Computing the Fatigue Life of Cold Spray Repairs to Simulated Corrosion Damage.

This paper summarises the findings of an investigation into the durability of cold spray repairs, also known as supersonic particle deposition or SPD repairs, to simulated corrosion damage in AA7075-T7351 aluminium alloy specimens. A feature of this paper is that it is the first to show how to perform the mandatory durability analysis of repaired corroded structures, where the corroded material is first removed by machining and then repaired using cold spray, in a fashion consistent with the requirements delineated in USAF Structures Bulletin EZ-19-01, MIL-STD-1530D, and the US Joint Services Structural Guidelines JSSG2006.

Review of Requirements for the Durability and Damage Tolerance Certification of Additively Manufactured Aircraft Structural Parts and AM Repairs.

The USAF requirements for the durability and damage tolerance certification for additively manufactured (AM) aircraft structural parts, which are detailed in Structures Bulletin EZ-19-01, raise a number of new and, as yet, unanswered questions. The present paper attempts to address three questions: How to perform a fracture mechanics-based analysis of crack growth in an AM part so as to account for the residual stresses, how to perform a fracture mechanics-based durability analysis of a cold spray repair so as to account for both the induced residual stresses and the presence of multiple co-located cracks, and how to perform a fracture mechanics-based durability analysis of an AM part so as to account for the presence of multiple collocated surface braking cracks. In this context, the present paper reveals the potential of the Hartman-Schijve variant of the NASGRO crack growth equation to accurately predict the growth of each of the individual (collocated) cracks that arose in a cold spray-repaired specimen and in a specimen from a crack that nucleated and grew from a rough surface.