NAVAIR Cold Spray Initiative Update

1
NAVAIR Cold Spray Initiative Update

• Cold Spray Action TEAM

• CSAT 2014 TIM Worcester Polytechnic Institute

• Frederick A. Lancaster AIR 4.3.4 ST Lead

• June 2014

2
Objective

• The US Navy has the need to perform
  dimensional restoration of metallic components
  caused by corrosion, restoration of material due
  to wear or damage, and the ability to easily and
  rapidly repair structures in place on Naval
  Aircraft.
• The objective is to develop a metallization
  process that can be used to facilitate repairs on
  naval aviation assets at all levels of
  maintenance.
• Naval ST Focus Areas
• Affordability v
• Maintainability v
• Reliability
• Naval ST Objectives
• Platform Affordability v
• Availability v

3
NAVAIR Workforce Development
Engineer 1 Ground Support
Engineer 8, Tech 1 Low Pressure unit
Engineer 4 Tech 1 Low/High Pressure units
Engineer 3 Tech 1 Low Pressure, 2 Robotic High
pressure units
Engineer 4 Tech 1 Low Pressure
4
NAVAIR Cold Spray Timeline
Pre-Section 219 Timeframe (5 Years)
Section 219 ST Investment
8 F-18 parts back in service 3 H-1 parts back in
service 2 approved repair processes 2 new process
pending/local approval 5 parts OEM approved (SAC)
for rework
Gearbox CS Repaired
Part Repair Approval
Initiate Army Contact
Army Collaboration (Demval, Testing, Information
Exchange, Project Teaming, DOD Vision)
SME
Trained
Pax River
SME
Modeling
SME
Trained
SME
FRC-East
SME
4 Low pressure CS units Operational All FRCs w/
full repair capability Technical staff trained _at_
all sites 2 sites high pressure capable
FRC-SE
Trained
SME
Trained
FRC-SW
MIL-STD-3021 Cold Spray Spec
MIL-PRF-XXXX Aerospace Powder Spec
Cold spray specifications for process
Approved Aerospace Powder Spec Developing
Specifications
3-------------------------4------------------5----
---TRL Level--------------6--------7--------------
-------8--9
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Current Navy Cold Spray Capabilities

• NAVAIR Facilities
• FRC-East. 2 high 1 low pressure
• Pax River, low pressure portable
• FRC Southeast (Jax), low pressure portable
• FRC Southwest (NI), low pressure portable, 2 high
  pressure robotic units (fy 14)
• NAVSEA
• - NSWCCD Inovati since 2004
• - Keyport?
• NPS
• - Low Pressure cabinet

6
Technology Assessment

• Target Material Applications Air Vehicles
• Aluminum alloys used for naval aviation
  applications
• 7075-T73651 Plate,
• 7075-T76511 Extruded,
• 7075-T6 sheet/clad skin,
• 2024-T3 sheet/cladskin,
• A356-T61 Cast,
• Steel alloys used for naval aviation applications
  
• AISI 4130 AISI 4340,
• Stainless Steel PH13-8Mo,
• High Strength Steels (landing gear, arresting
  hooks),
• 300M,
• Aermet 100,
• AF1410
• Magnesium alloys (AZ-91, ZE41A)
• Titanium (Ti6-4)

7
Partnerships / Collaborations

• Direct collaboration with
• AIR 4.4.2.3 Power Propulsion
• AIR 4.3.3.2 Structures
• AIR 4.3.4.2 NDI (Pax FRC-SW)
• Penn State ARL (REPTECH)
• PMA 265, PMA 299
• FRC East, Southeast, Southwest
• Sikorsky Aircraft, Boeing Aircraft
• Australian DSTO
• NSWC Carderock US Naval Postgrad

• Partnerships with
• USMC Corrosion Program
• NSWC Carderock Materials
• Engineer/Scientist Rotation
• NRL Code 35
• US Naval Postgrad School, Monterey
• Army Research Lab
• AMRDEC

• TIPS H-1 Combining Gearbox Repair
• DLA IVD Aluminum Repair, Cad Alternative, Hard
  Chrome Alternative
• SBIR Low pressure repairs, two small businesses
  academia
• AERMIP Low Pressure Portable Metallization
  FRC-SE, Hole restoration F-18
• OSD Corrosion Portable Robotic System
• REPTECH- PSU ARL Portable Repair and Restoration
  of Aluminum and Magnesium Components
• OSD Mantech-2012 Cold Spray Repair Rebuild
  Technology (automated)
• ONR SBA (NSWC Carderock/NPS) Single Particle
  Impact Study

8
FY12 Progress

• Key Milestones Achieved
• All depots operational workforce trained
• DT/OT for AMAD Fretting Corrosion Repair
• Parts released back into fleet
• DT for AMAD internal damage rebuild repair
• FRC-East System Upgrade
• Auxiliary heater installed on CGT Unit.

FY13 Progress

• Key Milestones Achieved
• Continued flight time for AMAD repairs
• Upgrade of CGT-4000 _at_ FRC-E w/ 47kW heater
• OSD Corrosion Office sponsorship for continued
  working relation with Australian DSTO.
• (overall, slow due to sequestration)

9
FY14 Expectations

• Future
• F-18
• Radar Racks, AMAD Gear Hard Chrome Alt, Wing/spar
  fastener hole repair (ie bushing repair)
• 20 F-18 Radar Racks est 220K each tot 4.4M
• IVD Repair
• H-60
• Canted bulkhead repair (bushing alternative)
• Gearbox repair (SAC Australian DSTO)
• V-22
• V-22 Sills est 80K each sending back to CP.
• H-1
• Cobox O-Level Repairs
• FRC independent teams can now perform repairs
• Continue ST work at Pax River with FRCs to
  expand applications
• Refine portable repair process (field and depot
  roll up to the airframe)
• Further Navy Marine Corps Collaborative
  projects
• Collaborative engineer rotation set-up with NSWC
  Carderock

10
Change Authorizations to Date

• Local Process Specifications Authority granted
  by the cognizant engineering authority at the
  Fleet Readiness Center (With local Materials
  involved competencies concurrence)
• Engineering Orders from Sikorsky (ORI/(MEO
  Army)) OEM approval. For Cold Spray the parts to
  date are for using cold spray aluminum as an
  alternative to flame spray aluminum, mainly for
  wear areas, 5 applications.

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FRC-SW Cold Spray Apps Repairs

• F/A-18E/F AMAD Main Housing (hydraulic pad
  restoration) LPS
• F/A-18E/F AMAD Main Housing (gear failure repair)
  LPS
• F/A-18E/F AMAD Hydraulic Gearshaft (seal surface
  repair) LPS
• F/A-18E/F Main Landing Gear Brake Carrier
• F/A-18A-D AMAD Housing PTS Axis (fretting repair)
• F/A-18E/F Radar Rack Assembly (dimensional
  restoration)
• F/A-18A-D GCU Tube Flange (pitted repair)
• F/A-18E/F GCU PMG Shaft (dimensional restoration)
• F/A-18E/F Wing Panel Fastener Holes (dimensional
  restore)
• F/A-18A-D Center Pylon (dimensional restoration)
• 10. F/A-18E/F Steering Collar Cover (HSS
  dimensional restore)
• 11. F/A-18E/F Arresting Hook Pivot (HSS
  dimensional restore)
• AMAD Aircraft Mounted Accessory Drive
  GCU Generator Control UnitPTS Power Take-Off
  Shaft PMG Permanent
  Magnet GroupHSS High-Strength Steel
  LPS Local Process Specification

Mature
In-Process
RecentlyIdentified
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FRC-E Cold Spray Apps Repairs

• H-60 Sump (wear restoration, dimensional repair)
  SAC ORI
• H-53 Five SAC ORIs for various drivetrain
  parts. (detail coming)
• H-1 Combining Gearbox Chafing repair
  (dimensional) LPS
• First Operational Level Repair
• V-22 Window Sill Corrosion Repair (dimensional)
  LPS
• H-60 Gearbox Pad Restoration
• Intermediate,
• Tail,
• Combining,
• Main
• AMAD Aircraft Mounted Accessory DriveGCU
  Generator Control UnitPTS Power Take-Off
  ShaftPMG Permanent Magnet GroupHSS
  High-Strength Steel
• LPS Local Process Specification

Mature
In-Process
13
FRC-SE Cold Spray Apps Repairs

• F-18 Bomb Rack Repair (coating repair) LPS
• GSE Spotting Dolly Pin Coating Repair (coating
  repair) Engineering Test
• IVD Aluminum repair
• AMAD Aircraft Mounted Accessory DriveGCU
  Generator Control UnitPTS Power Take-Off
  ShaftPMG Permanent Magnet GroupHSS
  High-Strength Steel\
• GSE Ground Support Equipment
• LPS Local Process Specification

Mature
In-Process
14
Current Future Projects
Repair of IVD(DLA)
Repair of Cad Alt to Brush Plate (DLA)
F-18 E/F/G AMAD Transmission Housing High
Pressure Fretting/Dim Rep(Section 219) FRC-SW
PSU-ARL Repairability, F-18 (REPTECH)
Key
H-53 MGB Pad Mounts ( POM15)
Corrosion
Dimensional/Non-structural
Future
Structural (Repair within struct limits)
15
Current Future Projects
Repair of Cad Alt to Brush Plate (DLA)
Repair of IVD(DLA)
Repair of Cad Alt to Brush Plate (DLA)
F-18 Wing Spar Fastener Hole Elongation
Repair(AERMIP)
PSU-ARL Repairability, F-18 (REPTECH)
Portable Robotic Cold Spray Application
Key
Corrosion/Coat
Dimensional/Non-structural
Structural (Repair within struct limits)
To Be Proposed (wish list)
16
Future Field/FRC Deployable Robotic Systems
Example Australian DSTO has adapted a robotic
cold spray metallization system for Mobile Repair
Advantage Ability to apply CS portably at High
Pressures for structural applications or precise
repair. Goal A system that artisan teams can
deploy and repair aircraft in the field,
operational level, or at the aircraft at the
Intermediate level. Worked with RAN under a
Coalition Warfare project to further develop this
technology for structural applications. Currently
awarded an OSD Corrosion effort to further
collaboration demonstration of portable repairs.
Rosebank Engineering presentation TSS Cold
Spray Conference 2010-Cold Spray application in
Australian Aerospace Industries-Neil Matthews
DSTO Project
17
ST Analysis
Issues for all materials of interest to the
Navy/NAVAIR

• Fatigue
• Corrosion
• Evaluation/Development of NDT
• Significance of Flaws
• Specifications and Requirements
• Fitness for service acceptance criteria
  logistics
• In-service repair
• Safety/Environmental concerns
• Application based cost benefit analysis
• Modeling, process materials
• Logistics constraints
• Material
• Equipment

• Process parameters
• Repair limitations
• Coating optimization
• Powder
• Surface preparation
• Spray parameters
• Coating bond strength
• Coating cohesion
• Post-coating preparation
• Sealing
• Welding
• Machining
• Microstructural characterization
• Metallurgical bond
• Dislocation density
• Coating formation
• Mechanical properties (comparison to existing
  technology)
• Residual stress

Need to tie fundamental understanding of process
parameters/operating envelope to coating
properties
18
Hierarchy of Cold Spray Application Projects
Advanced Powder/Alloy Development
Structural
Corrosion Dimensional Non-Structural
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Approach
Develop Qualify Check Assure

• Establish Procedure(s)
• Develop Process(es) Equipment
• NRL, ARL, NSWC-Carderock, Industry, Academia
• Certify Testing Results (laboratory)
• Physical Tests
• Corrosion Tests
• Non-destructive
• Develop Process Certification Procedures/Methods
• System/Process Functional Tests
• Apply to aircraft
• Flight Test

20
Take-Aways

• All Fleet Readiness Centers are capable of Cold
  Spray repairs
• Hardware in place
• Personnel trained, SMEs in place
• Active ST portfolio to support new process
  applications
• Still a significant amount of applications
  repairs to develop
• New alloy development still an open technology
  area.
• Continue process development, verification
  validation, and qualification of applications
• Next Step Portable Systems for Depot Field Use
• Develop portable repair processes for field and
  depot roll up to the airframe in place.

21
Summary

• Responsive to fleet needs with solutions that
  keep fleet assets affordable maintainable
• Establishing for NAVAIR a solid base to grow from
• Material Process Protocols
• Capabilities
• Processes
• Manpower
• Logistics