RPI’s 20 Stories for 20 Years – Cold Spray Technology
To demonstrate the impact that applied research projects make on all Manitobans, we present RPI’s 20 Stories for 20 Years. A compilation showcasing successful partnerships from the past and the present, with a constant focus on the future.
Manitoba’s aerospace industry faced a maintenance, repair and overhaul (MRO) challenge: repairing aircraft components made from alloys highly susceptible to degradation and oxidization. These materials are lightweight but costly to maintain and repair—until now.
A collaboration between StandardAero and RRC Polytech’s Technology Access Centre for Aerospace and Manufacturing (TACAM) proved that cold spray technology can provide an innovative solution that meets the Original Equipment Manufacturing (OEM) standards.
“I was very appreciative of the work that RRC Polytech performed on this project and pleased with the collaboration between the two technical teams to produce an output we’ll hopefully be able to use for years to come,” says Brent Ostermann, Vice President of Product Assurance and Quality at Standard Aero. “[Cold spray] is going to help us advance our business, technology and capability in the future.”
Cold spray is an additive manufacturing process where metal particles half the thickness of a strand of hair move at 23 times the speed of sound, impacting to a surface to form a bond. Light alloys are highly reactive so they can’t be repaired using traditional methods like welding, but they can be repaired using cold spray because the process occurs at a very low heat.
StandardAero worked with RRC Polytech researchers, faculty and students to identify which alloys had the best bonding properties and prove the technology’s capacity to repair those materials.
“Now that we have the proof of concept on specific materials, we’ll look at the data and identify some candidates from all the products we service…Sometime in 2025, we’ll start applying the technology to those products,” says Ostermann. “We believe this project has positioned us to be right there with the demands of the OEMs as they need new and advanced repair technologies to support their products.”
TACAM’s strong presence in the aerospace sector, experience with cold spray technology from ongoing projects and long-standing relationship with StandardAero made the Centre an ideal partner.
“We were a bit challenged on having some of the internal expertise,” says Ostermann. “The collaboration gave us the bandwidth to get to the end result much quicker.
The year-long project took place at the Centre for Aerospace Technology & Training (CATT), co-located at StandardAero’s Plant 5 facility, engaging RRC Polytech researchers, faculty and students. It allowed the College and StandardAero to build in-house capabilities, provide training and foster technology transfer to support this MRO method.
Along with producing highly skilled graduates, this project will have a broader impact across our province: The new experience and capabilities developed with cold spray technology can be transferred to support partners in other sectors across Manitoba.
“This project showed TACAM’s ability to push the boundaries of advanced manufacturing and repair techniques for critical aerospace components,” says Ryan Cummine, Research Manager, TACAM.
“We are proud to have supported one of the province’s leading aerospace companies in developing innovative techniques for aircraft component repair by combining advanced manufacturing technologies and applied research.”