Transcript No Slide Title
OKLAHOMA CITY AIR LOGISTICS CENTER
TEAM TINKER
OC-ALC Chrome Plate Reduction
20 FEB 2002 Johnny Tsiao OC-ALC/LPARR (405)736-3481 [email protected]
I n t e g r i t y - S e r v i c e - E x c e l l e n c e
OVERVIEW
•
CHROME WORKLOAD AT TINKER
•
HVOF AS ALTERNATIVE
•
TF33 HVOF QUALIFICATION
•
TINKER HVOF CAPABILITY
•
FUTURE TASKS
2
• • • •
TINKER CHROME PLATE WORKLOAD
2063 total parts in CY 2001
– –
constant average of 172 parts per month 29% increase from CY 2000 F110/101 increase due to ENSIP schedule F100 increase due to organic repair qualifications TF33 decrease due to C141 a/c retirement CY 2001 3% CY2000 4% 16% 10% TF33 F100 F110 AND F101 OTHERS 39% 40% 70% 18%
3
NEED FOR CHROME REDUCTION
•
CURRENTLY TINKER IS A BIG USER OF HEXAVALENT CHROME FOR REPAIR OF ENGINE COMPONENTS
•
INCREASED RESTRICTIONS ON CHROME USAGE WILL SIGNIFICANTLY IMPACT MISSION READINESS FOR AIR FORCE PROPULSION
•
IDENTIFY CHROME PLATE FEATURES TO DETERMINE BEST ALTERNATIVES
– –
Review tech data for all chrome callouts Categorize by location and geometric features
4
HVOF AS ALTERNATIVE
•
LP HAS IDENTIFIED HIGH VELOCITY OXYGEN FUEL (HVOF) COATING AS THE LEADING TECHNOLOGY TO REPLACE CHROME PLATING AT TINKER AFB
–
TF33 HVOF substitutions provide the greatest initial reduction in chrome usage
–
F110/101 Aft Shaft is bulk of chrome usage. Chrome repair also used for #4 Seal Housing on as needed basis to support DLA shortage. HVOF alternative is currently available for Aft Shaft.
–
Currently few F100 components identified for HVOF substitution. However, continual efforts for repair qualifications will identify additional needs
•
OEMs ALSO SPECIFIES HVOF IN THEIR DESIGNS
•
LP HAS IDENTIFIED COMPONENTS HAVING SUBSTRATES AND GEOMETRY SUITABLE FOR HVOF APPLICATION
5
HVOF CANDIDATES
•
TF33 COMPONENTS :
– – – – – – –
AMS 5613, #1 Bearing Support; #2, #4, #5 and #6 Bearing Housing AMS 5616, #6 Hub AMS 5660, Rear Compressor Rear Hub AMS 6280, #2 Bearing . Housing Alternate AMS 6304, LPT Shaft; HPT Shaft AMS 6322, #4.5 Bearing . Retaining Nut AMS 6415, #2 Hub; #2.5 Bearing . Housing
•
F110/101 COMPONENTS :
– – –
INCO 718, HPT Aft shaft A-286, #4 Carbon Seal Seat (recent addition) SAE 8740, #5 Carbon Seal Seat (may be planned)
•
F100 COMPONENTS:
– –
AMS 6265, Impeller shaft AMS 6265, Gear shaft
6
TF33 HVOF QUALIFICATION
•
TF33 IS THE LEAD PROGRAM FOR CHROME REPLACEMENT VIA HVOF
–
F100 agrees to pattern qualification methodology after TF33
–
T56 will qualify thermal spray based on Joint Materials Test Protocol
•
7 COMPONENTS IDENTIFIED FOR ENGINE TEST
–
Remaining 5 to be qualified by similarity
•
FUNCTIONAL TEST PROCEEDS ENDURANCE TEST
–
Fit Check completed
– –
Metallurgical analysis by PW Need Wright Lab assistance for sonic testing
7
TF33 HVOF COMPONENTS FOR ENGINE TEST
#4 hub LPT shaft HPT shaft #1 brg hsg #2 hub #5 brg hsg #6 brg hsg
8
TF33 HVOF COMPONENTS FOR ENGINE TEST
•
ENGINE TEST PROBLEMS
– – –
Hardware installed on test engine Engine at PW test facility Significant delay due to technical and financial problems unrelated to this effort
–
Project completion of test by Aug 02
•
POST ENGINE TEST MATERIAL ANALYSIS IS REQUIRED BEFORE PARTS ARE VALIDATED
9
TF33 HVOF Functional Test #1 Bearing Housing As finished by Engelhard 2/01
10
TF33 HVOF Functional Test #5 Bearing Housing As finished by Engelhard 2/01
11
TF33 HVOF Functional Test #6 Bearing Housing & Seal Runner As finished by Engelhard 2/01
12
TF33 HVOF Functional Test #2, 2.5 and 3 Bearing Journals As finished by Engelhard 2/01
13
TF33 HVOF AMT HPC Rear Hub As received by Engelhard 2/01
14
TF33 HVOF Functional Test #4.5 Bearing & Seal Journals As finished by Engelhard 2/01
15
TF33 HVOF Functional Test #5 Bearing & Seal Journals As finished by Engelhard 2/01
16
•
TINKER HVOF CAPABILITY KEY PARAMETERS
Booth Installation
– – –
Purchased and installed one Sulzer-Metco DJ system Bio-environmental, safety certification Long term Oxygen supply
•
Training
–
Classroom and practical
–
PW, Engelhard, Metco support
•
LP Quality Plan
–
Amend LPP process order to include HVOF
•
Coating Parameter
– – –
Sampling method Evaluation standards Masking Tools
17
•
TINKER HVOF CAPABILITY KEY PARAMETERS
Finishing
– – –
Fine finish required for oil wetted parts Tinker has not developed finishing capability Engelhard support
•
Coating Removal
–
Need to determine removal method for subsequent repairs
–
Chemical vs mechanical
•
OEM Qualification
–
Two part PW source approval: General Process and Part Specific
– –
Working on establishing PW support for source approval Need to address GE components
18
TINKER INHOUSE HVOF ROADMAP
START HVOF Roadmap Legend:
Tinker Englehard PWA Spray Equipment Installation Jan '02 Metco Bio, Fire Safety Approval Englehard and Metco Facility Operational Training Bulk Oxygen HQ Approval Develope Training Manual Funded Fy '02 OJT Classroom Testing Bulk Oxygen Installation TIESV Met Lab RDE Contract Evaluation Standards Coating Polishing Procedures Hands on w/ MCL Lab Quality Documents Revision PWA Program Plan Quality Plan LPOI 21-166 Process Order LPP 85-11 LPA/ LPF/ LPQ Approval Coatings Parameters PWA 36206-1 Robotic Programs Tinker and Englehard Lab Samples Masking/ Tooling Coating meets Specification Requirements?
No Yes SEE PAGE 12 Preliminary Qualification Part Specific Qualification See PWA Flowsheet Proceed to the next part requiring qualification Program Plan Requirements Met?
Yes END Approval Granted
19
PW QUALIFICATION PROCESS
PRELIMINARY
Improve Process Qualification Request See Note 1 Preparation of Requested Material See Note 3 Submittal of Requested Material Rework Process Schedule Meeting to Review Qualification requirements Process Process Qualification Samples Submittal of Qualification Samples Rework Process Qualification Granted Samples Fail - Creates Replog Entry See Note 2 - Identifies Necessary Steps for Qualification Process - Notifies Requester - Submits Material For MCL Review and Approval to Specifications - Review Results and Communicate to Source Samples Pass - Review of Process Qualification Requirements and Plans See Note 4 Samples Fail Samples & Document Review Acceptable - Submits Material For MCL Review and Approval to Specifications - Review Results and Communicate to Source - MCL Prepares the Material for Review and Compares Samples to Specifications - Provide Results to MME
PARTS SPECIFIC
- MCL Prepares the Material for Review and Compares Samples to Specifications - Provide Results to MME 20
FUTURE TASKS
•
New part numbers and Tech Data must be introduced
–
Class I Engineering Changes required for configuration control
–
Additional funding for OEM through CIP needed
•
More extensive process quality control requirements
–
Standardized evaluation of process qualification
–
Process tech data incorporation to T O 2-1-111
•
Particle liberation in oil wet areas
–
Design requirements defined by OEM
•
JOAP trending impacts
–
Atomic absorption limitations with tungsten
–
AMT engine will define criteria
program specific issue joint issue 21
TEAM TINKER