Presented to:

Presented by:

NAVAIR Cold Spray Initiative UpdateNAVAIR Cold Spray Initiative Update

CSAT 2014 TIM; Worcester Polytechnic Institute

Frederick A. Lancaster AIR 4.3.4 S&T Lead

Cold Spray Action TEAM

June 2014

1911-2011 100 Years of Naval Aviation

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 S&T Focus Areas: – Affordability √

– Maintainability √ – Reliability

Naval S&T Objectives: – Platform Affordability √

– Availability √

2

1911-2011 100 Years of Naval Aviation

NAVAIR Workforce Development

04/22/23

3

Engineer 8, Tech 1; Low Pressure unit

Engineer 4Tech 1; Low Pressure

Engineer 3Tech 1; Low Pressure, 2 Robotic High pressure units

Engineer 4Tech 1; Low/High Pressure units

Engineer 1 Ground Support

1911-2011 100 Years of Naval Aviation

FY-05 FY-06 FY-07 FY-08 FY-09 FY-10 FY-11 FY-12+

FRC-East

Pax River

FRC-SE

FRC-SW

Part Repair Approval

MIL-STD-3021Cold Spray Spec

Specifications

MIL-PRF-XXXXAerospace Powder Spec

8 F-18 parts back in service3 H-1 parts back in service2 approved repair processes2 new process pending/local approval5 parts OEM approved (SAC) for rework

4 Low pressure CS units OperationalAll FRC’s w/ full repair capability

Technical staff trained @ all sites2 sites high pressure capable

Cold spray specifications for process Approved

Aerospace Powder Spec Developing

SME

SME

SME

SMETrained

Trained

Trained

Trained

SME

SME

Modeling

Section 219 S&T Investment

Initiate Army

ContactArmy Collaboration (Demval, Testing, Information Exchange, Project Teaming, DOD Vision)

3-------------------------4------------------5-------TRL Level--------------6--------7---------------------8--9

Gearbox CS Repaired

Pre-Section 219 Timeframe (5 Years)

NAVAIR Cold Spray Timeline

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

Technology AssessmentTarget 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)

Partnerships / CollaborationsDirect 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

FY12 ProgressKey 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 ProgressKey Milestones Achieved

– Continued flight time for AMAD repairs– Upgrade of CGT-4000 @ FRC-E w/ 47kW heater– OSD Corrosion Office sponsorship for continued working relation with Australian

DSTO.

– (overall, slow due to sequestration)

FY14 ExpectationsFuture:

– 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 S&T work at Pax River with FRC’s 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

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.

FRC-SW Cold Spray Apps & Repairs1. F/A-18E/F AMAD Main Housing (hydraulic pad restoration) LPS2. F/A-18E/F AMAD Main Housing (gear failure repair) LPS3. F/A-18E/F AMAD Hydraulic Gearshaft (seal surface repair) LPS4. F/A-18E/F Main Landing Gear Brake Carrier 5. F/A-18A-D AMAD Housing PTS Axis (fretting repair)

6. F/A-18E/F Radar Rack Assembly (dimensional restoration) 7. F/A-18A-D GCU Tube Flange (pitted repair)8. F/A-18E/F GCU PMG Shaft (dimensional restoration)9. F/A-18E/F Wing Panel Fastener Holes (dimensional restore)10.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

Matu

re

In-

Pro

cess

Recen

tly

Iden

tified

FRC-E Cold Spray Apps & Repairs1. H-60 Sump (wear restoration, dimensional repair) SAC ORI2. H-53 – Five SAC ORI’s for various drivetrain parts. (detail

coming)3. H-1 Combining Gearbox Chafing repair (dimensional) LPS *

1. First Operational Level Repair

4. V-22 Window Sill Corrosion Repair (dimensional) LPS5. H-60 Gearbox Pad Restoration;

1. Intermediate, 2. Tail, 3. Combining, & 4. Main

AMAD = Aircraft Mounted Accessory DriveGCU = Generator Control UnitPTS = Power Take-Off ShaftPMG = Permanent Magnet GroupHSS = High-Strength SteelLPS = Local Process Specification

Matu

re

In-

Pro

cess

FRC-SE Cold Spray Apps & Repairs1. F-18 Bomb Rack Repair (coating repair) LPS2. GSE Spotting Dolly Pin Coating Repair (coating repair)

Engineering Test

3. IVD Aluminum repair

AMAD = Aircraft Mounted Accessory DriveGCU = Generator Control UnitPTS = Power Take-Off ShaftPMG = Permanent Magnet GroupHSS = High-Strength Steel\GSE= Ground Support EquipmentLPS= Local Process Specification

Matu

re

In-P

rocess

14

Yr-13 Yr-10 Yr-11 Yr-12

Aircraft Component &Transition(s) TimelineAircraft Component &Transition(s) Timeline

H-60 Gearbox repairs – Australian Navy/USN/US Army/SAC

Repair of Cad & Al Coatings (OSD)

UH-1N/AH-1W COMBINING GEARBOX HOUSING REPAIR – PORTABLE (TIPS) FRC-E

Dimensional Repair/Aerospace Powder Spec(DLA)

UH-1N/AH-1W RING GEAR High Pressure (Section 219) FRC-E

F-18 EMI REPAIR – PORTABLE (TBD)

UH-1N/AH-1W SUPPORT CASE PAD MOUNT – PORTABLE (TBD)

UH-1N/AH-1W CAD ALTERNATIVE ELECTTRICAL CONNECTORS – PORTABLE (TBD)

F-18 E/F/G AMAD Transmission Housing High Pressure Fretting/Dim Rep(Section 219) FRC-SW

H-53 MGB Pad Mounts ( POM15)

Corrosion

Dimensional/Non-structural

Structural (Repair within struct limits)

Key

PSU-ARL Repairability, F-18 (REPTECH)

Fu

ture

Current & Future Projects

Repair of Cad Alt to Brush Plate (DLA)

Repair of IVD(DLA)

15

Yr-17 Yr-14 Yr-15 Yr-16

Aircraft Component &Transition(s) TimelineAircraft Component &Transition(s) Timeline

Portable Robotic CS - H-60 Intermediate Gearbox repairs – Australian Navy DSTO/USN NAVAIR (OSD Corrosion)

UH-1N/AH-1W COMBINING GEARBOX HOUSING REPAIR – PORTABLE (TIPS) FRC-E (Deployment to O-Level)

Aerospace Powder Spec(DLA)

F-18 EMI REPAIR – PORTABLE (TBD)

UH-1N/AH-1W CAD ALTERNATIVE ELECTTRICAL CONNECTORS – PORTABLE (TBD)

Corrosion/Coat

Dimensional/Non-structural

Structural (Repair within struct limits)

Key

PSU-ARL Repairability, F-18 (REPTECH)

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)

Portable Robotic Cold Spray Application

To 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 Project

Future: Field/FRC Deployable Robotic Systems

S&T Analysis

– 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

– 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

Issues for all materials of interest to the Navy/NAVAIR

Need to tie fundamental understanding of process parameters/operating envelope to coating properties

Hierarchy of Cold Spray Application Hierarchy of Cold Spray Application ProjectsProjects

Approach

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

Develop

Qualify

Check

Assure

Take-Aways– All Fleet Readiness Centers are capable of Cold Spray

repairs• Hardware in place• Personnel trained, SME’s in place• Active S&T 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.

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