Cold Spray
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Cold Spray Making metals work longer and harder than ever before...

The Leader in Complete Cold Spray Solutions VRC leads the way in designing the most capable cold spray systems with specifications to meet or exceed our customer’s expectations. We also specify and integrate complete turnkey solutions ranging from installation of the equipment into an existing space to integration of complete automation and enclosure solutions needed to do their job. Each Customer Has Specific Requirements –VRC Designs Customized Solutions To Meet Those Needs VRC Specializes in Fixture Design and Tooling, to Optimize Repair Cost and Time 1 | VRC Metal Systems |...

Cold Spray – The case for HIGH pressure Cold spray, also referred to as supersonic particle deposition, is a solid-state coating process utilizing a heated high-pressure carrier gas, like nitrogen or helium, or air to accelerate metal powders through a supersonic de Laval nozzle to bond particles to a substrate. Low-pressure cold spray generates lower particle velocities, and primarily relies on mechanical interlocking with some metallurgical bonding. Low-pressure cold spray adhesion is comparable with other traditional thermal spray processes, which operate at higher temperatures. However,...

The VRC Cold Spray Systems VRC Gen IV™ High -Pressure System with our new 23kW applicator heater and dual powder feeders VRC® Raptor™ High-Pressure System with a Deployable 21kW Heater and Handheld Pendant VRC® Dragonfly™ High-Pressure System with Modular Components, a 21kW Heater and Handheld Pendant 3 | VRC Metal Systems | vrcmetalsystems.com

VRC Cold Spray Systems Capabilities Features Human Machine Interface Heater Type Applicator Temp Range 1202°-1650° (650°-900°C) Compatible with Applicator Heater VRC®Dragonfly™ Electrical Module 41”L x 22”W x 12”H (104cm L x 56cm W x 30cm H) Gas Module 41”L x 22”W x 12”H (104cm L x 56cm W x 30cm H) Heaviest Component 94lbs (42.63kg) 480 VAC, 3 PH, 50 Amps Full Touch Screen Controls Tethered w/Full Touch Screen Controls Tethered Pendant Parameter Readout 21kW Remotable Floor Heater 21kW Remotable Floor Heater Multi-Powder Feeder Standard Gas Supply: Max Input Pressure Max Gas Flow 88 CFM...

The VRC Additive & Subtractive Systems VRC is the global leader in cold spray equipment manufacturing and experts at cold spray process development for both defense and commercial applications. We will match our customers with the right cold spray equipment, material, and process to make them successful. Integrated Additive & Subtractive Systems: VRC’s line of additive cold spray systems with integrated automation in an acoustical spray booth with dust collection. Medium System VRC’s line of additive & subtractive systems with integrated CNC machining, automation, acoustical booth and dust...

Support Equipment & Consumables Acoustical Booths VRC®Dragonfly™ Cart Vark™ Portable Dust Collector Portable Spray Booth Liquid Cooled Applicator Heater VRC supports all consumable products such as, powders, nozzles and hoses. MKS0001 REV E VRC Metal Systems | vrcmetalsystems.com |

The C.A.M.P. Site™ Cold Spray Cell Scan the QR Code to see the full capabilities of the C.A.M.P. Site™. Gas Storage: Two 12-packs of high pressure rated (4500psi) DOT bottles of compressed air totaling 11,840 cubic feet 125kVA output capacity Provides 3-phase 480VAC power “Power Balance” system to maintain sufficient load on the engine 4-Stage, air-cooled compressor 26.4 standard cubic feet per minute charge rate 20 HP 3-phase motor 7 | VRC Metal Systems | vrcmetalsystems.com

Brolga Trailerized Systems Field Portable Cold Spray Systems Mobile Cold Spray Cart Includes an on-board VRC®Raptor™ cold spray system, compressed air storage and a separate diesel generator. Fanuc 6-axis articulating arm robot with 10 lb. payload capacity Robot controller and pendant on-board Battery-powered, manually operated 2WD cart with built-in charger Deployable outriggers for in-process stability during rapid motion Hose and cable storage VRC Metal Systems | vrcmetalsystems.com | 8

Industries Served 9 | VRC Metal Systems | vrcmetalsystems.com

Cold Spray Repairs Aircraft Skin Panel Fastener Hole Repair1 Pipe Joint Leak Repair Leaky pipe coupling can be sealed with cold spray on-site at temps low enough that most operations can remain running [1] Ch. 9 Cold Spray Applications: V.K. Champagne et al. Cold Spray Coatings, ASM International (2018) pp. 25-56. Corrosion Resistant Layers SS Shaft Defect Repair Damaged Sprayed Machined Weld joint sprayed with Aluminum to protect from corrosion Steel pipe internally sprayed with Aluminum to protect from corrosion Bronze Corrosion Repair Corroded Bronze Impeller Pipe Repair without High...

Mechanical Wear Resistance Chrome Replacement Shaft Repair Cold Sprayed with 410SS/CrC—48 HRC Family of Chrome Replacements / Hard Coating Options—Plus Many More Cold Spray Shaft Repair Process—Ni/CrC on 4140 Steel* Damaged area/prep Cold spray repair Cross section of the mockup; 28ksi bond Finish machining *Pictures courtesy of US Army Research Lab—Victor Champagne, Aaron Nardi, Gehn Ferguson, Isaac Nault, William Story, & Dan Nikolov 11 | VRC Metal Systems | vrcmetalsystems.com

Enhancement & Specialty Coatings Cold Spraying Metal on Thermoplastic (wear resistance or RF shielding) 7075 Al on PEEK Thermoplastic Shaft Infrared Energy Reflective Stainless Steel Blend on A36 Steel Antimicrobial Copper Coating Tin Based Alloy on Carbon Fiber Filled Plastic Acid Resistance Tantalum Coating High Heat Resistance Niobium Coating VRC Metal Systems | vrcmetalsystems.com | 12

Cold Spray Materials, Properties and Testing Materials Single or Mixed Powder Feeding Unique tumbling drum powder feeder enables uniform coatings with mixed powders - does not separate heavier materials like competitors’ vibratory feeders. Aluminum Copper Titanium Steel & SS Nickel - CP Al - CP Cu - CP Ti (all grds) - 1018 - CP Ni - 2024 - Bronze - Ti-6Al-4V - 4340 - Inco 625 - 6061 – 90Cu-10Sn And more - 17-7 SS - Inco 718 - 7050 – Cu-Ni-Inco - 316 SS - Ni/CrC - 7075 – Ni-Al-Cu - 410 SS - NiCr/CrC And more And more And more And more Specialty Powders Tantalum, Niobium, Chromium, MCrAIYs...