Supersonic particle deposition as a means for enhancing the structural integrity of aircraft structures

•SPD can seal joints under both constant amplitude and flight load spectra.•SPD has been shown to be able to repair corrosion cutouts without failure.•SPD has been shown to be able to be applied to full scale structures.•SPD has been shown to withstand flight loads with peak stresses of up to 250 MPa.

The paper presents the results of experimental studies into the application of supersonic particle deposition (SPD) for repairing and enhancing the airworthiness and integrity of aging aircraft structures. Presented are the results of coupon tests on the application of SPD doublers to mechanically fastened joints and to simulated corrosion damage tested under constant amplitude fatigue loads. These successful tests are then supported by an application to an F/A-18 Hornet wing attachment centre barrel laboratory test article.