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ElectroSpark DepositionElectroSpark Deposition
Hard Chrome Alternatives TeamJoint Cadmium Alternatives Team
Canadian Hard Chrome Alternatives TeamJoint Group on Pollution Prevention
Propulsion Environmental Working Group
Replacement of Hard Chrome Plating Replacement of Cadmium Plating
Program Review Meeting
23-25 January 2007
Marriott New Orleans at the Convention Center859 Convention Center Blvd
New Orleans, LA 70130
Report Documentation Page Form ApprovedOMB No. 0704-0188
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1. REPORT DATE JAN 2007 2. REPORT TYPE
3. DATES COVERED 00-00-2007 to 00-00-2007
4. TITLE AND SUBTITLE ElectroSpark Deposition
5a. CONTRACT NUMBER
5b. GRANT NUMBER
5c. PROGRAM ELEMENT NUMBER
6. AUTHOR(S) 5d. PROJECT NUMBER
5e. TASK NUMBER
5f. WORK UNIT NUMBER
7. PERFORMING ORGANIZATION NAME(S) AND ADDRESS(ES) Advanced Surfaces And Processes, Inc.,85 N 26th Ave,Cornelius,OR,97113
8. PERFORMING ORGANIZATIONREPORT NUMBER
9. SPONSORING/MONITORING AGENCY NAME(S) AND ADDRESS(ES) 10. SPONSOR/MONITOR’S ACRONYM(S)
11. SPONSOR/MONITOR’S REPORT NUMBER(S)
12. DISTRIBUTION/AVAILABILITY STATEMENT Approved for public release; distribution unlimited
13. SUPPLEMENTARY NOTES 27th Replacement of Hard Chrome and Cadmium Plating Program Review Meeting, January 23-25, 2007,New Orleans, LA. Sponsored by SERDP/ESTCP.
14. ABSTRACT
15. SUBJECT TERMS
16. SECURITY CLASSIFICATION OF: 17. LIMITATION OF ABSTRACT Same as
Report (SAR)
18. NUMBEROF PAGES
53
19a. NAME OFRESPONSIBLE PERSON
a. REPORT unclassified
b. ABSTRACT unclassified
c. THIS PAGE unclassified
Standard Form 298 (Rev. 8-98) Prescribed by ANSI Std Z39-18
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IntroductionsIntroductions
Norma PriceNorma Price
Advanced Surfaces And Processes, Inc.Advanced Surfaces And Processes, Inc.
ElectroSpark Deposition (ESD)ElectroSpark Deposition (ESD)Results of Materials Testing and Technology InsertionResults of Materials Testing and Technology Insertion
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What is ESD?What is ESD?
The ESD process is comprised of generating an arc through The ESD process is comprised of generating an arc through a consumable electrode via capacitive discharge. The a consumable electrode via capacitive discharge. The electrode and substrate materials are melted, rapidly electrode and substrate materials are melted, rapidly solidify, and buildsolidify, and build--up occurs incrementally.up occurs incrementally.
Metallurgical bondMetallurgical bondLow heat inputLow heat inputRapid solidificationRapid solidificationNo preNo pre--ESD preparationESD preparationNo postNo post--ESD processingESD processingEnvironmentally benignEnvironmentally benignPortablePortableApplicable for NLOSApplicable for NLOS
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HistoryHistory
January 25, 2007January 25, 2007Advanced Surfaces And Processes, Inc.Advanced Surfaces And Processes, Inc.
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ProjectProject ObjectiveObjective
The goals of this project were to The goals of this project were to demonstrate and validatedemonstrate and validate
ElectroSpark Deposition (ESD) ElectroSpark Deposition (ESD) as technically feasible and as technically feasible and commercially viable for a commercially viable for a productionproduction--scale process, and scale process, and to perform the tests to perform the tests necessary to transition ESD necessary to transition ESD for use on gas turbine engine for use on gas turbine engine components.components.
January 25, 2007January 25, 2007Advanced Surfaces And Processes, Inc.Advanced Surfaces And Processes, Inc.
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ESTCP/HCATESTCP/HCATPEWGPEWGPortland State UniversityPortland State UniversityEdison Welding InstituteEdison Welding InstituteGeneral Electric Aircraft Engines General Electric Aircraft Engines Pacific Northwest National LabPacific Northwest National Lab
ParticipantsParticipants
Air Force Research LabAir Force Research LabMetcut Metcut Hamilton SundstrandHamilton SundstrandPratt & WhitneyPratt & WhitneyTinker AFBTinker AFBRowan Technology GroupRowan Technology Group
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!! Optimization of ESD (Material Studies)Optimization of ESD (Material Studies)!! Joint Test Protocol (IN 718)Joint Test Protocol (IN 718)!! Joint Test Protocol (three more materials)Joint Test Protocol (three more materials)
–– 410 Stainless Steel410 Stainless Steel–– TiTi--6Al6Al--4V4V–– ChromeChrome--plated IN 718plated IN 718
!! ESD/Robotics/UITESD/Robotics/UIT!! ComponentsComponents
MilestonesMilestones
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www.HCAT.orgwww.HCAT.org
HCAT Member WorkSpace HCAT Member WorkSpace
→→Projects and Partners Projects and Partners
→→Hard Chrome Alternative Team Hard Chrome Alternative Team
→→ ESD ESD -- Electrospark Deposition for Repair (mostly GTEs) Electrospark Deposition for Repair (mostly GTEs) ––PEWGPEWG--HCAT Project EPP 0202 HCAT Project EPP 0202 –– COMPLETED Reports COMPLETED Reports
→→ Final Report Final Report
→→ ESD Final Report Draft.docESD Final Report Draft.doc (updated 8/17/2006)(updated 8/17/2006)
MilestonesMilestones
January 25, 2007January 25, 2007Advanced Surfaces And Processes, Inc.Advanced Surfaces And Processes, Inc.
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410 Stainless Steel410 Stainless Steel
TiTi--6Al6Al--4V4V
ChromeChrome--plated IN 718plated IN 718
Joint Test ProtocolJoint Test ProtocolFor Three Other MaterialsFor Three Other Materials
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OptimizationOptimization
–– Deposition RateDeposition Rate
–– MicrohardnessMicrohardness
–– DiscontinuitiesDiscontinuities
FatigueFatigue
TensileTensile
CorrosionCorrosion
Joint Test ProtocolJoint Test ProtocolFor Three Other MaterialsFor Three Other Materials
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1111
410 Stainless Steel410 Stainless Steel
January 25, 2007January 25, 2007Advanced Surfaces And Processes, Inc.Advanced Surfaces And Processes, Inc.
1212
OptimizationOptimization410 Stainless Steel410 Stainless Steel
January 25, 2007January 25, 2007Advanced Surfaces And Processes, Inc.Advanced Surfaces And Processes, Inc.
1313
OptimizationOptimization410 Stainless Steel410 Stainless Steel
Run Order
Coupon Number
Pulse Rate(Hz)
Voltage(V)
Capacitance(mF)
Electrode Speed(rpm)
1 410-34 300 100 30 8002 410-35 300 150 40 12003 410-36 300 200 50 14004 410-37 500 150 30 14005 410-38 500 200 40 8006 410-39 500 100 50 12007 410-31 700 200 30 12008 410-32 700 100 40 14009 410-33 700 150 50 800
January 25, 2007January 25, 2007Advanced Surfaces And Processes, Inc.Advanced Surfaces And Processes, Inc.
1414
410 Stainless Steel410 Stainless SteelOptimizationOptimization
Deposition Rate of 410SS Coupons
0.000
0.005
0.010
0.015
0.020
0.0250
200
400
600
800
1000
1200
Energy (kJ)
Dep
ositi
on R
ate
(g/m
in)
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1515
410 Stainless Steel410 Stainless SteelOptimizationOptimization
Microhardness in 410SS Coupons
0
100
200
300
400
5000
200
400
600
800
1000
1200
Energy (kJ)
Mic
roha
rdne
ss (K
noop
)
ESD Interface Substrate
January 25, 2007January 25, 2007Advanced Surfaces And Processes, Inc.Advanced Surfaces And Processes, Inc.
1616
410 Stainless Steel410 Stainless SteelOptimizationOptimization
Discontinuities in 410SS Coupons
0.00
1.00
2.00
3.00
4.00
5.00
6.00
7.000
200
400
600
800
1000
1200
Energy (kJ)
Dis
cont
inui
ties
(% A
rea)
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Parameters SelectedParameters Selected410 Stainless Steel410 Stainless Steel
ESD Parameters ESD Parameters –– Based on DOE results: Based on DOE results: 500 Hz Pulse Rate500 Hz Pulse Rate40 mF Capacitance40 mF Capacitance150 volts Voltage150 volts Voltage1100 rpm electrode rotation speed1100 rpm electrode rotation speed
January 25, 2007January 25, 2007Advanced Surfaces And Processes, Inc.Advanced Surfaces And Processes, Inc.
1818
FatigueFatigue410 Stainless Steel410 Stainless Steel
ASTM E466ASTM E466
January 25, 2007January 25, 2007Advanced Surfaces And Processes, Inc.Advanced Surfaces And Processes, Inc.
1919
FatigueFatigue410 Stainless Steel410 Stainless Steel
January 25, 2007January 25, 2007Advanced Surfaces And Processes, Inc.Advanced Surfaces And Processes, Inc.
2020
TensileTensile410 Stainless Steel410 Stainless Steel
ASTM E8ASTM E8
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2121
Tensile Strength
195
196
197
198
199
Baseline Divot ESD 32 ESD V4 Bead-on-Plate
UIT
Ave
rage
Ten
sile
Str
engt
h (k
si)
Yield Strength
168
169
170
171
172
173
174
Baseline Divot ESD 32 ESD V4 Bead-on-Plate
UIT
Ave
rage
Yie
ld S
treng
th (k
si)
TensileTensile410 Stainless Steel410 Stainless Steel
Elongation
15
20
25
30
Baseline Divot ESD 32 ESD V4 Bead-on-Plate
UIT
Aver
age
Elon
gatio
n (%
)
Reduction in Area
25
30
35
40
Baseline Divot ESD 32 ESD V4 Bead-on-Plate
UIT
Ave
rage
Red
uctio
n in
Are
a (%
)
Method 22
Method 22Method 22
Method 22
January 25, 2007January 25, 2007Advanced Surfaces And Processes, Inc.Advanced Surfaces And Processes, Inc.
2222
TensileTensile410 Stainless Steel410 Stainless Steel
410 All Conditions
0
20
40
60
80
100
120
140
160
0 1 2 3 4 5 6 7 8 9 10 11 12
Strain, ε (%)
Stre
ss, σ
(ksi
)
Baseline with Defect
Baseline
Bead On Plate
ESD
ESD with UITMethod 2
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2323
CorrosionCorrosion410 Stainless Steel410 Stainless Steel
ASTM B117ASTM B117
Performed by Performed by Cascade Technical Sciences, Inc.Cascade Technical Sciences, Inc.
Hillsboro, OregonHillsboro, Oregon
January 25, 2007January 25, 2007Advanced Surfaces And Processes, Inc.Advanced Surfaces And Processes, Inc.
2424
CorrosionCorrosion410 Stainless Steel410 Stainless Steel
Before TestBefore Test
January 25, 2007January 25, 2007Advanced Surfaces And Processes, Inc.Advanced Surfaces And Processes, Inc.
2525
CorrosionCorrosion410 Stainless Steel410 Stainless Steel
After TestAfter Test
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2626
TiTi--6Al6Al--4V4V
January 25, 2007January 25, 2007Advanced Surfaces And Processes, Inc.Advanced Surfaces And Processes, Inc.
2727
TiTi--6Al6Al--4V4V
TiTi--6Al6Al--4V Specimens Prepared in a Glove Box4V Specimens Prepared in a Glove Box
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2828
Run Order
Coupon Number
Pulse Rate(Hz)
Voltage(V)
Capacitance(mF)
Electrode Speed(rpm)
1 Ti-21 500 130 50 8002 Ti-19 300 130 40 12003 Ti-11 300 170 50 14004 Ti-15 400 130 30 14005 Ti-13 400 170 40 8006 Ti-20 400 90 50 12007 Ti-17 500 170 30 12008 Ti-14 500 90 40 14009 Ti-12 300 90 30 800
Run Order
Coupon Number
Pulse Rate(Hz)
Voltage(V)
Capacitance(mF)
Electrode Speed(rpm)
1 Ti-21 500 130 50 8002 Ti-19 300 130 40 12003 Ti-11 300 170 50 14004 Ti-15 400 130 30 14005 Ti-13 400 170 40 8006 Ti-20 400 90 50 12007 Ti-17 500 170 30 12008 Ti-14 500 90 40 14009 Ti-12 300 90 30 800
OptimizationOptimizationTiTi--6Al6Al--4V4V
January 25, 2007January 25, 2007Advanced Surfaces And Processes, Inc.Advanced Surfaces And Processes, Inc.
2929
Deposition Rate of Ti-6Al-4V Coupons
-0.005
0.000
0.005
0.010
0.015
0.020
0.0250
100
200
300
400
500
600
700
800
Energy (kJ)
Dep
ositi
on R
ate
(g/m
in)
TiTi--6Al6Al--4V4VOptimizationOptimization
January 25, 2007January 25, 2007Advanced Surfaces And Processes, Inc.Advanced Surfaces And Processes, Inc.
3030
Microhardness in Ti-6Al-4V Coupons
0
100
200
300
400
5000
100
200
300
400
500
600
700
800
Energy (kJ)
Mic
roha
rdne
ss (K
noop
)
ESD Interface Substrate
TiTi--6Al6Al--4V4VOptimizationOptimization
January 25, 2007January 25, 2007Advanced Surfaces And Processes, Inc.Advanced Surfaces And Processes, Inc.
3131
Discontinuities in Ti-6Al-4V Coupons
0.00
1.00
2.00
3.00
4.00
5.00
6.00
7.000
100
200
300
400
500
600
700
800
Energy (kJ)
Dis
cont
inui
ties
(% A
rea)
TiTi--6Al6Al--4V4VOptimizationOptimization
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3232
ESD Parameters ESD Parameters –– Based on DOE results: Based on DOE results: 500 Hz Pulse Rate500 Hz Pulse Rate50 mF Capacitance50 mF Capacitance130 volts Voltage130 volts Voltage1400 rpm electrode rotation speed1400 rpm electrode rotation speed
Parameters SelectedParameters SelectedTiTi--6Al6Al--4V4V
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3333
FatigueFatigueTiTi--6Al6Al--4V4V
January 25, 2007January 25, 2007Advanced Surfaces And Processes, Inc.Advanced Surfaces And Processes, Inc.
3434
Tensile Strength
130.0
135.0
140.0
145.0
150.0
Baseline Baselinewith Defect
ESD Bead-on-Plate
ESD withUIT
Ave
rage
Ten
sile
Stre
ngth
(ksi
)
Yield Strength
168
169
170
171
172
173
174
Baseline Divot ESD 32 ESD V4 Bead-on-Plate
UIT
Ave
rage
Yie
ld S
treng
th (k
si)
TensileTensileTiTi--6Al6Al--4V4V
Elongation
0.00
10.00
20.00
30.00
40.00
50.00
Baseline Baselinewith Defect
ESD Bead-on-Plate
ESD withUIT
Ave
rage
Elo
ngat
ion
(%)
Reduction in Area
0.0
5.0
10.0
15.0
20.0
25.0
30.0
Baseline Baseline withDefect
ESD Bead-on-Plate
ESD with UIT
Ave
rage
Red
uctio
n in
Are
a (%
)
Method 22
Method 22Method 22
Method 22
January 25, 2007January 25, 2007Advanced Surfaces And Processes, Inc.Advanced Surfaces And Processes, Inc.
3535
TensileTensileTiTi--6Al6Al--4V4V
Ti-6Al-4V All Conditions
0
20
40
60
80
100
120
140
0 2 4 6 8 10 12 14 16 18 20
Strain, ε (%)
Stre
ss, σ
(ksi
)
Baseline with DefectBaselineBead On PlateESDESD with UITMethod 2
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3636
CorrosionCorrosionTiTi--6Al6Al--4V4V
Before TestBefore Test
January 25, 2007January 25, 2007Advanced Surfaces And Processes, Inc.Advanced Surfaces And Processes, Inc.
3737
CorrosionCorrosionTiTi--6Al6Al--4V4V
After TestAfter Test
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3838
ChromeChrome--Plated IN 718Plated IN 718
January 25, 2007January 25, 2007Advanced Surfaces And Processes, Inc.Advanced Surfaces And Processes, Inc.
3939
Run Order
Coupon Number
Pulse Rate(Hz)
Voltage(V)
Capacitance(mF)
Electrode Speed(rpm)
1 Chrome-1 300 100 10 8002 Chrome-2 300 125 20 12003 Chrome-3 300 150 30 14004 Chrome-4 400 100 20 14005 Chrome-5 400 125 30 8006 Chrome-6 400 150 10 12007 Chrome-7 500 100 30 12008 Chrome-8 500 125 10 14009 Chrome-9 500 150 20 800
OptimizationOptimizationChromeChrome--Plated IN 718Plated IN 718
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4040
ChromeChrome--Plated IN 718Plated IN 718OptimizationOptimization
Deposition RateDeposition Rate
Because of the difficulty with depositing material on Because of the difficulty with depositing material on chrome plated coupons, and with some areas of chrome plated coupons, and with some areas of chrome plate debonding (or having been debonded), chrome plate debonding (or having been debonded), the weight gain measurements, and therefore, the the weight gain measurements, and therefore, the deposition rates were not determined.deposition rates were not determined.
January 25, 2007January 25, 2007Advanced Surfaces And Processes, Inc.Advanced Surfaces And Processes, Inc.
4141
Microhardness in Cr-Plated IN718 Coupons
0
100
200
300
400
5000 10 20 30 40 50 60 70 80
Energy (kJ)
Mic
roha
rdne
ss (K
noop
)
ESD Interface Substrate
ChromeChrome--Plated IN 718Plated IN 718OptimizationOptimization
January 25, 2007January 25, 2007Advanced Surfaces And Processes, Inc.Advanced Surfaces And Processes, Inc.
4242
Discontinuities in Cr-Plated IN718 Coupons
0.00
1.00
2.00
3.00
4.00
5.00
6.00
7.000 10 20 30 40 50 60 70 80
Energy (kJ)
Dis
cont
inui
ties
(% A
rea)
ChromeChrome--Plated IN 718Plated IN 718OptimizationOptimization
January 25, 2007January 25, 2007Advanced Surfaces And Processes, Inc.Advanced Surfaces And Processes, Inc.
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Parameters SelectedParameters SelectedChromeChrome--Plated IN 718Plated IN 718
January 25, 2007January 25, 2007Advanced Surfaces And Processes, Inc.Advanced Surfaces And Processes, Inc.
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Parameters SelectedParameters SelectedChromeChrome--Plated IN 718Plated IN 718
ESD Parameters ESD Parameters –– Based on Metallographic results: Based on Metallographic results: 300 Hz Pulse Rate300 Hz Pulse Rate30 mF Capacitance30 mF Capacitance150 volts Voltage150 volts Voltage1400 rpm electrode rotation speed1400 rpm electrode rotation speed
January 25, 2007January 25, 2007Advanced Surfaces And Processes, Inc.Advanced Surfaces And Processes, Inc.
4545
FatigueFatigueChromeChrome--Plated IN 718Plated IN 718
January 25, 2007January 25, 2007Advanced Surfaces And Processes, Inc.Advanced Surfaces And Processes, Inc.
4646
Tensile Strength
140.0
145.0
150.0
155.0
160.0
Baseline Baseline withDefect
ESD Bead-on-Plate
Ave
rage
Ten
sile
Stre
ngth
(ksi
)
Yield Strength
120.0
125.0
130.0
135.0
140.0
Baseline Baseline withDefect
ESD Bead-on-Plate
Ave
rage
Yie
ld S
treng
th (k
si)
TensileTensileChromeChrome--Plated IN 718Plated IN 718
Elongation
0.00
10.00
20.00
30.00
40.00
50.00
Baseline Baseline withDefect
ESD Bead-on-Plate
Ave
rage
Elo
ngat
ion
(%)
Reduction in Area
0.0
5.0
10.0
15.0
20.0
25.0
30.0
35.0
Baseline Baseline withDefect
ESD Bead-on-Plate
Ave
rage
Red
uctio
n in
Are
a (%
)
January 25, 2007January 25, 2007Advanced Surfaces And Processes, Inc.Advanced Surfaces And Processes, Inc.
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TensileTensileChromeChrome--Plated IN 718Plated IN 718
Chrome Plated IN718 - All Conditions
0
50
100
150
200
250
0 1 2 3 4 5 6 7 8 9 10
Strain, ε (%)
Stre
ss, σ
(ksi
)
Baseline with Defect
Baseline
Bead on Plate
ESD
January 25, 2007January 25, 2007Advanced Surfaces And Processes, Inc.Advanced Surfaces And Processes, Inc.
4848
CorrosionCorrosion410 Stainless Steel410 Stainless Steel
Before TestBefore Test
January 25, 2007January 25, 2007Advanced Surfaces And Processes, Inc.Advanced Surfaces And Processes, Inc.
4949
CorrosionCorrosion410 Stainless Steel410 Stainless Steel
After TestAfter Test
January 25, 2007January 25, 2007Advanced Surfaces And Processes, Inc.Advanced Surfaces And Processes, Inc.
5050
Project CompleteProject Complete
Addendum to Final Report sent to Addendum to Final Report sent to ESTCP on December 12, 2006.ESTCP on December 12, 2006.
January 25, 2007January 25, 2007Advanced Surfaces And Processes, Inc.Advanced Surfaces And Processes, Inc.
5151
From Material PropertiesFrom Material Properties……
#5 Bearing Housing (410 SS)Stator Segment (IN 718)Compressor Rear Shaft (Chrome Plate)
To ComponentsTo Components
January 25, 2007January 25, 2007Advanced Surfaces And Processes, Inc.Advanced Surfaces And Processes, Inc.
5252
Other Projects and ApplicationsOther Projects and Applications
Army Army –– Anniston Anniston –– Abrams TankAbrams Tank
Navy Navy –– Carderock Carderock –– Nuclear SubNuclear Sub
Army Army –– Watervliet/Benet Watervliet/Benet -- RailRail
ElectroSpark DepositionElectroSpark Deposition
Advanced Surfaces And Process, Inc.Advanced Surfaces And Process, Inc.
503.640.4072503.640.4072www.advancedwww.advanced--surfaces.comsurfaces.com
FAA Repair facility # V9PR575YFAA Repair facility # V9PR575Y
P.O. Box 729P.O. Box 729 85 N 2685 N 26thth AveAveForest Grove, OR 97116Forest Grove, OR 97116 Cornelius, OR 97113Cornelius, OR 97113