Autonomous-controlled fabrication of hybrid cold spray-friction stir processed next-generation high-entropy alloy surfaces and structural repair

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Innovative breakthroughs in enabling technologies can revolutionize the Albertan and Canadian landscape, bringing permanent developmental change. Technological advances and innovation apply across a broad spectrum of industrial activities to drive radical change in industry capabilities. Investments in the oil & gas sector will increase over the next 5 years. The aerospace sector is expected to grow over the same period, demanding innovation through research and technology development. Industry and government emphasize the need for novel materials development and manufacturing to keep pace with growth. They also stress urgency in connecting state-of-the-art digital and autonomous technologies to drive radical change and improve infrastructure lifetimes. Our proposed research will tackle these challenges by contributing new high-strength reinforced metal matrix composite materials and nanograin-stabilized high entropy alloys in an additive manufacturing repair paradigm using an autonomous mobile system. It will be built on the multifaceted hybridization of cold spraying and friction stir processing to fabricate wrought material repairs with high strength, structurally and functionally integrated into the repaired structure to ensure longevity. This will be accomplished for extreme environments that are unsuitable or inaccessible for human work using autonomous mobile systems integrated with surface assessment, monitoring, and navigation systems. Use of remote sensing, data communication systems, and machine learning to improve integration of autonomous system dynamics into sensor network architectures will produce state-of-the-art research outcomes for autonomy of high-payload additive manufacturing and materials processing systems hybridized for in field repairs with augmented sensing capability. In line with Alberta's advanced materials & manufacturing technologies and information and communications technologies target areas, outcomes of this project will underpin a paradigm shift in new materials development and autonomous fabrication and processing. This will make substantive contributions to place Canada and Alberta as global leaders in surface engineering, repair, and manufacturing.