Electrospark Deposition (ESD) for Depot- and Field-Level Component Repair, and Replacement of Hard Chromium Plating

1. 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

2. Agenda • Organizations • Program Overview • Program Update • Technical Issues • Summary

3. ORGANIZATIONS

4. Principal Organizations • ESTCP/HCAT • Chuck Pellerin • Bruce Sartwell • PEWG • Lt. Steve Elliott • Norm Matthews • NSWC Carderock • Richard Hays • ARL • Wayne Ziegler

5. Funding FYDP • ESTCP • USAF - ASC/ENVV • NSWC Carderock • ARL

6. 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

7. 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

8. Program Overview

9. ESTCP FY02 PMRJune 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

10. 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

11. 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 on-site repair • For GTEs, approved changes will be implemented via Service approved procedures • JTRs would be issued to cognizant maintenance facilities

12. Program Update

13. ESTCP Preliminary Test Strategy26 June 2001 • Participants met to discuss preliminary strategy • Outline: • Joint Materials Testing • Substrate Applications • Coating Applications • Coating Repair • Component Verification • Technology Demo Baseline

14. 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

15. Program Review Meeting 8 January 2002 • SERDP NLOS Program Review • FY02 Budget Impacts • ESTCP Funds Allocation

16. Winter PEWG & TWG Meeting 7 February 2002 • Program Review • Bruce Sartwell, ESTCP • Clayton Lindsay, ASAP • Technical Review • Test Process Discussion

17. Technical Issues Components Depot requirements Test protocol(s) Develop ESTCP schedule

18. 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

19. Technical Issues Component confirmation Depot requirements Test protocol(s) Develop ESTCP schedule

20. 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, complex- geometry 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

21. Depot Requirements for Validating Technology Component Testing Component testing for aircraft will initially involve non-flight-critical 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 OC-ALC, 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

22. 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 Approach for Obtaining Costand Performance Data

23. Technical Issues Component confirmation Depot requirements Test protocol(s) Develop ESTCP schedule

24. Test Protocols ESTCP JTP Process Overarching/Common Procedures Separate JTPs for specific Protocols Anniston Oklahoma City North Island ...

25. Technical Issues Component confirmation Depot requirements Test protocol(s) Develop ESTCP schedule

26. Proposed Project Events and Milestones(assumed project start date of January 2002) Milestone/EventInitiate Complete Candidate component analysis1-026-02 Test plan #1 for complex-geom. Cr replacement 3-02 9-02 Develop “calibrated defect” for test coupons 6-02 10-02 Test plan #2 for localized repair of alloys 6-02 1-03 Test plan #3 for localized repair of Cr, Cd, Ni 9-02 4-03 Optimize ESD parameters for applications 6-02 6-03 Complete materials testing for TP #1 (JTR) 11-03 Complete materials testing for TP #2 (JTR) 1-04 Complete materials testing for TP #3 (JTR) 5-04 Producibility studies 1-03 6-04 Rig and AMT component testing 9-02 9-04 Cost/benefit analysis on field repair 6-04 Cost/benefit analysis on component recovery 12-04 Issue specifications and QA procedures 3-05 Issue new tech orders and manual changes 6-05 Final Report 9-05

27. 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

28. Back Up Slides

29. 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

30. 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

31. 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

32. 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-cost- of ownership and environmental issues • Carderock acquired ESD system from ASAP • Investigating technology for in-situ ship repair, repair of high-value components, performance improvements and HazMat reduction • Project directly tied in to user community • NAVSEA 05N Engineering for Reduced Maintenance Coordinator directly involved • Technical Approach: • Identify applications • Develop deposition parameters • Characterize coatings • Process control & QA methods

33. ESD Repair of K-monel Submarine Steering Control Rod (potential in-situ repair) As Received After Repair Finished Part

34. Industry Partners ASAP, INC

35. 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