E&M and innovation
Cold Spray machine inaugurated at KLM E&M
One of the projects within BrightSky is Cold Spray. EPCOR is leading this project. Together with TU Delft, SAM|XL in Delft, the Amsterdam University of Applied Sciences, NLR, and KLM E&M, research is being conducted to determine if cold spray can be used as a certified repair technique in the future. To this end, EPCOR and SAM|XL have installed a medium pressure Cold Spray machine at SAM|XL in Delft.
After the installation of the machine was completed and all safety procedures were followed, EPCOR technicians took their first steps in thermal spraying at SAM|XL in Delft on Wednesday, 20 November. Following a brief instruction from TU Delft, Jeroen Vermond and Rick de Vos operated the Cold Spray machine and conducted the first spray tests themselves.
Rick and Jeroen receiving instructions from Mary Patrick (left) and Stratos Koufis (right) of TU Delft.
To closely simulate real-life conditions, a cold spray repair was performed on two B737 Main Landing Gear Brackets from KLM E&M. Both parts had been rejected due to corrosion formation and were slated for scrapping.
In Cold Spray, a fine metal powder is sprayed onto a part at high speed, causing the powder material to fuse with the part material without melting. The result is a growing metal layer with material properties equal to or better than the part material.
At first glance, the initial results look impressive. To master the cold spraying process and optimize the results, tests with (scrap) parts will be continued, and research will be conducted into the strength, porosity, and adhesion of the repair material. Additionally, collaboration will be sought with companies such as Boeing and Airbus. The ultimate goal is to establish cold spray as an approved repair technology.