OC-ALC Chrome

Plate Reduction 20 FEB 2002

OKLAHOMA CITY OKLAHOMA CITY AIR LOGISTICS CENTERAIR LOGISTICS CENTER

Johnny Tsiao

OC-ALC/LPARR

(405)736-3481

Johnny.tsiao@tinker.af.mil

I n t e g r i t y - S e r v i c e - E x c e l l e n c e

TEAM TINKER

2

OVERVIEW

• CHROME WORKLOAD AT TINKER

• HVOF AS ALTERNATIVE

• TF33 HVOF QUALIFICATION

• TINKER HVOF CAPABILITY

• FUTURE TASKS

3

CY2000

70%

10%

16%

4%

TINKER CHROME PLATE TINKER CHROME PLATE WORKLOADWORKLOAD

CY 2001

40%

18%

39%

3%

TF33

F100

F110 AND F101

OTHERS

• 2063 total parts in CY 2001– constant average of 172 parts per month– 29% increase from CY 2000

• F110/101 increase due to ENSIP schedule• F100 increase due to organic repair qualifications• TF33 decrease due to C141 a/c retirement

4

NEED FOR CHROME REDUCTION

• CURRENTLY TINKER IS A BIG USER OF HEXAVALENT CHROME FOR REPAIR OF ENGINE COMPONENTS

• INCREASED RESTRICTIONS ON CHROME USAGE WILL SIGNIFICANTLY IMPACT MISSION READINESS FOR AIR FORCE PROPULSION

• IDENTIFY CHROME PLATE FEATURES TO DETERMINE BEST ALTERNATIVES– Review tech data for all chrome callouts

– Categorize by location and geometric features

5

HVOF AS ALTERNATIVE

• LP HAS IDENTIFIED HIGH VELOCITY OXYGEN FUEL (HVOF) COATING AS THE LEADING TECHNOLOGY TO REPLACE CHROME PLATING AT TINKER AFB– TF33 HVOF substitutions provide the greatest initial reduction in

chrome usage – F110/101 Aft Shaft is bulk of chrome usage. Chrome repair also

used for #4 Seal Housing on as needed basis to support DLA shortage. HVOF alternative is currently available for Aft Shaft.

– Currently few F100 components identified for HVOF substitution. However, continual efforts for repair qualifications will identify additional needs

• OEMs ALSO SPECIFIES HVOF IN THEIR DESIGNS

• LP HAS IDENTIFIED COMPONENTS HAVING SUBSTRATES AND GEOMETRY SUITABLE FOR HVOF APPLICATION

6

HVOF CANDIDATES

• TF33 COMPONENTS:– AMS 5613, #1 Bearing Support; #2, #4, #5 and #6 Bearing Housing – AMS 5616, #6 Hub– AMS 5660, Rear Compressor Rear Hub – AMS 6280, #2 Bearing . Housing Alternate– AMS 6304, LPT Shaft; HPT Shaft – AMS 6322, #4.5 Bearing . Retaining Nut– AMS 6415, #2 Hub; #2.5 Bearing . Housing

• F110/101 COMPONENTS:– INCO 718, HPT Aft shaft– A-286, #4 Carbon Seal Seat (recent addition)– SAE 8740, #5 Carbon Seal Seat (may be planned)

• F100 COMPONENTS:– AMS 6265, Impeller shaft– AMS 6265, Gear shaft

7

TF33 HVOF QUALIFICATION

• TF33 IS THE LEAD PROGRAM FOR CHROME REPLACEMENT VIA HVOF– F100 agrees to pattern qualification methodology after

TF33– T56 will qualify thermal spray based on Joint Materials

Test Protocol

• 7 COMPONENTS IDENTIFIED FOR ENGINE TEST– Remaining 5 to be qualified by similarity

• FUNCTIONAL TEST PROCEEDS ENDURANCE TEST– Fit Check completed– Metallurgical analysis by PW– Need Wright Lab assistance for sonic testing

8

TF33 HVOF COMPONENTS FOR ENGINE TEST

#1 brg hsg

#2 hub

#4 hub

HPT shaftLPT shaft

#5 brg hsg #6 brg hsg

9

TF33 HVOF COMPONENTS FOR ENGINE TEST

• ENGINE TEST PROBLEMS– Hardware installed on test engine

– Engine at PW test facility

– Significant delay due to technical and financial problems unrelated to this effort

– Project completion of test by Aug 02

• POST ENGINE TEST MATERIAL ANALYSIS IS REQUIRED BEFORE PARTS ARE VALIDATED

10

TF33 HVOF Functional Test#1 Bearing HousingAs finished by Engelhard 2/01

11

TF33 HVOF Functional Test#5 Bearing HousingAs finished by Engelhard 2/01

12

TF33 HVOF Functional Test#6 Bearing Housing & Seal RunnerAs finished by Engelhard 2/01

13

TF33 HVOF Functional Test#2, 2.5 and 3 Bearing JournalsAs finished by Engelhard 2/01

14

TF33 HVOF AMTHPC Rear HubAs received by Engelhard 2/01

15

TF33 HVOF Functional Test#4.5 Bearing & Seal JournalsAs finished by Engelhard 2/01

16

TF33 HVOF Functional Test#5 Bearing & Seal JournalsAs finished by Engelhard 2/01

17

TINKER HVOF CAPABILITY KEY PARAMETERS

• Booth Installation– Purchased and installed one Sulzer-Metco DJ system– Bio-environmental, safety certification– Long term Oxygen supply

• Training– Classroom and practical – PW, Engelhard, Metco support

• LP Quality Plan– Amend LPP process order to include HVOF

• Coating Parameter – Sampling method– Evaluation standards– Masking Tools

18

TINKER HVOF CAPABILITY KEY PARAMETERS

• Finishing – Fine finish required for oil wetted parts– Tinker has not developed finishing capability– Engelhard support

• Coating Removal– Need to determine removal method for subsequent repairs– Chemical vs mechanical

• OEM Qualification– Two part PW source approval: General Process and Part

Specific– Working on establishing PW support for source approval– Need to address GE components

19

TINKER INHOUSE HVOF ROADMAP

Tinker and Englehard

See PWA Flowsheet

SprayEquipment

InstallationJan '02

Bio, FireSafety

Approval

FacilityOperational

TrainingDevelopeTraining Manual

OJTClassroom

Testing

TIESV Met Lab

RDE Contract

EvaluationStandards

CoatingPolishing

Procedures

Hands onw/

MCL Lab

QualityDocuments

Revision

Coatings

PreliminaryQualification

PWAProgram

Plan

Quality Plan

LPOI 21-166

ProcessOrder

LPP 85-11

LPA/ LPF/ LPQ

Approval

Bulk OxygenHQ

ApprovalFundedFy '02

BulkOxygen

Installation

ParametersPWA

36206-1

RoboticPrograms

PartSpecific

Qualification

LabSamples

Masking/Tooling

Coating meetsSpecification

Requirements?

HVOFRoadmap

Proceed to the nextpart requiring qualification

Tinker Englehard PWA MetcoEnglehard

andMetco

ApprovalGranted

Program PlanRequirements

Met?

No

Yes

Legend:

Yes

START

END

SEE PAGE 12

20

PW QUALIFICATION PROCESS

QualificationGranted

- Creates Replog EntrySee Note 2

- Review Resultsand Communicate to

Source- Provide Results to

MME

- Identifies NecessarySteps for Qualification

Process

- Notifies Requester

- Submits Material ForMCL Review and

Approval toSpecifications

- Review of ProcessQualification

Requirements andPlans

See Note 4

Rework Process

QualificationRequest

See Note 1

Preparation ofRequested

Material

See Note 3

Submittal ofRequested

Material

- MCL Prepares theMaterial for Review and

Compares Samples toSpecifications

SamplesFail

ImproveProcess

Schedule Meetingto Review

Qualificationrequirements

Process ProcessQualification

Samples

- Review Resultsand Communicate to

Source- Provide Results to

MME

- Submits Material ForMCL Review and

Approval toSpecifications

Rework Process

Submittal ofQualification

Samples

- MCL Prepares theMaterial for Review and

Compares Samples toSpecifications

SamplesFail

SamplesPass

Samples &Document

Review Acceptable

PRELIMINARY

PARTSSPECIFIC

21

FUTURE TASKS

• New part numbers and Tech Data must be introduced

– Class I Engineering Changes required for configuration control

– Additional funding for OEM through CIP needed

• More extensive process quality control requirements

– Standardized evaluation of process qualification– Process tech data incorporation to T O 2-1-111

• Particle liberation in oil wet areas– Design requirements defined by OEM

• JOAP trending impacts– Atomic absorption limitations with tungsten

– AMT engine will define criteria

program specific issue

joint issue

TEAM TINKER