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Use or disclosure of data contained on this sheet is subject to the restriction on the title page of this presentation. This presentation includes data.

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Presentation on theme: "Use or disclosure of data contained on this sheet is subject to the restriction on the title page of this presentation. This presentation includes data."— Presentation transcript:

1 Use or disclosure of data contained on this sheet is subject to the restriction on the title page of this presentation. 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 Automated Industrial Metallography (AIM) Bob Bondaruk UES, Inc Chief Sustainment Officer Cold Spray Action Team (CSAT) Worcester Polytechnic Institute Worcester, Massachusetts June 18 – 19, 2014 Cold Spray Structural Repair & Additive Manufacturing

2 Use or disclosure of data contained on this sheet is subject to the restriction on the title page of this presentation. 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 2

3 Use or disclosure of data contained on this sheet is subject to the restriction on the title page of this presentation. 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) 3

4 Use or disclosure of data contained on this sheet is subject to the restriction on the title page of this presentation. 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) David.ellicks@us.af.mil UES PI: Dr. Rabi S. Bhattacharya Division Manager, Surface Engineering Laboratory rbhattacharya@ues.com, 937-426-6900 x114 (continued) rbhattacharya@ues.com 4

5 Use or disclosure of data contained on this sheet is subject to the restriction on the title page of this presentation. Structural Repair UES Team Members Curtiss-Wright Surface Technologies Peter Ruggiero, CWST Regional Manager Peter.ruggiero@cwst.com, 860-623.9901 x5160 Peter.ruggiero@cwst.com Dr. Xinqing (Chin) Ma, 860.623.9901 x5121 Chin.ma@cwst.com, Chin.ma@cwst.com Flame-Spray Industries Keith Kowalsky, Owner kkowalsky@flame-spray.com, 516.459.7154 kkowalsky@flame-spray.com 5

6 Use or disclosure of data contained on this sheet is subject to the restriction on the title page of this presentation. 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 1 st part yield (continued) 6

7 Use or disclosure of data contained on this sheet is subject to the restriction on the title page of this presentation. Additive Manufacturing (AM) USAF TPOC: John Kleek Materials Engineer AFRL, Wright-Patterson AFB, Dayton, Ohio John.kleek@us.af.mil, John.kleek@us.af.mil UES PI: Dr John Porter Material Scientist, Material Characterization Facility jporter@ues.com, 937.255.1310 jporter@ues.com 7

8 Use or disclosure of data contained on this sheet is subject to the restriction on the title page of this presentation. ContractFA8750-12C-0197 Award Date & Start Date8/8/2012 Completion Date5/10/2014 (2 Units = Hill/Robins AFBs) AF TPOC Troy Graham, 76 PMXG/QPE troy.graham@us.af.mil Chad Odell, 309 CMXG/ENS chad.odell@us.af.mil Mufit Yalcin, 802 MXSG/MXDTA mufit.yalcin@us.af.mil Contracting Officer Tiara Moore, AFSC/PZAB tiara.moore@us.af.mil AFSC PM Ed Kincaid, AFSC/ENS edwin.kincaid@us.af.mil AIM Project

9 Use or disclosure of data contained on this sheet is subject to the restriction on the title page of this presentation. ContractFA8750-12C-0197 =UP Award Date & Start Date9/23/2013 Completion DateAward + 1 year (1 Unit = Tinker AFB) UES TPOC Jake Freemen, Project Engineer jfreeman@ues.comjfreeman@ues.com, Umesh Adiga, PH.D., Software Development uadiga@ues.comuadiga@ues.com, Tom Kielbaso, Technical Sales tkielbaso@ues.com Bob Bondaruk, UES Midwest City bbondaruk@ues.combbondaruk@ues.com, Contracting Officer Rick Weddle, Director of Contracts rweddle@ues.comrweddle@ues.com, PMNina Joshi, Ph.D., CEO njoshi@ues.comnjoshi@ues.com, AIM Project

10 Use or disclosure of data contained on this sheet is subject to the restriction on the title page of this presentation. RoboMet.3D Common Applications: Magnetic domains Dendrites, voids True shape of grains, grain boundary engineering AFRL SBIR Phase II, Topic AF083-77 10 Automated system generating 2D microstructural data for 3D characterization

11 Use or disclosure of data contained on this sheet is subject to the restriction on the title page of this presentation. 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 Use or disclosure of data contained on this sheet is subject to the restriction on the title page of this presentation. 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 12

13 Use or disclosure of data contained on this sheet is subject to the restriction on the title page of this presentation. AIM - Automated Reporting Parameters 13 PARAMETERRESULTS Coat Thickness Voids Oxides Porosity Un-Melted Particle Transverse Cracks Grit De-Iaminations Interface Separation Specimen Name Specimen # Coating Booth # Technician # Date/Time Coated Date/Time Tested Coating Type Substrate Type Pass / Fail Comments Specimen Image:

14 Use or disclosure of data contained on this sheet is subject to the restriction on the title page of this presentation. 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 14

15 Use or disclosure of data contained on this sheet is subject to the restriction on the title page of this presentation. AIM - Timeline 15 System & software design, development Hardware: Q1 2014 Algorithm development Artificial Intelligence: Q2 2014 Hardware/Soft- ware integration AI integration Verification Integration: Q3 2014 Installation, Trng, & Ver/Val, Hill, Robins, & Tinker AFBs Final Reports Delivery: Q4 2014

16 Use or disclosure of data contained on this sheet is subject to the restriction on the title page of this presentation. 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) 16

17 Use or disclosure of data contained on this sheet is subject to the restriction on the title page of this presentation. AIM Networking Concept 17

18 Use or disclosure of data contained on this sheet is subject to the restriction on the title page of this presentation. Jake Freeman – Project Engineer, Dayton, Ohio – 937.426.6900 X172 – jfreeman@ues.com jfreeman@ues.com Bob Bondaruk – Chief Sustainment Officer, Midwest City, Oklahoma – 405.361.4266 – bbondaruk@ues.com bbondaruk@ues.com UES POCs

19 Use or disclosure of data contained on this sheet is subject to the restriction on the title page of this presentation. 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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