Navy valve actuator repair using cold spray

C. A. Widener, M. J. Carter, R. H. Hrabe, B. Hoiland, T. E. Stamey, V. K. Champagne, T. J. Eden

Research output: Chapter in Book/Report/Conference proceedingConference contribution


Cold spray is a reduced temperature, supersonic thermal spray process that is increasingly being used to perform repairs on high value components. In this case, a valve actuator internal bore sealing surface was repaired on an aluminum 6061 hydraulic valve body using high pressure cold spray. Corrosion damage to non-critical surfaces was also repaired, allowing the part to be returned to service. The VRC Gen III high-pressure cold spray system was used to deposit gas atomized 6061 aluminum powder. The internal bore surfaces were approximately 100 mm in diameter with a depth of nearly 200 mm, and were sprayed using a 45-degree nozzle 65 mm in length. The minimum required adhesion strength on critical surfaces was 69 MPa. The average adhesion strength was 71.4 MPa, with glue failures on ASTM C633 bond test specimens.

Original languageEnglish (US)
Title of host publicationASM International - International Thermal Spray Conference and Exposition, ITSC 2015
EditorsArvind Agarwal, Yuk-Chiu Lau, Christian A. Widener, Erja Turunen, Giovanni Bolelli, Amadeu Concustell, Andre McDonald, Filofteia-Laura Toma
PublisherASM International
Number of pages6
ISBN (Electronic)9781510811546
StatePublished - 2015
EventInternational Thermal Spray Conference and Exposition, ITSC 2015 - Long Beach, United States
Duration: May 11 2015May 14 2015

Publication series

NameProceedings of the International Thermal Spray Conference


OtherInternational Thermal Spray Conference and Exposition, ITSC 2015
Country/TerritoryUnited States
CityLong Beach

All Science Journal Classification (ASJC) codes

  • Surfaces and Interfaces
  • Surfaces, Coatings and Films
  • Materials Chemistry


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