military helicopter

Cold Spray Solutions For Military Rotorcraft

The Military Rotorcraft market comprises attack, utility, maritime, transport, multi-mission, and training helicopters. Their uses include military operations, evacuating civilians, reconnaissance, transporting personnel out of hostile conditions, medical evacuation, and transporting dignitaries. 

An increase in the number of natural disasters in recent years has increased the need for military rotorcraft, as aerial rescue missions are considered the most secure way of rescue. In these situations, they also supply medical support and lifesaving goods, such as potable water, food, and sanitary supplies.

Military Rotorcraft Challenges

Replacement cycles for helicopter fleets are coming to an end; however, future vertical lift isn’t expected until the late 2020s and early 2030s, meaning existing craft will need to be maintained until future vertical lift vehicles are produced and deployed.

In addition, flat or declining military budgets will require existing assets to be maintained as long as possible and done in a cost-effective manner.

Swapping out parts for new ones is an expensive and time-consuming process not in line with future budget limitations.

Like other military equipment, rotorcraft are subject to harsh environments, including exposure to extreme temperatures, saltwater, humidity, or dust conditions that lead to wear and corrosion. Repeatedly removing panels and fasteners places additional stress on joints and leads to wear of the fastener holes within the panels.

VRC Cold Spray Solutions for Military Rotorcraft

VRC Metal Systems’ High-Pressure Cold Spray (HPCS) equipment and technology provides an efficient method of applying metals, metal alloys, and composite blends for various purposes. The powder particles are accelerated to supersonic speeds, causing them to deform on impact and create a metallurgical bond instead of a mechanical interlock with the substrate.

This process allows the coating material to retain its original microstructure and material properties, thereby creating enhanced corrosion resistance, wear resistance, dimensional structure, or electromagnetic interference shielding while maintaining or strengthening the original base part.

The portability of the VRC Metal Systems’ HPCS equipment allows parts to remain in place for repair, eliminating the need for replacement parts and minimizing “aircraft on ground” hours, in addition to the following applicable benefits:

  • The base part can be strengthened by applying similar or dissimilar metals or metal blends due to the molecular bonding of the materials in this process.
  • The atomic copper and aluminum structure of aircraft aluminum alloys is not disrupted by cold spray.
  • HPCS technology restores dimensional features that are no longer within tolerances due to erosion or corrosion by applying nickel, titanium, copper, bronze, or other metals.
  • Applying composite blends adds a wear-resistant coating, extending the time between repairs.
  • Worn or damaged cold spray repairs can be repaired with additional HPCS applications.

VRC Metal Systems is trusted by government organizations and reputable institutions worldwide. With VRC’s High-Pressure Cold Spray systems, you receive expert on-site implementation and maintenance support from highly-trained staff. 

If you’re interested in a cost-effective, portable repair solution for your military rotorcraft request a quote, and one of our Sales Engineers will contact you.

Contact VRC Metal Systems today to find out how cold spray technologies can support your Hydropower industry infrastructure. 

our Services


We provide on-site support for all our services as standard


Products can be configured by one of our experienced technicians.


We offer a variety of equipment lease options for you and your company.


Our trained engineers across the nation offer short & long term solutions for your aircrafts


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