization Test Results
• Optimum Gun Conditions to Apply a MIL-DTL-83488

Cold Spray Al Coating
• Stand-off Distance = 0.5 inch (-0.25/+0.5)
• Speed = 100 to 150 mm/sec
• Line Index = 1 to 2 mm
• Air Pressure = 90 to 100 psig
• Temperature = 250 to 300oC
• Flow = 20% (+/- 10%)
• SST-A0017 Blended Aluminum Powder

Optimization Test Results (Cont.)
• Preferred Procedure for Applying MIL-DTL-83488 Cold

Spray Al Coatings
• Degrease with MPK or Desoclean 45
• Grit Blast @ 40 to 60 psig (2 passes) with 80 grit Al Oxide
(white preferred)
• Apply 1 to 3 mil Al coating
– 90 to 100 psig – 250 to 300o C
– Multiple Passes May Be Required
• Glass Bead Burnish @ 40 to 60 psig with #10 Glass Beads
– 100% Adhesion Test (Used for IVD Al Process)

MIL-DTL-83488D Certification Tests
• 3.1.1 - Composition
• 3.2.1 - Process
• 3.2.1.1 - Cleaning
• 3.3 - Areas of Deposit
• 3.4 - Chromate Treatment
• 3.5 - Thickness
• 3.6 - Stripping of Aluminum Coating
• 3.7 - Adhesion
• 3.8 - Corrosion Resistance
• 3.10 - Base Metal Integrity

3.1.1 Composition
Requirement: Coating shall be > 99% Al
Composition of SST-A0017 Al Powder

3.2.1 Process
• Requirement - Process shall not cause a temperature rise

that has an adverse reaction between the coating and the
substrate or adversely affect the substrate.
• For example – If Substrate is High Strength Steel alloy, such as
300M, 4340 or 4130, the temperature shall not exceed 400o F.
• Process Test Performed:

• Apply thermocouples to back side of 0.040 thick steel test panel.
• Apply a 1 to 3 mils of aluminum coating using high gun
temperatures (350o C) on 4x6 inch test panel.
• Check thermocouple readout during metal spraying to insure that
temperature did not exceed 400o F.

3.2.1 Process – Test Set-Up

3.2.1 Process - Test Results (Cont.)

3.2.1.1 Cleaning
• Requirement - Base metal shall be cleaned IAW MIL-S-

5002 or equivalent prior to coating application
• Test Results –
• MIL-S-5002 Cleaning Process Used:
– All test specimens were solvent cleaned and then abrasive
cleaned by grit blasting with aluminum oxide grit (80 grit size).

3.3 Areas of Deposit
• Requirement - Coating shall completely cover all

visible surfaces
• All cold spray aluminum coated test specimens were visually
examined for coverage and found to be acceptable

3.3 Areas of Deposit – Test Results
IVD Aluminum Bare Steel Cold Spray Al Repair
Damaged IVD Aluminum Steel Panel Damaged IVD Aluminum Steel Panel
After Repair with Cold Spray Aluminum
Showing Uniform Aluminum Coating
Over Entire Surface

3.4 Chromate Treatment
• Requirement - Type II specimens shall be conversion

coated per MIL-DTL-5541
• Iridite 14-2 conversion coat was easily applied directly to Type
II Cold Spray Aluminum test specimens.
• Specimens did not require a chemical etch or deoxidize prior

to conversion coating.

3.4 Chromate Treatment – Test Results
Type II Conversion Coating on Cold Spray Al

3.5 Thickness
• Thickness Requirement for Class 1 Aluminum Coating

• 0.001 inch (Min) and thickness shall not exceed 0.003 inch.
• Cold spray aluminum coating shall be free of any defects and
base metal shall also be free of any irregularities.
• Test Procedure –
• Measure thickness on aluminum coated steel test strips with a
magnetic induction thickness gage (DeFelsko Positector).
• Aluminum coating thickness on test specimens shall be
Class 1.
• Also measure thickness and determine workmanship (see
requirement 3.9) by micro-examination of metallographic
cross-sections.

3.5 Thickness - Test Results

3.6 Stripping of Aluminum Coatings
• Requirement - Remove cold spray aluminum coating

on steel by stripping in a caustic solution, Steel parts
> Rc 40 shall be hydrogen embrittlement relief baked
for appropriate time and temp.
• Strip 4 aluminum coated test strips in caustic etch to remove
aluminum cold spray coating.
• Strip in a caustic solution containing 14 to 18 ounces of
sodium hydroxide per gallon of water at a temperature of 120o
to 130o F.
• Verify complete removal on two of the stripped specimens by
examining surface for aluminum by SEM/EDX analysis.
• Apply a Class 1 (1 to 3 mils) cold spray aluminum coating to
the remaining two specimens and perform a glass bead
burnish adhesion test on them to verify good adhesion.

3.6 Stripping – Test Results
Cold Spray Al Coating Stripped from Steel
Cold Spray Al Coating Reapplied and Bend-to-Break

Adhesion Test Performed
Stripped (Top) – Recoated (Bottom)

3.6 - Stripping Test Results (Cont.)
• SEM/EDX Analyses Conducted to verify that all Cold

Spray Aluminum Coating was Removed by Caustic
(NaOH) Stripping Solution

SEM/EDX Analysis for Steel Surface After Stripping Cold
Spray Aluminum Coating in NaOH Solution
Residual Aluminum Oxide Particles Found Embedded in Steel

Copyright © 2010 Boeing. All rights reserved.
but No Residual Cold Spray Al Coating Found
EOT_TE_Sub_Template.ppt | 29
3.7 Adhesion
• Requirement - When tested per 4.4.2 (of MIL-DTL-

83488) the adhesion of the coating shall not show
separation from the base metal
• First perform magnetic induction thickness test on cold spray
aluminum coated 1x4x.040 steel strips to verify Class 1
thickness
• Next perform glass bead burnishing tests on the cold spray

aluminum coated test specimens
• Finally perform strip rupture tests (bend-to-break) on the cold

spray aluminum coated test specimens.

3.7 Adhesion – Glass Bead Burnish Test Results
IVD Al Coating Cold Spray Aluminum Coating
Bad Good Good
Bare Steel
Example of Good and Bad Adhesion After Glass Bead Burnishing

At 60 psig with #10 Glass Beads
Test Specimen with Cold Spray Al on Steel / IVD
View #1 View #3
View #4
Cold Spray Al View #2
IVD Al
Coating
Steel Substrate

3.7 Adhesion – Bend-to-Break Test Results
Cold Spray Al on IVD

(View #3)
Cold Spray Al on Steel

(View #1)
Cold Spray Al Coating Passed Bend-To-Break Adhesion Test

on Bare Steel and IVD Coated Steel
3.8 Corrosion Resistance
• Requirement - When tested per 4.4.3 (of MIL-DTL-

83488) the test samples shall show no evidence of
corrosion of the base metal after testing per Table 1 (of
MIL-DTL-83488).
• Mask the uncoated edges and back side of 4x6x0.040 cold
spray aluminum coated steel test specimens with masking
tape
• Subject the masked test specimens to ASTM B 117 neutral salt
spray for:
– 504 hrs. minimum for Class 1, Type I specimens
– 672 hrs. minimum for Class 1, Type II specimens
• Look for red rust after required exposure times and no red
rust is passing

3.8 Corrosion Resistance – Test Results
1000 Hours in ASTM B 117 (Scribed Corrosion Test) –

Cold Spray Al on Steel (Left) and Cold Spray Al on Damaged IVD Al (Right) –
No Red Rust Observed on Scribed Test Panels
3.10 Base Metal Integrity
• Requirement - For aluminum parts, after application of

cold spray aluminum coating, check the Rockwell B
hardness and verify that hardness did not vary by 3
points and still meets the hardness range for the
aluminum alloy and temper being inspected.
• Apply cold spray aluminum to two 3x6 pieces of 7075-T6
aluminum
– Coat one at 250o C and the other at 300o C spray gun
temperatures
• Check hardness and conductivity before and after cold spray
application

3.10 Base Metal Integrity – Test Results
Specimen Results HRb Pre Coating (% IACS)
Plate 1 91.7 32.9

91.8
92.0
Average 91.8
Plate 2 91.7 33.0

91.8
91.9
Average 91.8
After Coating
Plate 1 92.2
o
300 C 92.3
92.5
Average 92.3 32.8
Plate 2 Not Done.

o
250 C

Health Risk Assessment
• HRA of Cold Spray Equipment was Performed at

Boeing – STL
• Air Force does not want to introduce a hazardous coating
process into their ALCs (Air Logistic Centers)
– New Cold Spray Aluminum Coating Process Shall Not be Harmful
to Workers or Environment
• HRA Requirements specified in:
– AIR FORCE MANUAL 48-153 (28 MARCH 2007)

HRA for Cold Spray Aluminum Technology
• Parameters Used For Operation Of Cold Spray Unit

• Gas – Air
• Pressure – 90 to 100 psig
• Gas Temperature – 250 to 300oC
• Stand-off Distance ~ 0.5 inch
• Travel Speed ~ 100 to 150 mm/sec
• Line to Line Index ~ 1 to 3 mm
• Aluminum Powder – KSF-AL0017, Centerline
• Powder Flow Rate Setting – 20 to 30%
• Operation Mode – Manual
• Location of Test – Boeing Parking Lot

Cold Spray Equipment Used for HRA
Control Console Air Filter
Spray Gun
Copyright © 2010 Boeing. All rights reserved.
Centerline SST Portable Cold Spray EOT_TE_Sub_Template.ppt | 40
Monitoring For Aluminum Particles During
Portable Cold Spray Operation

HRA Results for Cold Spray Equipment
Average Total Dust: 0.25 mg/m3

Peak Total Dust: 0.51 mg/m3
Average Respirable Dust: 0.073 mg/m3
Peak Respirable Dust : 0.081 mg/m3
OSHA PEL – 15 mg/m3 for Total Dust 5 mg/m3 for Respirable Fraction
NIOSH REL – 10 mg/m3 for Total Dust 5 mg/m3 for Respirable Fraction
ACGIH TLV – 10 mg/m3 for Metal Dust
Recommended Personal Protection
Equipment (PPE)
• Safety glasses with face shield; or safety goggles

• Filtering face piece respirator (i.e. dust mask) if face
shield not utilized
• Disposable gloves (any)
• Disposable coveralls

Conclusions
• Centerline SST Cold Spray Equipment Can Be Used to

Apply MIL-DTL-83488 Aluminum Coatings
• Providing that proper materials and processes are carried out.
• Testing was conducted to repair damaged IVD
Aluminum but Cold Spray Aluminum process could
also be used to repair damaged Alumiplate, Sputter
Aluminum, CVD Aluminum and Ionic Liquid Aluminum
Coatings.
• Additional work is required to use the Cold Spray
process to repair damaged Alclad Aluminum Coatings
• Additional requirements apply for qualifying an Alclad repair
process (e.g. specular reflectance)

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Qualification of Cold Spray for

Repair of MIL-DTL-83488 Aluminum

1. REPORT DATE 3. DATES COVERED

6. AUTHOR(S) 5d. PROJECT NUMBER

5e. TASK NUMBER

5f. WORK UNIT NUMBER

7. PERFORMING ORGANIZATION NAME(S) AND ADDRESS(ES) 8. PERFORMING ORGANIZATION

11. SPONSOR/MONITOR’S REPORT

12. DISTRIBUTION/AVAILABILITY STATEMENT

15. SUBJECT TERMS

Standard Form 298 (Rev. 8-98)

• POP - 24 month project

• Program Manager – Brian Tobin ASC/ENVV

Copyright © 2010 Boeing. All rights reserved. EOT_TE_Sub_Template.ppt | 3

Copyright © 2010 Boeing. All rights reserved. EOT_TE_Sub_Template.ppt | 4

Copyright © 2010 Boeing. All rights reserved. EOT_TE_Sub_Template.ppt | 5

• Centerline SST • Low cost

Copyright © 2010 Boeing. All rights reserved. EOT_TE_Sub_Template.ppt | 6

Copyright © 2010 Boeing. All rights reserved. EOT_TE_Sub_Template.ppt | 7

• PO Placed February 2008

Copyright © 2010 Boeing. All rights reserved. EOT_TE_Sub_Template.ppt | 8

Copyright © 2010 Boeing. All rights reserved. EOT_TE_Sub_Template.ppt | 9

Copyright © 2010 Boeing. All rights reserved. EOT_TE_Sub_Template.ppt | 10

Copyright © 2010 Boeing. All rights reserved. EOT_TE_Sub_Template.ppt | 11

• Optimum Gun Conditions to Apply a MIL-DTL-83488

Copyright © 2010 Boeing. All rights reserved. EOT_TE_Sub_Template.ppt | 12

• Preferred Procedure for Applying MIL-DTL-83488 Cold

Copyright © 2010 Boeing. All rights reserved. EOT_TE_Sub_Template.ppt | 13

Copyright © 2010 Boeing. All rights reserved. EOT_TE_Sub_Template.ppt | 14

Requirement: Coating shall be > 99% Al

Composition of SST-A0017 Al Powder

Copyright © 2010 Boeing. All rights reserved. EOT_TE_Sub_Template.ppt | 15

• Requirement - Process shall not cause a temperature rise

• Process Test Performed:

Copyright © 2010 Boeing. All rights reserved. EOT_TE_Sub_Template.ppt | 16

Copyright © 2010 Boeing. All rights reserved. EOT_TE_Sub_Template.ppt | 17

Copyright © 2010 Boeing. All rights reserved. EOT_TE_Sub_Template.ppt | 18

• Requirement - Base metal shall be cleaned IAW MIL-S-

Copyright © 2010 Boeing. All rights reserved. EOT_TE_Sub_Template.ppt | 19

• Requirement - Coating shall completely cover all

Copyright © 2010 Boeing. All rights reserved. EOT_TE_Sub_Template.ppt | 20

IVD Aluminum Bare Steel Cold Spray Al Repair

Copyright © 2010 Boeing. All rights reserved. EOT_TE_Sub_Template.ppt | 21

• Requirement - Type II specimens shall be conversion

• Specimens did not require a chemical etch or deoxidize prior

Copyright © 2010 Boeing. All rights reserved. EOT_TE_Sub_Template.ppt | 22

Type II Conversion Coating on Cold Spray Al

• Thickness Requirement for Class 1 Aluminum Coating

Copyright © 2010 Boeing. All rights reserved. EOT_TE_Sub_Template.ppt | 24

Copyright © 2010 Boeing. All rights reserved. EOT_TE_Sub_Template.ppt | 25

• Requirement - Remove cold spray aluminum coating

Copyright © 2010 Boeing. All rights reserved. EOT_TE_Sub_Template.ppt | 26

Cold Spray Al Coating Stripped from Steel

Cold Spray Al Coating Reapplied and Bend-to-Break

Stripped (Top) – Recoated (Bottom)

• SEM/EDX Analyses Conducted to verify that all Cold

Copyright © 2010 Boeing. All rights reserved. EOT_TE_Sub_Template.ppt | 28

Residual Aluminum Oxide Particles Found Embedded in Steel

• Requirement - When tested per 4.4.2 (of MIL-DTL-