Sierra Army Depot’s (SIAD) Metal Fabrication branch completed operator training on January 16, 2025, with their new VRC Dragonfly cold spray unit. This advanced capability enables Sierra to repair high-value components within the M149 Buffalo, rather than replacing them or decommissioning the entire piece of equipment – a very expensive course of action.
In its aim to provide top quality maintenance, reset and supply operations, the depot took a significant step forward in modernization by expanding its capabilities. The High-Pressure Cold Spray (HPCS) technology offers a cost-efficient way to repair expensive and hard-to-acquire components. It significantly reduces repair process times, improves systems availability and can be used across a variety of platforms.
What is Cold Spray?
Cold spray is an emerging technology that enables Sierra and the Army to reclaim worn components that were previously replaced with new parts. Cold spraying, also known as supersonic particle deposition, is a high-energy solid-state coating and powder consolidation process. Used in various industries such as aerospace, military, automotive, maritime, and heavy equipment, it applies metals, metal alloys (aluminum, steel, and copper alloys), and metal blends to metallurgically bond with the base substrate. Cold spray has the lowest overall temperatures and highest velocities of the thermal spray family. It involves accelerating metal powders through a high-pressure gas jet to create coatings or free-standing structures. Here are some key points about cold spraying:
- Process: Metal powders are accelerated to high velocities (up to 1200 m/s) using a gas like nitrogen or helium. Upon impact with a substrate, the particles deform and bond to the surface.
- Benefits: It results in very low heat input, preserving the microstructure and properties of the powders. This method also avoids oxidation and phase transformations. It is hand operable. Finally, the number of repair cycles that can be completed with HPCS is limitless, as cold spray deposits, once worn or damaged, can be repaired again with HPCS.
- Applications: Cold spraying is used for corrosion-resistant coatings, wear-resistant coatings, dimensional restoration, and repair (including in the field), among other applications.
- Additive Manufacturing: Cold spray can also be used for additive manufacturing (3D printing) to create complex shapes and structures layer-by-layer.
The Metal Fabrication team eagerly anticipates harnessing the cutting-edge capabilities of our latest technology, revolutionizing processes and driving substantial cost savings for both the Army and taxpayers.
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