Engineered Applications of Electro-Spark Deposition (ESD) for Component Repair

1. Engineered Applications ofElectro-Spark Deposition (ESD) for Component Repair Replacement of Hard Chrome Plating Program Review Meeting 1-2 April 2003 Loews Coronado Bay Resort COMPONENT REPAIR PROJECTS Electrospark deposition studies for gas turbine engine component repair Advanced Surfaces and Processes, Inc.

2. Introductions Larry McCarty – President and CEO John Kelley – VP R&D Norma Price – Mechanical Engineer, Project Manager Advanced Surfaces and Processes, Inc.

3. Project Objective Advanced Surfaces and Processes, Inc will identify, evaluate and qualify applications of the Electrospark Deposition (ESD) process for repair of gas turbine engine components. Advanced Surfaces and Processes, Inc.

4. PEWG/ESTCP/HCAT Portland State University EWI Rowan Technology Group AFRL GEAE PW Tinker AFB PNNL Participants Advanced Surfaces and Processes, Inc.

5. The Project Plan • Phase 1 • Period of Performance: 10/01/01 – 9/30/02 • Objective: Determine the feasibility of using the ESD process to effect repairs on Gas Turbine Engine (GTE) components. • Phase 2 • Period of Performance: 9/1/02 – 6/30/03 • Objective: Gather and evaluate data regarding the effects of the ESD process on common GTE component materials. • Phase 3 • Period of Performance: 7/01/03 – 6/30/04 • Objective: Identify GTE components to be processed for performance testing. Develop ESD repair procedures and specifications for these specific components. Advanced Surfaces and Processes, Inc.

6. Phase 1 • 10/01/01 – 9/30/02 • Determine the feasibility of utilizing the ESD process to effect cost effective repairs on a wide range of high cost, long lead-time, GTE components for which: • there are no known method of repair • existing repair methods are impractical • replacement parts are no longer available • existing methods of repair involve the utilization of HAZMATS such as electrolytic hard chrome (EHC). Advanced Surfaces and Processes, Inc.

7. Phase 1 • Tasks: • Identify candidate materials • Select candidate materials • Optimize ESD parameters and specifications for selected substrate/electrode combinations • Identify repair liabilities for the ESD process on GTE materials • Create Process Specification Template Advanced Surfaces and Processes, Inc.

8. Phase 1Task 1 • Identify candidate materials • This task involved the identification of substrate materials widely used in GTE’s. DoD and OEM facilities and personnel were contacted and provided input. A wide variety of materials were identified as potential candidate materials. 100% Complete Advanced Surfaces and Processes, Inc.

9. Phase 1Task 2 • Select candidate materials. 100% Complete Advanced Surfaces and Processes, Inc.

10. Phase 1Task 3 • Optimize ESD parameters and specifications for selected materials. A Design of Experiment (DOE) was created for each of the six materials. 36 coupons would be repaired varying the ESD parameters: • Capacitance • Voltage • Current • Pulse Rate Based on material testing results, the optimum parameters will be selected. Further parameter optimization may be conducted. Advanced Surfaces and Processes, Inc.

11. Phase 1Task 4 • Identify repair liabilities for the ESD process on GTE materials. This task involves the collection of data related to materials and weld repair (i.e. “specific problems with welding selected materials”) concerns, such as • Susceptibility to HAZ • Micro cracking • Porosity • Phase changes. Advanced Surfaces and Processes, Inc.

12. Phase 1Task 5 • Create Process Specification Template A Welding Procedure Specification format has been developed by EWI, which represents one page of the entire Welding Specification. AFRL provided ASAP with templates that can be used for the development of complete Welding Specs which will be created for each application. This task is dependant on the completion of component selection and has been moved to Phase 3, Task 4. Advanced Surfaces and Processes, Inc.

13. Phase 1 • Status • Task 1 and 2 complete • Task 3 in process • Task 4 and 5 need to be revisited Advanced Surfaces and Processes, Inc.

14. Phase 2 • 9/1/02 – 6/30/03 • Gather and evaluate information and data regarding the effects of the ESD process on common GTE component materials. This information and data will form the basis for our ESD/GTE compatibility criteria. Advanced Surfaces and Processes, Inc.

15. Phase 2 • Tasks: • Produce Materials Test Coupons • Identify Materials and Mechanical Testing Protocol • Produce materials testing specimens • Evaluate materials testing results • Produce mechanical testing specimens • Evaluate mechanical testing results • Create candidate part screening requirements Advanced Surfaces and Processes, Inc.

16. Phase 2 • Tasks: • PSU Contract • EWI Contract • Reclamation Project Advanced Surfaces and Processes, Inc.

17. Phase 2Task 1 • Produce Materials Test Coupons 216 coupons have been: • Procured • Heat treated, if necessary • Defects drilled • Pre ESD (surface finish, clean, weigh) • Repaired (defect filled) • Post ESD (surface photograph, weigh) 100% Complete Advanced Surfaces and Processes, Inc.

18. Phase 2Task 1 • Produce Materials Test Coupons Advanced Surfaces and Processes, Inc.

19. Phase 2Task 2 • Identify Materials and Mechanical Testing Protocol • ASAP will perform qualitative materials testing • PSU will perform material and mechanical testing • EWI will perform mechanical testing • Other facilities will review testing procedures • Working with Keith Legg et al to develop Joint Test Protocol (JTP) Advanced Surfaces and Processes, Inc.

20. Phase 2Task 3 • Produce materials testing specimens 216 coupons have been: • Cut and sent to PSU • Mounted, Polished and Etched • Micrographed • 3 parameter sets have been duplicated 5 times to confirm repeatability 100% Complete Advanced Surfaces and Processes, Inc.

21. Phase 2Task 4 • Evaluate materials testing results • Compare ASAP and PSU analysis • Select optimum parameters for each material • Continue to optimize parameters, if necessary • Revisit material testing after component selection • Additional materials testing, per the JTP Advanced Surfaces and Processes, Inc.

22. Phase 2Task 5 • Produce mechanical testing specimens • PSU will address Low Cycle Fatigue testing • EWI will address Low Cycle Fatigue, Tensile and Bend testing Advanced Surfaces and Processes, Inc.

23. Phase 2Task 6 • Evaluate mechanical testing results • Compare EWI and PSU analysis • Continue to optimize parameters, if necessary • Revisit mechanical testing after component selection • Additional mechanical testing, per the JTP Advanced Surfaces and Processes, Inc.

24. Phase 2Task 7 • Create candidate part screening requirements • Criteria: • 1 of the 6 materials • Replace/prevent EHC coatings • Format created, revise as needed Advanced Surfaces and Processes, Inc.

25. Phase 2Task 8 • PSU Contract • Oregon Metal Initiative • Tasks Advanced Surfaces and Processes, Inc.

26. Phase 2Task 8 • Quantitative image analysis – optical & SEM • Microhardness – deposit- interface- substrate • Fatigue - Evaluation Capabilities • Axial – tension-tension (room & elevated Temp) • Flex bending – “Krauss”-tapered constant stress • Air & salt water • Rotating bending – “Fatigue Dynamics”- hour glass • Thermal & thermal-mechanical fatigue –controlled atmosphere Courtesy of Portland State University Advanced Surfaces and Processes, Inc.

27. Phase 2Task 8 • Installation of ESD system at PSU • Enhanced characterization facilities • PC based Microhardness • ESD controlled atmosphere chambers being configured • High resolution field emission SEM and TEM installed • Scratch tester • Axial, rotating, and bending fatigue • Collaborative user facility relationships • FEI Co -- Dual Beam FIB/SEM • PNNL & EMSL National laboratory user facility Courtesy of Portland State University Advanced Surfaces and Processes, Inc.

28. Phase 2Task 8 • Introduction Web Page for ESD Research Project (v2.5) Courtesy of Portland State University Advanced Surfaces and Processes, Inc.

29. Phase 2Task 8 • Alloy 718 - As polished (100X) Demonstrating Interference Contrast Courtesy of Portland State University Advanced Surfaces and Processes, Inc.

30. Phase 2Task 8 • ESD voltage-current-porosity relationship Courtesy of Portland State University Advanced Surfaces and Processes, Inc.

31. Phase 2Task 9 • EWI Contract • GEAE Project • Tasks Advanced Surfaces and Processes, Inc.

32. Phase 2Task 8 • Workscope for GEAE work • Focus on developing mechanical property data for ESD deposits in IN718 • Apply ESD welds in machined grooves • Machine deposits flush and perform tensile, bend and LCF testing • Compare with unwelded specimens • Showed Favorable Results Courtesy of Edison Welding Institute & GEAE Advanced Surfaces and Processes, Inc.

33. Phase 2Task 8 • LCF specimen – before and after Courtesy of Edison Welding Institute & GEAE Advanced Surfaces and Processes, Inc.

34. Phase 2Task 8 • LCF specimen – before and after Courtesy of Edison Welding Institute & GEAE Advanced Surfaces and Processes, Inc.

35. Phase 2Task 10 • Reclamation Project • Reclaim super alloy materials from scrap to be used to manufacture electrodes for the ESD process Advanced Surfaces and Processes, Inc.

36. Phase 2 • Status • All tasks in process Advanced Surfaces and Processes, Inc.

37. Phase 3 • 7/01/03 – 6/30/04 • Identify GTE components in which to effect cost effective ESD repairs. Candidate components will be selected and processed for performance testing as required. ESD repair procedures and specifications will be developed for the specific components in anticipation of deployment in DoD facilities. Advanced Surfaces and Processes, Inc.

38. Phase 3 • Tasks: • Develop a database of components as candidates • Select candidate parts • Identify performance testing requirements • Create repair instructions and specifications (From Process Specification Template) • Repair candidate parts for performance testing • Evaluate performance testing results, report findings • Demonstrate process techniques Provide training • Begin Technology Transfer • Final reports Advanced Surfaces and Processes, Inc.

39. Phase 3Task 1 • Develop a comprehensive database of GTE components as candidates for ESD repair. • Some prior work completed Advanced Surfaces and Processes, Inc.

40. Phase 3Task 2 • Select candidate parts (3-5) for ESD repair development. • Begin immediately (Scheduled to begin July, 2003) • Run parallel with materials and mechanical testing Advanced Surfaces and Processes, Inc.

41. Phase 3Task 3 • Identify performance testing requirements for ESD repaired parts. • Per JTP Advanced Surfaces and Processes, Inc.

42. Phase 3Task 4 • Create repair instructions and specifications for ESD repair of GTE components. • (From Process Specification Template, Phase 1, task 5) Advanced Surfaces and Processes, Inc.

43. Phase 3Task 6 • Repair candidate parts for performance testing. • Conduct Performance testing (execute the JTP) Advanced Surfaces and Processes, Inc.

44. Phase 3Task 7 • Evaluate performance testing results, report findings. • Document results in a Joint Test Report (JTR) Advanced Surfaces and Processes, Inc.

45. Phase 3Task 8 • Demonstrate process techniques for OEM’s and DoD facilities Advanced Surfaces and Processes, Inc.

46. Phase 3Task 9 • Provide training for OEM’s and DoD customers wishing to own/license ESD technology Advanced Surfaces and Processes, Inc.

47. Phase 3Task 10 • Begin Technology Transfer Advanced Surfaces and Processes, Inc.

48. Phase 3Task 11 • Final reports • Monthly Status Reports (MSR) • Potential Alternatives Report (PAR) • Joint Test Protocol (JTP) • Joint Test Report (JTR) • ESTCP Technology Demonstration Report Advanced Surfaces and Processes, Inc.

49. Phase 3 • Status • With the exception of “Component Selection”, all tasks should begin July, 2003 Advanced Surfaces and Processes, Inc.

50. Engineered Applications ofElectro-Spark Deposition (ESD) for Component Repair Questions? Advanced Surfaces and Processes, Inc.