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Advanced Surfaces and Processes, Inc. 1 Engineered Applications of Electro-Spark Deposition (ESD) for Component Repair Replacement of Hard Chrome Plating.

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Presentation on theme: "Advanced Surfaces and Processes, Inc. 1 Engineered Applications of Electro-Spark Deposition (ESD) for Component Repair Replacement of Hard Chrome Plating."— Presentation transcript:

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2 Advanced Surfaces and Processes, Inc. 1 Engineered Applications of Electro-Spark Deposition (ESD) for Component Repair Replacement of Hard Chrome Plating Program Review Meeting 1-2 April 2003 Loews Coronado Bay Resort COMPONENT REPAIR PROJECTS Electrospark deposition studies for gas turbine engine component repair

3 Advanced Surfaces and Processes, Inc. 2 Introductions Larry McCarty – President and CEO John Kelley – VP R&D Norma Price – Mechanical Engineer, Project Manager

4 Advanced Surfaces and Processes, Inc. 3 Project Objective Advanced Surfaces and Processes, Inc will identify, evaluate and qualify applications of the Electrospark Deposition (ESD) process for repair of gas turbine engine components.

5 Advanced Surfaces and Processes, Inc. 4 Participants PEWG/ESTCP/HCAT PEWG/ESTCP/HCAT Portland State University Portland State University EWI EWI Rowan Technology Group Rowan Technology Group AFRL AFRL GEAE GEAE PW PW Tinker AFB Tinker AFB PNNL PNNL

6 Advanced Surfaces and Processes, Inc. 5 The Project Plan Phase 1 Phase 1 Period of Performance: 10/01/01 – 9/30/02 Period of Performance: 10/01/01 – 9/30/02 Objective: Determine the feasibility of using the ESD process to effect repairs on Gas Turbine Engine (GTE) components. Objective: Determine the feasibility of using the ESD process to effect repairs on Gas Turbine Engine (GTE) components. Phase 2 Phase 2 Period of Performance: 9/1/02 – 6/30/03 Period of Performance: 9/1/02 – 6/30/03 Objective: Gather and evaluate data regarding the effects of the ESD process on common GTE component materials. Objective: Gather and evaluate data regarding the effects of the ESD process on common GTE component materials. Phase 3 Phase 3 Period of Performance: 7/01/03 – 6/30/04 Period of Performance: 7/01/03 – 6/30/04 Objective: Identify GTE components to be processed for performance testing. Develop ESD repair procedures and specifications for these specific components. Objective: Identify GTE components to be processed for performance testing. Develop ESD repair procedures and specifications for these specific components.

7 Advanced Surfaces and Processes, Inc. 6 Phase 1 10/01/01 – 9/30/02 10/01/01 – 9/30/02 Determine the feasibility of utilizing the ESD process to effect cost effective repairs on a wide range of high cost, long lead-time, GTE components for which: Determine the feasibility of utilizing the ESD process to effect cost effective repairs on a wide range of high cost, long lead-time, GTE components for which: there are no known method of repair there are no known method of repair existing repair methods are impractical existing repair methods are impractical replacement parts are no longer available replacement parts are no longer available existing methods of repair involve the utilization of HAZMATS such as electrolytic hard chrome (EHC). existing methods of repair involve the utilization of HAZMATS such as electrolytic hard chrome (EHC).

8 Advanced Surfaces and Processes, Inc. 7 Phase 1 Tasks: Tasks: Identify candidate materials Identify candidate materials Select candidate materials Select candidate materials Optimize ESD parameters and specifications for selected substrate/electrode combinations Optimize ESD parameters and specifications for selected substrate/electrode combinations Identify repair liabilities for the ESD process on GTE materials Identify repair liabilities for the ESD process on GTE materials Create Process Specification Template Create Process Specification Template

9 Advanced Surfaces and Processes, Inc. 8 Identify candidate materials Identify candidate materials This task involved the identification of substrate materials widely used in GTE’s. DoD and OEM facilities and personnel were contacted and provided input. A wide variety of materials were identified as potential candidate materials. This task involved the identification of substrate materials widely used in GTE’s. DoD and OEM facilities and personnel were contacted and provided input. A wide variety of materials were identified as potential candidate materials. Phase 1 Task 1 100% Complete

10 Advanced Surfaces and Processes, Inc. 9 Phase 1 Task 2 Select candidate materials. Select candidate materials. SubstrateSpecification Electrode Specification IN 718 AMS 5663 AMS 5832 IN 625 AMS 5666 AMS 5837 Hastelloy X AMS 5754 AMS 5798 Haynes 188 AMS 5772 AMS Stainless AMS 5504 AMS PH AMS 5604 AMS % Complete

11 Advanced Surfaces and Processes, Inc. 10 Optimize ESD parameters and specifications for selected materials. Optimize ESD parameters and specifications for selected materials. A Design of Experiment (DOE) was created for each of the six materials. 36 coupons would be repaired varying the ESD parameters: Capacitance Capacitance Voltage Voltage Current Current Pulse Rate Pulse Rate Based on material testing results, the optimum parameters will be selected. Further parameter optimization may be conducted. Phase 1 Task 3

12 Advanced Surfaces and Processes, Inc. 11 Identify repair liabilities for the ESD process on GTE materials. Identify repair liabilities for the ESD process on GTE materials. This task involves the collection of data related to materials and weld repair (i.e. “specific problems with welding selected materials”) concerns, such as Susceptibility to HAZ Susceptibility to HAZ Micro cracking Micro cracking Porosity Porosity Phase changes. Phase changes. Phase 1 Task 4

13 Advanced Surfaces and Processes, Inc. 12 Create Process Specification Template Create Process Specification Template A Welding Procedure Specification format has been developed by EWI, which represents one page of the entire Welding Specification. AFRL provided ASAP with templates that can be used for the development of complete Welding Specs which will be created for each application. This task is dependant on the completion of component selection and has been moved to Phase 3, Task 4. Phase 1 Task 5

14 Advanced Surfaces and Processes, Inc. 13 Phase 1 Status Status Task 1 and 2 complete Task 1 and 2 complete Task 3 in process Task 3 in process Task 4 and 5 need to be revisited Task 4 and 5 need to be revisited

15 Advanced Surfaces and Processes, Inc. 14 Phase 2 9/1/02 – 6/30/03 9/1/02 – 6/30/03 Gather and evaluate information and data regarding the effects of the ESD process on common GTE component materials. This information and data will form the basis for our ESD/GTE compatibility criteria. Gather and evaluate information and data regarding the effects of the ESD process on common GTE component materials. This information and data will form the basis for our ESD/GTE compatibility criteria.

16 Advanced Surfaces and Processes, Inc. 15 Phase 2 Tasks: Tasks: Produce Materials Test Coupons Produce Materials Test Coupons Identify Materials and Mechanical Testing Protocol Identify Materials and Mechanical Testing Protocol Produce materials testing specimens Produce materials testing specimens Evaluate materials testing results Evaluate materials testing results Produce mechanical testing specimens Produce mechanical testing specimens Evaluate mechanical testing results Evaluate mechanical testing results Create candidate part screening requirements Create candidate part screening requirements

17 Advanced Surfaces and Processes, Inc. 16 Phase 2 Tasks: Tasks: PSU Contract PSU Contract EWI Contract EWI Contract Reclamation Project Reclamation Project

18 Advanced Surfaces and Processes, Inc. 17 Produce Materials Test Coupons Produce Materials Test Coupons 216 coupons have been: Procured Procured Heat treated, if necessary Heat treated, if necessary Defects drilled Defects drilled Pre ESD (surface finish, clean, weigh) Pre ESD (surface finish, clean, weigh) Repaired (defect filled) Repaired (defect filled) Post ESD (surface photograph, weigh) Post ESD (surface photograph, weigh) Phase 2 Task 1 100% Complete

19 Advanced Surfaces and Processes, Inc. 18 Phase 2 Task 1 Produce Materials Test Coupons Produce Materials Test Coupons

20 Advanced Surfaces and Processes, Inc. 19 Identify Materials and Mechanical Testing Protocol Identify Materials and Mechanical Testing Protocol ASAP will perform qualitative materials testing ASAP will perform qualitative materials testing PSU will perform material and mechanical testing PSU will perform material and mechanical testing EWI will perform mechanical testing EWI will perform mechanical testing Other facilities will review testing procedures Other facilities will review testing procedures Working with Keith Legg et al to develop Joint Test Protocol (JTP) Working with Keith Legg et al to develop Joint Test Protocol (JTP) Phase 2 Task 2

21 Advanced Surfaces and Processes, Inc. 20 Produce materials testing specimens Produce materials testing specimens 216 coupons have been: Cut and sent to PSU Cut and sent to PSU Mounted, Polished and Etched Mounted, Polished and Etched Micrographed Micrographed 3 parameter sets have been duplicated 5 times to confirm repeatability 3 parameter sets have been duplicated 5 times to confirm repeatability Phase 2 Task 3 100% Complete

22 Advanced Surfaces and Processes, Inc. 21 Evaluate materials testing results Evaluate materials testing results Compare ASAP and PSU analysis Compare ASAP and PSU analysis Select optimum parameters for each material Select optimum parameters for each material Continue to optimize parameters, if necessary Continue to optimize parameters, if necessary Revisit material testing after component selection Revisit material testing after component selection Additional materials testing, per the JTP Additional materials testing, per the JTP Phase 2 Task 4

23 Advanced Surfaces and Processes, Inc. 22 Produce mechanical testing specimens Produce mechanical testing specimens PSU will address Low Cycle Fatigue testing PSU will address Low Cycle Fatigue testing EWI will address Low Cycle Fatigue, Tensile and Bend testing EWI will address Low Cycle Fatigue, Tensile and Bend testing Phase 2 Task 5

24 Advanced Surfaces and Processes, Inc. 23 Evaluate mechanical testing results Evaluate mechanical testing results Compare EWI and PSU analysis Compare EWI and PSU analysis Continue to optimize parameters, if necessary Continue to optimize parameters, if necessary Revisit mechanical testing after component selection Revisit mechanical testing after component selection Additional mechanical testing, per the JTP Additional mechanical testing, per the JTP Phase 2 Task 6

25 Advanced Surfaces and Processes, Inc. 24 Phase 2 Task 7 Create candidate part screening requirements Create candidate part screening requirements Criteria: Criteria: 1 of the 6 materials 1 of the 6 materials Replace/prevent EHC coatings Replace/prevent EHC coatings Format created, Format created, revise as needed

26 Advanced Surfaces and Processes, Inc. 25 PSU Contract PSU Contract Oregon Metal Initiative Oregon Metal Initiative Tasks Tasks Phase 2 Task 8

27 Advanced Surfaces and Processes, Inc. 26 Phase 2 Task 8 Quantitative image analysis – optical & SEM Quantitative image analysis – optical & SEM Microhardness – deposit- interface- substrate Microhardness – deposit- interface- substrate Fatigue - Evaluation Capabilities Fatigue - Evaluation Capabilities Axial – tension-tension (room & elevated Temp) Axial – tension-tension (room & elevated Temp) Flex bending – “Krauss”-tapered constant stress Flex bending – “Krauss”-tapered constant stress Air & salt water Air & salt water Rotating bending – “Fatigue Dynamics”- hour glass Rotating bending – “Fatigue Dynamics”- hour glass Thermal & thermal-mechanical fatigue –controlled atmosphere Thermal & thermal-mechanical fatigue –controlled atmosphere Courtesy of Portland State University

28 Advanced Surfaces and Processes, Inc. 27 Phase 2 Task 8 Installation of ESD system at PSU Installation of ESD system at PSU Enhanced characterization facilities Enhanced characterization facilities PC based Microhardness PC based Microhardness ESD controlled atmosphere chambers being configured ESD controlled atmosphere chambers being configured High resolution field emission SEM and TEM installed High resolution field emission SEM and TEM installed Scratch tester Scratch tester Axial, rotating, and bending fatigue Axial, rotating, and bending fatigue Collaborative user facility relationships Collaborative user facility relationships FEI Co -- Dual Beam FIB/SEM FEI Co -- Dual Beam FIB/SEM PNNL & EMSL National laboratory user facility PNNL & EMSL National laboratory user facility Courtesy of Portland State University

29 Advanced Surfaces and Processes, Inc. 28 Phase 2 Task 8 Introduction Web Page for ESD Research Project (v2.5) Introduction Web Page for ESD Research Project (v2.5) Courtesy of Portland State University

30 Advanced Surfaces and Processes, Inc. 29 Phase 2 Task 8 Alloy As polished (100X) Alloy As polished (100X) Demonstrating Interference Contrast Courtesy of Portland State University

31 Advanced Surfaces and Processes, Inc. 30 Phase 2 Task 8 ESD voltage-current-porosity relationship ESD voltage-current-porosity relationship Courtesy of Portland State University

32 Advanced Surfaces and Processes, Inc. 31 EWI Contract EWI Contract GEAE Project GEAE Project Tasks Tasks Phase 2 Task 9

33 Advanced Surfaces and Processes, Inc. 32 Phase 2 Task 8 Workscope for GEAE work Workscope for GEAE work Focus on developing mechanical property data for ESD deposits in IN718 Focus on developing mechanical property data for ESD deposits in IN718 Apply ESD welds in machined grooves Apply ESD welds in machined grooves Machine deposits flush and perform tensile, bend and LCF testing Machine deposits flush and perform tensile, bend and LCF testing Compare with unwelded specimens Compare with unwelded specimens Showed Favorable Results Showed Favorable Results Courtesy of Edison Welding Institute & GEAE

34 Advanced Surfaces and Processes, Inc. 33 Phase 2 Task 8 LCF specimen – before and after LCF specimen – before and after Courtesy of Edison Welding Institute & GEAE

35 Advanced Surfaces and Processes, Inc. 34 Phase 2 Task 8 LCF specimen – before and after LCF specimen – before and after Courtesy of Edison Welding Institute & GEAE

36 Advanced Surfaces and Processes, Inc. 35 Reclamation Project Reclamation Project Reclaim super alloy materials from scrap to be used to manufacture electrodes for the ESD process Reclaim super alloy materials from scrap to be used to manufacture electrodes for the ESD process Phase 2 Task 10

37 Advanced Surfaces and Processes, Inc. 36 Phase 2 Status Status All tasks in process All tasks in process

38 Advanced Surfaces and Processes, Inc. 37 Phase 3 7/01/03 – 6/30/04 7/01/03 – 6/30/04 Identify GTE components in which to effect cost effective ESD repairs. Candidate components will be selected and processed for performance testing as required. ESD repair procedures and specifications will be developed for the specific components in anticipation of deployment in DoD facilities. Identify GTE components in which to effect cost effective ESD repairs. Candidate components will be selected and processed for performance testing as required. ESD repair procedures and specifications will be developed for the specific components in anticipation of deployment in DoD facilities.

39 Advanced Surfaces and Processes, Inc. 38 Phase 3 Tasks: Tasks: Develop a database of components as candidates Develop a database of components as candidates Select candidate parts Select candidate parts Identify performance testing requirements Identify performance testing requirements Create repair instructions and specifications Create repair instructions and specifications (From Process Specification Template) Repair candidate parts for performance testing Repair candidate parts for performance testing Evaluate performance testing results, report findings Evaluate performance testing results, report findings Demonstrate process techniques Provide training Demonstrate process techniques Provide training Begin Technology Transfer Begin Technology Transfer Final reports Final reports

40 Advanced Surfaces and Processes, Inc. 39 Develop a comprehensive database of GTE components as candidates for ESD repair. Develop a comprehensive database of GTE components as candidates for ESD repair. Some prior work completed Some prior work completed Phase 3 Task 1

41 Advanced Surfaces and Processes, Inc. 40 Select candidate parts (3-5) for ESD repair development. Select candidate parts (3-5) for ESD repair development. Begin immediately (Scheduled to begin July, 2003) Begin immediately (Scheduled to begin July, 2003) Run parallel with materials and mechanical testing Run parallel with materials and mechanical testing Phase 3 Task 2

42 Advanced Surfaces and Processes, Inc. 41 Identify performance testing requirements for ESD repaired parts. Identify performance testing requirements for ESD repaired parts. Per JTP Per JTP Phase 3 Task 3

43 Advanced Surfaces and Processes, Inc. 42 Create repair instructions and specifications for ESD repair of GTE components. Create repair instructions and specifications for ESD repair of GTE components. (From Process Specification Template, Phase 1, task 5) (From Process Specification Template, Phase 1, task 5) Phase 3 Task 4

44 Advanced Surfaces and Processes, Inc. 43 Repair candidate parts for performance testing. Repair candidate parts for performance testing. Conduct Performance testing (execute the JTP) Conduct Performance testing (execute the JTP) Phase 3 Task 6

45 Advanced Surfaces and Processes, Inc. 44 Evaluate performance testing results, report findings. Evaluate performance testing results, report findings. Document results in a Joint Test Report (JTR) Document results in a Joint Test Report (JTR) Phase 3 Task 7

46 Advanced Surfaces and Processes, Inc. 45 Demonstrate process techniques for OEM’s and DoD facilities Demonstrate process techniques for OEM’s and DoD facilities Phase 3 Task 8

47 Advanced Surfaces and Processes, Inc. 46 Provide training for OEM’s and DoD customers wishing to own/license ESD technology Provide training for OEM’s and DoD customers wishing to own/license ESD technology Phase 3 Task 9

48 Advanced Surfaces and Processes, Inc. 47 Begin Technology Transfer Begin Technology Transfer Phase 3 Task 10

49 Advanced Surfaces and Processes, Inc. 48 Final reports Final reports Monthly Status Reports (MSR) Monthly Status Reports (MSR) Potential Alternatives Report (PAR) Potential Alternatives Report (PAR) Joint Test Protocol (JTP) Joint Test Protocol (JTP) Joint Test Report (JTR) Joint Test Report (JTR) ESTCP Technology Demonstration Report ESTCP Technology Demonstration Report Phase 3 Task 11

50 Advanced Surfaces and Processes, Inc. 49 Phase 3 Status Status With the exception of “Component Selection”, all tasks should begin July, 2003 With the exception of “Component Selection”, all tasks should begin July, 2003

51 Advanced Surfaces and Processes, Inc. 50 Engineered Applications of Electro-Spark Deposition (ESD) for Component Repair Questions?


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