Current Navy Cold Spray CapabilitiesNAVAIR FacilitiesFRC-East. 2 high & 1 low pressurePax River, low pressure portable FRC Southeast (Jax), low pressure portableFRC Southwest (NI), low pressure portable, 2 high pressure robotic units (fy 14) NAVSEA- NSWCCD Inovati since 2004- Keyport? NPS- Low Pressure cabinet

Technology AssessmentTarget Material Applications Air VehiclesAluminum alloys used for naval aviation applications7075-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, AF1410Magnesium alloys (AZ-91, ZE41A)Titanium (Ti6-4)

Partnerships / CollaborationsDirect collaboration with AIR 4.4.2.3 Power & Propulsion AIR 4.3.3.2 StructuresAIR 4.3.4.2 NDI (Pax & FRC-SW)Penn State ARL (REPTECH)PMA 265, PMA 299FRC East, Southeast, SouthwestSikorsky Aircraft, Boeing AircraftAustralian DSTONSWC Carderock & US Naval Postgrad Partnerships withUSMC Corrosion ProgramNSWC Carderock MaterialsEngineer/Scientist RotationNRL Code 35US Naval Postgrad School, MontereyArmy Research LabAMRDECTIPS: H-1 Combining Gearbox RepairDLA: IVD Aluminum Repair, Cad Alternative, Hard Chrome AlternativeSBIR: Low pressure repairs, two small businesses & academiaAERMIP: Low Pressure Portable Metallization FRC-SE, Hole restoration F-18OSD Corrosion: Portable Robotic SystemREPTECH- PSU ARL Portable Repair and Restoration of Aluminum and Magnesium ComponentsOSD Mantech-2012 Cold Spray Repair & Rebuild Technology (automated)ONR SBA (NSWC Carderock/NPS) Single Particle Impact Study

FY12 ProgressKey Milestones AchievedAll depots operational & workforce trainedDT/OT for AMAD Fretting Corrosion RepairParts released back into fleetDT for AMAD internal damage rebuild repairFRC-East System UpgradeAuxiliary heater installed on CGT Unit. FY13 ProgressKey Milestones AchievedContinued flight time for AMAD repairsUpgrade of CGT-4000 @ FRC-E w/ 47kW heaterOSD Corrosion Office sponsorship for continued working relation with Australian DSTO. (overall, slow due to sequestration)

FY14 ExpectationsFuture: F-18Radar Racks, AMAD Gear Hard Chrome Alt, Wing/spar fastener hole repair (ie bushing repair)20 F-18 Radar Racks est $220K each tot $4.4MIVD Repair: H-60Canted bulkhead repair (bushing alternative)Gearbox repair (SAC & Australian DSTO)V-22V-22 Sills est $80K+ each sending back to CP.H-1Cobox O-Level RepairsFRC independent teams can now perform repairsContinue S&T work at Pax River with FRCs to expand applicationsRefine portable repair process (field and depot roll up to the airframe)Further Navy & Marine Corps Collaborative projectsCollaborative engineer rotation set-up with NSWC Carderock

Change Authorizations to DateLocal 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.

FRC-SW Cold Spray Apps & RepairsF/A-18E/F AMAD Main Housing (hydraulic pad restoration) LPSF/A-18E/F AMAD Main Housing (gear failure repair) LPSF/A-18E/F AMAD Hydraulic Gearshaft (seal surface repair) LPSF/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 Unit PTS = Power Take-Off Shaft PMG = Permanent Magnet Group HSS = High-Strength Steel LPS = Local Process SpecificationMatureIn-ProcessRecently Identified

FRC-E Cold Spray Apps & RepairsH-60 Sump (wear restoration, dimensional repair) SAC ORIH-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) LPSH-60 Gearbox Pad Restoration; Intermediate, Tail, Combining, & Main AMAD = Aircraft Mounted Accessory Drive GCU = Generator Control Unit PTS = Power Take-Off Shaft PMG = Permanent Magnet Group HSS = High-Strength SteelLPS = Local Process SpecificationMatureIn-Process

FRC-SE Cold Spray Apps & RepairsF-18 Bomb Rack Repair (coating repair) LPSGSE Spotting Dolly Pin Coating Repair (coating repair) Engineering Test

IVD Aluminum repair

AMAD = Aircraft Mounted Accessory Drive GCU = Generator Control Unit PTS = Power Take-Off Shaft PMG = Permanent Magnet Group HSS = High-Strength Steel\GSE= Ground Support EquipmentLPS= Local Process SpecificationMatureIn-Process

*F-18 E/F/G AMAD Transmission Housing High Pressure Fretting/Dim Rep(Section 219) FRC-SWH-53 MGB Pad Mounts ( POM15)CorrosionDimensional/Non-structuralStructural (Repair within struct limits)KeyPSU-ARL Repairability, F-18 (REPTECH)FutureCurrent & Future ProjectsRepair of Cad Alt to Brush Plate (DLA)Repair of IVD(DLA)

*Corrosion/CoatDimensional/Non-structuralStructural (Repair within struct limits)KeyPSU-ARL Repairability, F-18 (REPTECH)Current & Future ProjectsRepair 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)Portable Robotic Cold Spray ApplicationTo Be Proposed (wish list)

Example: Australian DSTO has adapted a robotic cold spray metallization system for Mobile RepairAdvantage: 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 ProjectFuture: Field/FRC Deployable Robotic Systems

S&T AnalysisProcess parametersRepair limitationsCoating optimizationPowderSurface preparationSpray parametersCoating bond strengthCoating cohesionPost-coating preparationSealingWeldingMachiningMicrostructural characterizationMetallurgical bondDislocation densityCoating formationMechanical properties (comparison to existing technology)Residual stress

FatigueCorrosionEvaluation/Development of NDTSignificance of FlawsSpecifications and RequirementsFitness for service acceptance criteria & logisticsIn-service repairSafety/Environmental concernsApplication based cost benefit analysisModeling, process & materialsLogistics constraintsMaterialEquipment

Issues for all materials of interest to the Navy/NAVAIRNeed to tie fundamental understanding of process parameters/operating envelope to coating properties

Hierarchy of Cold Spray Application Projects

ApproachEstablish Procedure(s) Develop Process(es) & EquipmentNRL, ARL, NSWC-Carderock, Industry, Academia Certify Testing & Results (laboratory)Physical TestsCorrosion TestsNon-destructiveDevelop Process Certification Procedures/MethodsSystem/Process Functional TestsApply to aircraftFlight TestDevelop

Qualify

Check

Assure

Take-AwaysAll Fleet Readiness Centers are capable of Cold Spray repairsHardware in placePersonnel trained, SMEs in placeActive S&T portfolio to support new process applicationsStill a significant amount of applications & repairs to developNew alloy development still an open technology area.Continue process development, verification & validation, and qualification of applicationsNext Step: Portable Systems for Depot & Field UseDevelop portable repair processes for field and depot roll up to the airframe in place.

Summary Responsive to fleet needs with solutions that keep fleet assets affordable & maintainable Establishing for NAVAIR a solid base to grow fromMaterial & Process ProtocolsCapabilitiesProcessesManpowerLogistics

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