Advanced Surfaces and Processes, Inc. 1 Engineered Applications of Electro-Spark Deposition (ESD)...

Advanced Surfaces and Processes, Inc. 1

Engineered Applications ofEngineered Applications ofElectro-Spark Deposition Electro-Spark Deposition

(ESD) for Component Repair(ESD) for Component Repair

Replacement of Hard Chrome Plating Program Review Meeting Replacement of Hard Chrome Plating Program Review Meeting

1-2 April 20031-2 April 2003Loews Coronado Bay ResortLoews Coronado Bay Resort

COMPONENT REPAIR PROJECTSCOMPONENT REPAIR PROJECTSElectrospark deposition studies for gas turbine engine component repairElectrospark deposition studies for gas turbine engine component repair


IntroductionsIntroductions

Larry McCarty – President and CEOLarry McCarty – President and CEOJohn Kelley – VP R&DJohn Kelley – VP R&DNorma Price – Mechanical Engineer, Project ManagerNorma Price – Mechanical Engineer, Project Manager


Project ObjectiveProject Objective

Advanced Surfaces and Processes, IncAdvanced Surfaces and Processes, Inc

will identify, evaluate will identify, evaluate and qualify applications and qualify applications of the Electrospark of the Electrospark Deposition (ESD) process Deposition (ESD) process for repair of gas turbine for repair of gas turbine engine components. engine components.


ParticipantsParticipants PEWG/ESTCP/HCATPEWG/ESTCP/HCAT Portland State UniversityPortland State University EWIEWI Rowan Technology GroupRowan Technology Group AFRLAFRL GEAEGEAE PWPW Tinker AFBTinker AFB PNNLPNNL


The Project PlanThe Project Plan Phase 1Phase 1

Period of Performance: 10/01/01 – 9/30/02 Period of Performance: 10/01/01 – 9/30/02 Objective: Determine the feasibility of using the ESD process to Objective: Determine the feasibility of using the ESD process to

effect repairs on Gas Turbine Engine (GTE) components. effect repairs on Gas Turbine Engine (GTE) components.

Phase 2Phase 2 Period of Performance: 9/1/02 – 6/30/03 Period of Performance: 9/1/02 – 6/30/03 Objective: Gather and evaluate data regarding the effects of the Objective: Gather and evaluate data regarding the effects of the

ESD process on common GTE component materials. ESD process on common GTE component materials.

Phase 3Phase 3 Period of Performance: 7/01/03 – 6/30/04 Period of Performance: 7/01/03 – 6/30/04 Objective: Identify GTE components to be processed for Objective: Identify GTE components to be processed for

performance testing. Develop ESD repair procedures and performance testing. Develop ESD repair procedures and specifications for these specific components.specifications for these specific components.


Phase 1Phase 1 10/01/01 – 9/30/0210/01/01 – 9/30/02 Determine the feasibility of utilizing the ESD Determine the feasibility of utilizing the ESD

process to effect cost effective repairs on a wide process to effect cost effective repairs on a wide range of high cost, long lead-time, GTE range of high cost, long lead-time, GTE components for which: components for which: there are no known method of repairthere are no known method of repair existing repair methods are impracticalexisting repair methods are impractical replacement parts are no longer availablereplacement parts are no longer available existing methods of repair involve the utilization of existing methods of repair involve the utilization of

HAZMATS such as electrolytic hard chrome (EHC). HAZMATS such as electrolytic hard chrome (EHC).


Phase 1Phase 1 Tasks:Tasks:

Identify candidate materialsIdentify candidate materials Select candidate materialsSelect candidate materials Optimize ESD parameters and specifications Optimize ESD parameters and specifications

for selected substrate/electrode combinationsfor selected substrate/electrode combinations Identify repair liabilities for the ESD process on Identify repair liabilities for the ESD process on

GTE materialsGTE materials Create Process Specification TemplateCreate Process Specification Template


Identify candidate materialsIdentify candidate materials

This task involved the identification of This task involved the identification of substrate materials widely used in GTE’s. substrate materials widely used in GTE’s. DoD and OEM facilities and personnel were DoD and OEM facilities and personnel were contacted and provided input. A wide variety contacted and provided input. A wide variety of materials were identified as potential of materials were identified as potential candidate materials.candidate materials.

Phase 1Phase 1Task 1Task 1

100% Complete100% Complete



Select candidate materials.Select candidate materials.

SubstrateSubstrate SpecificationSpecification Electrode Electrode SpecificationSpecification

IN 718IN 718 AMS 5663AMS 5663 AMS 5832AMS 5832

IN 625IN 625 AMS 5666AMS 5666 AMS 5837AMS 5837

Hastelloy XHastelloy X AMS 5754AMS 5754 AMS 5798AMS 5798

Haynes 188Haynes 188 AMS 5772AMS 5772 AMS 5801AMS 5801

410 Stainless410 Stainless AMS 5504AMS 5504 AMS 5823AMS 5823

17-4PH17-4PH AMS 5604AMS 5604 AMS 5825AMS 5825



Optimize ESD parameters and specifications Optimize ESD parameters and specifications for selected materials.for selected materials.A Design of Experiment (DOE) was created for each of the A Design of Experiment (DOE) was created for each of the six materials. 36 coupons would be repaired varying the six materials. 36 coupons would be repaired varying the ESD parameters:ESD parameters:

CapacitanceCapacitance VoltageVoltage CurrentCurrent Pulse RatePulse Rate

Based on material testing results, the optimum parameters Based on material testing results, the optimum parameters will be selected. Further parameter optimization may be will be selected. Further parameter optimization may be conducted.conducted.



Identify repair liabilities for the ESD Identify repair liabilities for the ESD process on GTE materials.process on GTE materials.

This task involves the collection of data related to This task involves the collection of data related to materials and weld repair (i.e. “specific problems materials and weld repair (i.e. “specific problems with welding selected materials”) concerns, such with welding selected materials”) concerns, such as as

Susceptibility to HAZSusceptibility to HAZ Micro crackingMicro cracking PorosityPorosity Phase changes. Phase changes.



Create Process Specification TemplateCreate Process Specification Template

A Welding Procedure Specification format has been A Welding Procedure Specification format has been developed by EWI, which represents one page of developed by EWI, which represents one page of the entire Welding Specification. AFRL provided the entire Welding Specification. AFRL provided ASAP with templates that can be used for the ASAP with templates that can be used for the development of complete Welding Specs which will development of complete Welding Specs which will be created for each application. be created for each application.

This task is dependant on the completion of This task is dependant on the completion of component selection and has been moved to Phase component selection and has been moved to Phase 3, Task 4.3, Task 4.



Phase 1Phase 1 StatusStatus

Task 1 and 2 completeTask 1 and 2 complete Task 3 in processTask 3 in process Task 4 and 5 need to be revisited Task 4 and 5 need to be revisited


Phase 2Phase 2 9/1/02 – 6/30/03 9/1/02 – 6/30/03

Gather and evaluate information and data Gather and evaluate information and data regarding the effects of the ESD process regarding the effects of the ESD process on common GTE component materials. on common GTE component materials. This information and data will form the This information and data will form the basis for our ESD/GTE compatibility basis for our ESD/GTE compatibility criteria. criteria.



Produce Materials Test CouponsProduce Materials Test Coupons Identify Materials and Mechanical Testing Identify Materials and Mechanical Testing

Protocol Protocol Produce materials testing specimensProduce materials testing specimens Evaluate materials testing resultsEvaluate materials testing results Produce mechanical testing specimensProduce mechanical testing specimens Evaluate mechanical testing resultsEvaluate mechanical testing results Create candidate part screening Create candidate part screening

requirementsrequirements



PSU Contract PSU Contract EWI ContractEWI Contract Reclamation ProjectReclamation Project


Produce Materials Test CouponsProduce Materials Test Coupons

216 coupons have been:216 coupons have been: ProcuredProcured Heat treated, if necessaryHeat treated, if necessary Defects drilledDefects drilled Pre ESD (surface finish, clean, weigh)Pre ESD (surface finish, clean, weigh) Repaired (defect filled)Repaired (defect filled) Post ESD (surface photograph, weigh)Post ESD (surface photograph, weigh)





Produce Materials Test CouponsProduce Materials Test Coupons


Identify Materials and Mechanical Identify Materials and Mechanical Testing Protocol Testing Protocol

ASAP will perform qualitative materials testingASAP will perform qualitative materials testing PSU will perform material and mechanical testingPSU will perform material and mechanical testing EWI will perform mechanical testingEWI will perform mechanical testing Other facilities will review testing proceduresOther facilities will review testing procedures Working with Keith Legg et al to develop Joint Test Working with Keith Legg et al to develop Joint Test

Protocol (JTP)Protocol (JTP)



Produce materials testing specimensProduce materials testing specimens

216 coupons have been:216 coupons have been: Cut and sent to PSUCut and sent to PSU Mounted, Polished and EtchedMounted, Polished and Etched MicrographedMicrographed 3 parameter sets have been duplicated 5 times 3 parameter sets have been duplicated 5 times

to confirm repeatabilityto confirm repeatability




Evaluate materials testing resultsEvaluate materials testing results

Compare ASAP and PSU analysisCompare ASAP and PSU analysis Select optimum parameters for each materialSelect optimum parameters for each material Continue to optimize parameters, if necessaryContinue to optimize parameters, if necessary Revisit material testing after component selectionRevisit material testing after component selection Additional materials testing, per the JTPAdditional materials testing, per the JTP



Produce mechanical testing specimensProduce mechanical testing specimens

PSU will address Low Cycle Fatigue testingPSU will address Low Cycle Fatigue testing EWI will address Low Cycle Fatigue, Tensile and EWI will address Low Cycle Fatigue, Tensile and

Bend testing Bend testing



Evaluate mechanical testing resultsEvaluate mechanical testing results

Compare EWI and PSU analysisCompare EWI and PSU analysis Continue to optimize parameters, if necessaryContinue to optimize parameters, if necessary Revisit mechanical testing after component Revisit mechanical testing after component

selectionselection Additional mechanical testing, per the JTPAdditional mechanical testing, per the JTP




Create candidate Create candidate part screening part screening requirementsrequirements Criteria: Criteria:

1 of the 6 materials1 of the 6 materials Replace/prevent EHC Replace/prevent EHC

coatingscoatings Format created, Format created,

revise as neededrevise as needed


PSU ContractPSU Contract

Oregon Metal InitiativeOregon Metal Initiative TasksTasks




Quantitative Quantitative image analysisimage analysis – optical & SEM – optical & SEM MicrohardnessMicrohardness – deposit- interface- substrate – deposit- interface- substrate FatigueFatigue - Evaluation Capabilities - Evaluation Capabilities

Axial – tension-tension (room & elevated Temp)Axial – tension-tension (room & elevated Temp) Flex bending – “Krauss”-tapered constant stressFlex bending – “Krauss”-tapered constant stress

Air & salt waterAir & salt water Rotating bending – “Fatigue Dynamics”- hour glassRotating bending – “Fatigue Dynamics”- hour glass Thermal & thermal-mechanical fatigue –controlled Thermal & thermal-mechanical fatigue –controlled

atmosphereatmosphere

Courtesy of Portland State UniversityCourtesy of Portland State University



Installation of ESD system at PSUInstallation of ESD system at PSU Enhanced characterization facilitiesEnhanced characterization facilities

PC based MicrohardnessPC based Microhardness ESD controlled atmosphere chambers being configuredESD controlled atmosphere chambers being configured High resolution field emission SEM and TEM installedHigh resolution field emission SEM and TEM installed Scratch testerScratch tester Axial, rotating, and bending fatigueAxial, rotating, and bending fatigue

Collaborative user facility relationshipsCollaborative user facility relationships FEI Co -- Dual Beam FIB/SEMFEI Co -- Dual Beam FIB/SEM PNNL & EMSL National laboratory user facilityPNNL & EMSL National laboratory user facility




Introduction Web Page for ESD Research Introduction Web Page for ESD Research Project Project (v2.5)(v2.5)




Alloy 718 - Alloy 718 - As polished (100X)As polished (100X)

Demonstrating Interference ContrastDemonstrating Interference Contrast




ESDESD voltage-current-porosity relationship voltage-current-porosity relationship


Porosity vs Current and Voltage

Current (a)Voltage (v)

Porosity

3.003.50

4.004.50

5.005.50

6.006.50

7.00 100

120

140

160

180

200

1.50

1.75

2.00

2.25

2.50


EWI ContractEWI Contract

GEAE ProjectGEAE Project TasksTasks




Workscope for GEAE work Workscope for GEAE work Focus on developing mechanical property Focus on developing mechanical property

data for ESD deposits in IN718data for ESD deposits in IN718 Apply ESD welds in machined groovesApply ESD welds in machined grooves Machine deposits flush and perform tensile, Machine deposits flush and perform tensile,

bend and LCF testingbend and LCF testing Compare with unwelded specimensCompare with unwelded specimens

Showed Favorable ResultsShowed Favorable Results

Courtesy of Edison Welding Institute & GEAECourtesy of Edison Welding Institute & GEAE



LCF specimen – before and afterLCF specimen – before and after



Reclamation ProjectReclamation Project

Reclaim super alloy Reclaim super alloy materials from scrap to be materials from scrap to be used to manufacture used to manufacture electrodes for the ESD electrodes for the ESD processprocess




All tasks in process All tasks in process


Phase 3Phase 3 7/01/03 – 6/30/04 7/01/03 – 6/30/04

Identify GTE components in which to effect Identify GTE components in which to effect cost effective ESD repairs. Candidate cost effective ESD repairs. Candidate components will be selected and processed components will be selected and processed for performance testing as required. ESD for performance testing as required. ESD repair procedures and specifications will be repair procedures and specifications will be developed for the specific components in developed for the specific components in anticipation of deployment in DoD facilities.anticipation of deployment in DoD facilities.



Develop a database of components as candidatesDevelop a database of components as candidates Select candidate parts Select candidate parts Identify performance testing requirements Identify performance testing requirements Create repair instructions and specifications Create repair instructions and specifications

(From Process Specification Template)(From Process Specification Template) Repair candidate parts for performance testingRepair candidate parts for performance testing Evaluate performance testing results, report Evaluate performance testing results, report

findingsfindings Demonstrate process techniques Provide trainingDemonstrate process techniques Provide training Begin Technology TransferBegin Technology Transfer Final reportsFinal reports


Develop a comprehensive Develop a comprehensive database of GTE components as database of GTE components as candidates for ESD repair.candidates for ESD repair.

Some prior work completedSome prior work completed



Select candidate parts (3-5) for Select candidate parts (3-5) for ESD repair development.ESD repair development.

Begin immediately (Scheduled to begin Begin immediately (Scheduled to begin July, 2003)July, 2003)

Run parallel with materials and mechanical Run parallel with materials and mechanical testingtesting



Identify performance testing Identify performance testing requirements for ESD repaired requirements for ESD repaired parts.parts.

Per JTPPer JTP



Create repair instructions and Create repair instructions and specifications for ESD repair of specifications for ESD repair of GTE components.GTE components.

(From Process Specification Template, (From Process Specification Template, Phase 1, task 5)Phase 1, task 5)



Repair candidate parts for Repair candidate parts for performance testing.performance testing.

Conduct Performance testing (execute the Conduct Performance testing (execute the JTP)JTP)



Evaluate performance testing Evaluate performance testing results, report findings.results, report findings.

Document results in a Joint Test Report (JTR)Document results in a Joint Test Report (JTR)



Demonstrate process techniques Demonstrate process techniques for OEM’s and DoD facilitiesfor OEM’s and DoD facilities



Provide training for OEM’s and DoD Provide training for OEM’s and DoD customers wishing to own/license customers wishing to own/license ESD technologyESD technology



Begin Technology TransferBegin Technology Transfer



Final reportsFinal reports

Monthly Status Reports (MSR)Monthly Status Reports (MSR) Potential Alternatives Report (PAR)Potential Alternatives Report (PAR) Joint Test Protocol (JTP)Joint Test Protocol (JTP) Joint Test Report (JTR) Joint Test Report (JTR) ESTCP Technology Demonstration ESTCP Technology Demonstration

ReportReport




With the exception of With the exception of “Component Selection”, all tasks “Component Selection”, all tasks should begin July, 2003 should begin July, 2003


Engineered Applications ofEngineered Applications ofElectro-Spark Deposition (ESD) for Electro-Spark Deposition (ESD) for

Component RepairComponent Repair

Questions?Questions?

Advanced Surfaces and Processes, Inc. 1 Engineered Applications of Electro-Spark Deposition (ESD)...

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