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Corporate Office  4401 Dayton-Xenia Rd.  Dayton, Ohio 45432-1894  Phone: 937-426-6900  Fax: 937-429-5413

Automated Industrial Metallography (AIM). Cold Spray Structural Repair & Additive Manufacturing. Cold Spray Action Team (CSAT) Worcester Polytechnic Institute Worcester, Massachusetts June 18 – 19, 2014 . Bob Bondaruk UES, Inc Chief Sustainment Officer.

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Corporate Office  4401 Dayton-Xenia Rd.  Dayton, Ohio 45432-1894  Phone: 937-426-6900  Fax: 937-429-5413

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  1. Automated Industrial Metallography (AIM) Cold Spray Structural Repair & Additive Manufacturing Cold Spray Action Team (CSAT) Worcester Polytechnic Institute Worcester, Massachusetts June 18 – 19, 2014 Bob Bondaruk UES, Inc Chief Sustainment Officer This presentation includes data that is proprietary to UES, Inc. and shall not be disclosed outside of Company or Contractor or the Government and shall not be duplicated, used, or disclosed – in whole or in part – for any purpose. This restriction does not limit Company or Contractor or the Government’s right to use information contained in this data if it is obtained from another source without restriction. The data subject to this restriction are contained herein. Corporate Office 4401 Dayton-Xenia Rd. Dayton, Ohio 45432-1894 Phone: 937-426-6900 Fax: 937-429-5413

  2. Subjects to be Covered • SBIR Phase 1 – Structural Repair • SBIR Phase 1 & 2 – Additive Manufacturing (AM) • RIF – Automated Industrial Metallography (AIM) • RoboMet.3D (R3D) • AIM Networking Concept • UES POCs • Summary

  3. Structural Repair • Dimensional Restoration of Corrosion Damaged Aircraft Components • SBIR Phase I • Contract Number: FA8117-14-C-0001 • POP: 20 January - 19 October 2014 • UES proposes metal spray technologies for dimensional restoration of Alloy 7075 (7050) aircraft components damaged by corrosion (continued)

  4. Structural Repair USAF TPOC: David F. Ellicks, DAF, DR-II Senior Materials Engineer AF Corrosion Prevention and Control Office (AFRL/RXSSR) 325 Richard Ray Blvd (Bldg 165), Robins AFB, GA 31098-1639 David.ellicks@us.af.mil, DSN 468-7701 (478-926-7701) UES PI: Dr. Rabi S. Bhattacharya Division Manager, Surface Engineering Laboratory rbhattacharya@ues.com, 937-426-6900 x114 (continued)

  5. Structural Repair • UES Team Members • Curtiss-Wright Surface Technologies • Peter Ruggiero, CWST Regional Manager • Peter.ruggiero@cwst.com, 860-623.9901 x5160 • Dr. Xinqing (Chin) Ma, 860.623.9901 x5121 • Chin.ma@cwst.com, • Flame-Spray Industries • Keith Kowalsky, Owner • kkowalsky@flame-spray.com, 516.459.7154

  6. Additive Manufacturing (AM) • Process Modeling for Additive Manufacturing of Titanium Alloys by Electron Beam Melting • SBIR Phase I (Notified Phase II Awardee) • Contract Number: FA8650-13-M-5059 • POP: 5/31/2013 – 3/3/2014 • UES proposed to obtain data to anchor models for AM by EBM. Predictive modeling of optimum machine parameters for a given powder and part dimensions will increase 1st part yield (continued)

  7. Additive Manufacturing (AM) • USAF TPOC: • John Kleek • Materials Engineer • AFRL, Wright-Patterson AFB, Dayton, Ohio • John.kleek@us.af.mil, • UES PI: • Dr John Porter • Material Scientist, Material Characterization Facility • jporter@ues.com, 937.255.1310

  8. AIM Project

  9. AIM Project

  10. RoboMet.3D Automated system generating 2D microstructural data for 3D characterization Common Applications: • Magnetic domains • Dendrites, voids • True shape of grains, grain boundary engineering AFRL SBIR Phase II, • Topic AF083-77

  11. Robo-Met.3D® Grinding Polishing Cleaning Sample Preparation Imaging (continued) Automated Industrial Metallography Indexing Sectioning Cold Mount Interface w/Robo-Met.3D® Reporting AIM Project

  12. AIM Project FEATURES • Precise metallography control for HVOF thermal spray coatings • Sectioning, Polishing, Cleaning, Imaging, Reporting • Evaluation/Qualification Tool • Rapid & Consistent • Artificial Intelligence (AI) • LAN/WAN Capability BENEFITS • Increased evaluation efficiency • Real-time, repeatable data • Reduced processing times; estimated results ~ 90 minutes • Reduced analysis subjectivity

  13. AIM - Automated Reporting Parameters Specimen Image:

  14. AIM - System Testing SYSTEM TESTING @ UES • Subroutines Functionality Testing • 20 coupons • Integrated Systems Functionality Testing - 250 coupons • Imaging System Reliability Testing • 250 coupon • Compare AI algorithms against manual metallography results • Determine AIM system accuracy to AMS and ASTM standards DEPOT INSTALLATION • Turnkey • UES will ship, de-crate, set-up, and ensure all subsystems and integrated equipment are operational prior to DD250 actions • Train • 4 Technicians per beddown site

  15. AIM - Timeline

  16. AIM Networking Concept The future open manufacturing concept for the AIM unit includes networking AIM instruments across USAF (AFSC, ALCs, & AFRL).  Once networked with other COEs the diagnostic tool will enable collaborative sharing of expertise and data. The ultimate goal of transitioning this technology is to improve the efficiency of the coating process by facilitating real time access to large pools of data from spray coatings and application methods. Commercialization represents a major success for both AFRL and the ALC’s, as the concept has evolved from the original Robo-Met.3D® microstructural characterization tool used in laboratories to a broadly applicable high-throughput coating quality analysis tool usable on the production floor. (continued)

  17. AIM Networking Concept

  18. Jake Freeman Project Engineer, Dayton, Ohio 937.426.6900 X172 jfreeman@ues.com Bob Bondaruk Chief Sustainment Officer, Midwest City, Oklahoma 405.361.4266 bbondaruk@ues.com UES POCs

  19. Bottom Line Adding an AIM unit to the DoD MetLab evaluation and certification process replaces manual steps with semi-automated functions thus reducing time while increasing data standardization in the decision process Summary

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