Methods utilizing cold spray techniques for repairing and protecting rotary components of aviation propulsion systems

A method, comprising:

• identifying a non-compliant surface of a component, the component comprising temperature sensitive material and at least one of electronic equipment, optical equipment, or fluid sensing devices, wherein the non-compliant surface is not within an allowable tolerance;
• cold spraying a powder comprising a metal onto the non-compliant surface, wherein the cold spraying comprises restricting heat to the non-compliant surface and avoiding one or more undamaged portions of the component by masking off one or more portions of the non-compliant surface from the undamaged portions of the component with a thermally insulating masking material, wherein the cold spraying does not damage the electronic equipment, the optical equipment, or the fluid sensing devices;
• localizing heat generated by the cold spraying away from the temperature sensitive material;
• and
• forming a coating comprising the metal over the non-compliant surface, wherein an outer surface of the coating is within an allowable tolerance.