Transcript Propulsion Environmental Working Group (PEWG)

Electrospark Deposition (ESD)
for
Depot- and Field-Level Component Repair, and
Replacement of Hard Chromium Plating
HCAT Program Review Meeting
Orlando, FL
21 February 2002
Norm Matthews, PEWG Management Office, ASC/LPJ
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Agenda
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Organizations
Program Overview
Program Update
Technical Issues
Summary
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ORGANIZATIONS
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Principal Organizations
• ESTCP/HCAT
– Chuck Pellerin
– Bruce Sartwell
• PEWG
– Lt. Steve Elliott
– Norm Matthews
• NSWC Carderock
– Richard Hays
• ARL
– Wayne Ziegler
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Funding
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ESTCP
USAF - ASC/ENVV
NSWC Carderock
ARL
FYDP
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Participating Organizations
• Advanced Surfaces and Processes, Inc.
– Clayton Lindsay
• Rowan Technology Group
– Keith Legg
• North Island Naval Aviation Depot
– Mike Holleron
• Anniston Army Depot
– Tony Pollard
• Oklahoma City Air Logistics Center
– Johnny Tsiao
– Glen Graham
• NADEP Jacksonville
– Rick Reckert
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Participating Organizations
• Pacific Northwest National Laboratory
– Roger Johnson
• Dynamics Research Corporation
– John Eberhardt
• US Army IEC
– Andy Goetz
• Boeing St. Louis
– Steve Gaydos
• NAVSEA 05N ERM
– Ken Scandell
• Pratt & Whitney
– Glenn Welcher
• GEAE
– Gary Trewiler
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Program Overview
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ESTCP FY02 PMR
June 2001
• Conduct a Dem/Val to assess qualification of
ESD for localized repair of components
– Brush plating
– Complete overhaul required or no repair currently
exists
• Prove that ESD technology will have significant
impact on:
– Total-cost-of-ownership
– Air and aqueous waste emissions
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ESTCP FY02 PMR
• North Island Naval Aviation Depot
• Oklahoma City Air Logistics Center
• Anniston Army Depot
ESD units will be purchased and installed at each
demo site.
ESD units at NSWC Carderock and ARL would be
used in materials studies
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ESTCP FY02 PMR
• End-use customers: DoD I- and D-level overhaul /
repair facilities & OEM overhaul/repair facilities
• Depots to develop:
– Deposition and processing specs (similar to AMEC
spec. developed for landing gear under HCAT);
– Quality assurance and facility qualification criteria
• Development of artisan training and certification
program that all depots can implement; certified
artisans could take ESD technology into field for onsite repair
• For GTEs, approved changes will be implemented via
Service approved procedures
• JTRs would be issued to cognizant maintenance
facilities
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Program Update
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ESTCP Preliminary Test Strategy
26 June 2001
• Participants met to discuss preliminary strategy
• Outline:
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Joint Materials Testing
Substrate Applications
Coating Applications
Coating Repair
Component Verification
Technology Demo Baseline
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PEWG TWG Meeting
27 November 2001
• Discuss/delineate Advanced Surfaces and
Processes, Inc. (ASAP) efforts supporting
OC-ALC requirements
• Develop a schedule that
– prioritizes those requirements
– complements the ESTC efforts
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Program Review Meeting
8 January 2002
• SERDP NLOS Program Review
• FY02 Budget Impacts
• ESTCP Funds Allocation
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Winter PEWG & TWG Meeting
7 February 2002
• Program Review
– Bruce Sartwell, ESTCP
– Clayton Lindsay, ASAP
• Technical Review
• Test Process Discussion
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Technical Issues
Components
Depot requirements
Test protocol(s)
Develop ESTCP schedule
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Components
• Each depot has numerous candidate components
• We’ll prioritize the list for this program
• Top candidates:
– North Island:
• F-18 Launch Bar (two guide lugs)
• E-2 Rotodome Shaft (two bearing areas)
• LM2500 High Pressure Turbine Rotor Rear Shaft
– OC-ALC:
• F100 Gear shaft assemblies
– ANAD/CCAD
• AGT 1500 High-Pressure Compressor Shaft
• AGT 1500 Intermediate Compressor Housing
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Technical Issues
Component confirmation
Depot requirements
Test protocol(s)
Develop ESTCP schedule
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Depot Requirements for Validating Technology
Materials Testing
1. Localized repair of candidate component alloys, including
iron- and nickel-based, aluminum, and titanium
2. Localized repair of coatings, including hard chrome, nickel,
IVD aluminum, and thermal spray cermet
3. Replacement of hard chrome plating in small-area, complexgeometry applications
– We will generate materials test plans that will include
• optimization of deposition parameters
• execution of fatigue, corrosion, and wear testing;
– for #1 and #2, “calibrated defect” [to simulate gouge,
corrosion pit, wear scar, etc.] will be put into test coupons, be
repaired with ESD, and then evaluated;
– for #3, will modify HCAT JTPs
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Depot Requirements for Validating Technology
Component Testing
Component testing for aircraft will initially involve non-flightcritical parts; lead-the-fleet flight testing will be conducted
for these components
For GTE parts, project team will pursue piggybacking onto
Accelerated Mission Tests for engines overhauled at OCALC, NADEP NI and JAX, and ANAD
Once level of confidence is achieved from materials and rig
testing, then in-situ repair of selected components will be
pursued
Producibility Testing and Assessment
- Stripping of coatings used for chrome replacement
- Grinding of coatings when used in localized repair and for
chrome replacement
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Approach for Obtaining Cost
and Performance Data
Costs
Evaluate all primary costs of
repair, including coating,
grinding, embrittlement relief
– labor, materials, waste
disposal
– shipping for depot repair
– spare parts inventory
PEWG has already contracted
with Dynamics Research Corp
to conduct these studies
Repair Frequency
Examine probability of
assembly and disassembly
damage, frequency of repair
of components during
overhaul
From results of materials and
component testing on ESD
coatings, assess both ability
to repair assembly damage
and in-service performance
with expected frequency of
repair
Assessments to be done for
different applications at
depots and OEMs
Technical Issues
Component confirmation
Depot requirements
Test protocol(s)
Develop ESTCP schedule
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Test Protocols
ESTCP JTP Process
Overarching/Common Procedures
Separate JTPs for specific Protocols
Anniston
Oklahoma City
North Island
...
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Technical Issues
Component confirmation
Depot requirements
Test protocol(s)
Develop ESTCP schedule
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Proposed Project Events and Milestones
(assumed project start date of January 2002)
Milestone/Event
Candidate component analysis
Test plan #1 for complex-geom. Cr replacement
Develop “calibrated defect” for test coupons
Test plan #2 for localized repair of alloys
Test plan #3 for localized repair of Cr, Cd, Ni
Optimize ESD parameters for applications
Complete materials testing for TP #1 (JTR)
Complete materials testing for TP #2 (JTR)
Complete materials testing for TP #3 (JTR)
Producibility studies
Rig and AMT component testing
Cost/benefit analysis on field repair
Cost/benefit analysis on component recovery
Issue specifications and QA procedures
Issue new tech orders and manual changes
Final Report
Initiate
1-02
3-02
6-02
6-02
9-02
6-02
1-03
9-02
6-04
12-04
Complete
6-02
9-02
10-02
1-03
4-03
6-03
11-03
1-04
5-04
6-04
9-04
3-05
6-05
9-05
Summary
• ESTCP Phase II Approved
• Funding Delayed
– Adjusted Scope
– Developing Program Schedule
• Kick off TWG 7 Feb 02
– Follow-up: Component Prioritization; JTPs
Development; Baseline Master Plan
• Next TWG: In Conjunction with August HCAT
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Back Up Slides
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F/A-18 C/D Launch Bar
• Base material is HP9-40-30
steel
• Repair area is two guide
lugs, 0.2 x 0.5 inches
• Requires buildup of 0.010
to 0.020 inches
• Plan is to make ESD
electrode out of base
material and perform
buildup repair
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E-2 Rotodome Shaft
• Size 81 inches long by 13
inches in diameter
• Normally damaged area
confined to two bearing
areas 4 inches in width
• Normal repair is to chrome
plate area 51 inches long
• Plan is to repair damaged
chrome plate using ESD
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M1 Intermediate Compressor Housing
• Chrome plating performed in
very localized areas
• Very complex geometry for
HVOF thermal spray
• Ideal for ESD
Chrome-plated areas
No coating allowed
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NAVSEA/NSWC Carderock Program
Office of Naval Research funding
NSWC to conduct 6.2/6.3 R&D to
investigate ESD as repair process
to impact Navy readiness, total-costof ownership and environmental
issues
NAVSEA
Submarine
Directorate
NAVSEA Life
Cycle
Managers
Marine
Corps
ONR ESD
PROGRAM
NSWCCD
NSWCCD
VA Class
Acqusition
Managers
PRIORITIZATION OF
ESD COATINGS AND SUBSTRATES
TO BE DEVELOPED
• Carderock acquired ESD
system from ASAP
• Investigating technology for insitu ship repair, repair of highvalue components,
performance improvements
and HazMat reduction
• Project directly tied in to user
community
• NAVSEA 05N Engineering for
Reduced Maintenance
Coordinator directly involved
• Technical Approach:
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Identify applications
Develop deposition parameters
Characterize coatings
Process control & QA methods
ESD Repair of K-monel Submarine Steering Control Rod
(potential in-situ repair)
As Received
After Repair
Finished Part
Industry Partners
ASAP, INC
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Technical Risks
• Localized repair effects on fatigue behavior; possible crack
initiation due to internal stress mismatch
– Note: Stellite 6 and 21 have demonstrated deposition without
cracks
• Ability to repair complex coated systems such as chrome,
cadmium and WC-CoCr not fully demonstrated as yet
ESD WC-Co
HVOF WC-Co
ESD alloy
High strength steel
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Potential spall
Potential fatigue crack
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