Sealant Removal from A-10 Center Wing Fuel Tanks Using a Portable Hand-Held Nd: YAG Laser System
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Transcript of Sealant Removal from A-10 Center Wing Fuel Tanks Using a Portable Hand-Held Nd: YAG Laser System
Sealant Removal from A-10 Center Wing Sealant Removal from A-10 Center Wing Fuel Tanks Using a Portable Hand-Held Fuel Tanks Using a Portable Hand-Held
Nd: YAG Laser SystemNd: YAG Laser System
Sealant Removal from A-10 Center Wing Sealant Removal from A-10 Center Wing Fuel Tanks Using a Portable Hand-Held Fuel Tanks Using a Portable Hand-Held
Nd: YAG Laser SystemNd: YAG Laser System
Norman J. OlsonPacific Northwest National Laboratory
Richland, Washington 99352
Mitchell WoolGeneral Lasertronics Corporation
San Jose, California 95112
2005 CTMA Symposium – Tacoma, WAApril 18-21, 2005
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The ProblemThe ProblemThe ProblemThe Problem
> 300 A-10 Aircraft in ServiceCenter Wing Fuel Tank Cells Have Fasteners Covered with Sealant (Primer Coating Elsewhere)
Sealant in Fuel Tanks Needs to be Removed for NDE and/or Repair
Sealant Removal from Center Wing Tanks is Tedious and Expensive
Need a Less-Expensive, Faster Alternative
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The ProblemThe ProblemThe ProblemThe Problem
Current Technology is Hand Scraping Difficult and Slow Incomplete Cleaning is Highly
Likely Damage to Substrate is Likely
Laser Coating Removal Offers Potential Minimal Experience in
Confined Spaces Many Unanswered Questions
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Demonstration Objectives Demonstration Objectives and Requirementsand Requirements
Demonstration Objectives Demonstration Objectives and Requirementsand Requirements
A portable Nd: YAG laser that can remove sealant more economically than current methods,
A hand-held delivery system that is capable of removing all sealant in the center wing section,
A hand-held delivery system that is easy and safe to use,
A system that has the potential to remove only sealant and not primer (color recognition), and
A system that has reasonable reliability so that it will be operational for long periods of time without maintenance.
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Target for DemonstrationTarget for DemonstrationTarget for DemonstrationTarget for Demonstration
A-10 SPO Sent Retired Center Wing Fuel Tank Section to General Lasertronics Corporation Facilities in San Jose, CA
Demo Wing Section Had Eight (8) Access Ports to Fuel Cells
There Were Approximately 600 Fasteners Covered with Sealant in Each of the Eight (8) Fuel Cells
Access Ports Barely Large Enough for Operator Cell
Opening
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Attributes Needed to Meet Requirements Attributes Needed to Meet Requirements for A-10 Center Wing Tankfor A-10 Center Wing Tank
Attributes Needed to Meet Requirements Attributes Needed to Meet Requirements for A-10 Center Wing Tankfor A-10 Center Wing Tank
Portability and reliability – DP Nd: YAG laser Compact hand-held end effector that can operate in confined space – GLC SBIR designAbility to see target area even if there are obstacles in line of sightMeet laser safety and environmental issuesTWO-dimensional automated beam scanning to eliminate substrate damage potential and to ensure complete and systematic coating removalColor recognition – potential to selectively remove sealant without disturbing other coatings
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200 and 500 Watt Demonstrations Using 200 and 500 Watt Demonstrations Using GLC-Developed SystemsGLC-Developed Systems
200 and 500 Watt Demonstrations Using 200 and 500 Watt Demonstrations Using GLC-Developed SystemsGLC-Developed Systems
200 watt , 13 kHz, Nd: YAG Lamp-Pumped, Q-Switched System was Used for the Demo Conducted 9/21/2004 US Laser 406Q laser
500 watt, 10 kHz, Nd: YAG, Diode-Pumped, Q-Switched System was Used for the Demo Conducted 12/9-10/2004 Cutting Edge Optronics Laser:
Northrop-Grumman
Operator Uses Video Display if Line-of-Sight Obstructions Exist
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GLC Confined Space Tool GLC Confined Space Tool for Laser Coating Removalfor Laser Coating RemovalGLC Confined Space Tool GLC Confined Space Tool for Laser Coating Removalfor Laser Coating Removal
End Effector Consists of: Laser Aperture Two-Dimensional Scanning 25 cfm Air Blow from
Aperture Cooling Clear Work Area
Video Camera Optical Fiber Umbilical
Cell Waste Evacuation Separate 300 CFM Purge Remove Ablated Debris Remove Sealant Vapors Maintain Good Visibility
Camera
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Demonstration ResultsDemonstration ResultsDemonstration ResultsDemonstration Results
Sealant Removed from Equivalent Fastener 200 watt in ~ 1 Minute 500 watt in < ½ Minute
Estimate of Labor for Entire Center Wing Fuel Tank GLC Laser Tool Using the
500 watt System
One 8 Hour Shift
Conventional Scraping Has never been fully
completed >> 800 work hours
24 Equivalent Fasteners
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Demonstration ResultsDemonstration ResultsDemonstration ResultsDemonstration Results
Color Recognition Potential Demonstrated on Automated System to Remove Coatings from Other AircraftColor Recognition Previously Demonstrated with a GLC Hand-Held Delivery Tool
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Demonstration Objectives MetDemonstration Objectives MetDemonstration Objectives MetDemonstration Objectives Met
A portable Nd: YAG laser can easily remove sealant more economically than current scraping methods
A hand-held delivery system could be configured to remove all sealant in the center wing section
With minimal operator training, a hand-held laser delivery system is easy and safe to use
The system could be configured to remove only sealant and not primer by implementing existing color-dependent sensing technology and automated laser firing controls
The system has reasonable reliability so that it will be operational for long periods of time without maintenance.
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SafetySafetySafetySafety
Requirements Filtered (Clear) Glasses Worn by Operators Work Area Secured the Same as a Welding Area No Other Personal Protective Equipment Needed
Recommendations Two Operators in Work Area
Improve Productivity by Maximizing Trigger Time Keep Work Area Clear of Unauthorized Personnel
Could Enclose Work Area with Filtered Glass
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Recommendation for NCMS/Recommendation for NCMS/CTMA ProjectCTMA Project
Recommendation for NCMS/Recommendation for NCMS/CTMA ProjectCTMA Project
Implement System at Hill AFB Build hand-held laser system for test, evaluation, and
subsequent installation Develop laser system operating parameters to ensure
sealant removal without 2024-T3 Al substrate damage Systematic exposure over a range of laser conditions Collect metallographic and SEM information and relate to
mechanical test data over statistically significant data sets Develop end-effector attachments for easier access to all
fasteners within A-10
Project Funding ~ $1500K, including cost-sharing