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UNCLASSIFIED 1 FileName.pptx UNCLASSIFIED Date: 6/3/2014 Status of Cold Spray Repair Efforts for Magnesium Transmission Components Presented by: Names: Ricky McNalley. Materials Engineer, Materials Branch, Aviation Engineering Directorate, U.S. Army Aviation and Missile Research, Development, and Engineering Center Approved for public release; distribution unlimited. 10JUN2014, Doc ID 305 Control Number 0849

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UNCLASSIFIED 2 FileName.pptx UNCLASSIFIED The Materials Branch of the Aviation Engineering Directorate (AEF-M) has notionally approved the use of cold spray repairs as developed by the Army Research Laboratory (ARL) for the repair of magnesium housings and gearboxes used in our aviation platforms. These repairs can address a significant portion of the $3.5M in magnesium housings currently considered BER in the Storage, Analysis, Failure evaluation, and Reclamation (SAFR) inventory at CCAD. Groups involved in repair process approval and implementation. UH-60 Sump Repair Status AH-64 Intermediate Gear Support Repair Status The Path to Structural Repairs UH-60 Lower Housing Summary Cold Spray Efforts - Introduction

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UNCLASSIFIED 3 FileName.pptx UNCLASSIFIED PEO Aviation AMRDEC Public Release: FN3832

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UNCLASSIFIED 4 FileName.pptx UNCLASSIFIED Director Technical Director ) Test & Integration Manager Rapid Response Initiative Manager Standardization Manager Aviation Chief (SED) Aeromechanics (AE-A) Propulsion (AE-P) Structures and Materials(AE-F) Mission Equipment (AE-S) Program Support Assistant Program Executive Officer ) ~ 562 Army Civilians 350 FTE Support Contractors Aviation Engineering Directorate (AED) Acquisition Business Mgr (AE-Z) ) Maintenance Engineering(AE-M) Sustainment Engineering(AE-K) Deputy Director Aviation Systems (AE-B) Cargo (AE-C) Apache (AE-D) Special Ops (AE-T) Utility (AE-U) Armed Scout (AE-R) UAS (AE-V) Associate Director of Programs Non Standard Rotary Wing (AE-N) Associate Director of Technology

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UNCLASSIFIED 5 FileName.pptx UNCLASSIFIED PMO- Each aircraft has its own Program Management Office; for sump repairs the cognizant organization is the Utility Helicopter Program Office, UH-PO; for the intermediate gear support the Apache Program Office has cognizance. As the owners of the aircraft platforms, these offices establish priorities for implementation of new repairs such as cold spray. Systems Engineering: this group acts as a liaison between the PMs and AED platform and functional groups. Systems Engineers organize task assignments and consolidate the input of platform and functional groups into a single AED position memo. DMWR Depot Maintenance Work Requirements: A document that provides step by step instructions for depot level maintenance efforts. MEO Maintenance Engineering Order: Written by AEM, once approved it revises the DMWR. Aviation Engineering Directorate in Cold Spray Approval - Roles and Definitions

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UNCLASSIFIED 6 FileName.pptx UNCLASSIFIED AEF Materials: has cognizance for all new materials and processes and evaluates them in terms of airworthiness and sustainability. AEP Propulsion: has structural cognizance for transmission components; in this case, magnesium housings. MED Maintenance Engineering Division: Identifies repair opportunities in the SAFR inventory and submits MEOs for approval to revise DMWRs when new processes are approved. CCAD: The Corpus Christi Army Depot is responsible for executing approved repairs either in house or via approved contractors. They also work closely with units and PMOs to determine emerging needs. Summary: the efforts of seven separate organizations (including ARL) must be coordinated just for the approval of a specific cold spray repair. The logistics for returning a repaired part to active inventory involves many other organizations. Aviation Engineering Directorate in Cold Spray Approval - Roles and Definitions (continued)

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UNCLASSIFIED 7 FileName.pptx UNCLASSIFIED UH-60 Main Transmission Sump Repair P/N 70351-48140-042 The ORing groove on the large diameter is the focal point of the sump repair

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UNCLASSIFIED 8 FileName.pptx UNCLASSIFIED UH-60 Main Transmission Sump Repair P/N 70351-48140-042 The First Article Test Report for the Cold Spray Repair of UH-60 Sumps has been approved by the AED Utility Division and two parts have been forwarded to MED / CCAD for fit and bench testing.

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UNCLASSIFIED 9 FileName.pptx UNCLASSIFIED The arrow shows the contact surface with witness marks left by the gear teeth. This area is also susceptible to pitting corrosion and fretting damage AH-64 Intermediate Gear Support P/N 7- 311310015-5.

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UNCLASSIFIED 10 FileName.pptx UNCLASSIFIED Apache Intermediate Gear Support P/N 7-311310015-5. AEF and AEP have approved this cold spray repair of the top land with defects up to.050 in depth. Current Status: ARL has completed the cold spray repair of two gear supports from the SAFR inventory and the first article test (FAT) inspection has been completed by ARL and CCAD. Review and approval by AEF and AEP will be conducted via the tasking system. An MEO will follow review and approval of the FAT test report.

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UNCLASSIFIED 11 FileName.pptx UNCLASSIFIED UH-60 PN 70351-38134-42 Main Gearbox Lower Housing Assy Candidate for First Structural Cold Spray Repair

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UNCLASSIFIED 12 FileName.pptx UNCLASSIFIED PN 70351-38134-42 Main Gearbox Lower Housing Assy Typical Packing Groove Corrosion No Current Repair

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UNCLASSIFIED 13 FileName.pptx UNCLASSIFIED PN 70351-38134-42 Main Gearbox Lower Housing Assy Liner Bore Seat Damage

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UNCLASSIFIED 14 FileName.pptx UNCLASSIFIED. Main Gearbox Lower Housing Assembly PN 70351-38134-42 Current Status: A test article has been identified from the SAFR inventory and is being forwarded to ARL/MOOG for review and proposed repair parameters.

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UNCLASSIFIED 15 FileName.pptx UNCLASSIFIED The efforts to approve and implement cold spray repairs for Army Aviation assets are progressing with two non structural repairs approved by AEF & AEP. ARL has completed the cold spray repair of two AH-64 intermediate gear supports. First Article Testing by ARL and CCAD is complete. AED will review these results vis the tasking system. The First Article Test Report for the Cold Spray Repair of UH-60 Sumps has been approved by the AED Utility Division and awaits fit and bench testing. Successful implementation of the two currently approved non structural repairs will build momentum for the approval of other more complex applications with structural aspects such as the UH-60 lower housing. Cold Spray Efforts - Summary