Presented to:

Presented by:
NAVAIR Cold Spray Initiative Update
CSAT 2014 TIM; Worcester Polytechnic Institute
Frederick A. Lancaster AIR 4.3.4 S&T Lead
Cold Spray Action TEAM
June 2014
1911-2011 100 Years of Naval Aviation
Objective
The US Navy has the need to perform dimensional restoration of metallic
components caused by corrosion, restoration of material due to wear or
damage, and the ability to easily and rapidly repair structures in place on
Naval Aircraft.

The objective is to develop a metallization process that can be used to
facilitate repairs on naval aviation assets at all levels of maintenance.

Naval S&T Focus Areas:
Affordability
Maintainability
Reliability
Naval S&T Objectives:
Platform Affordability
Availability
2
1911-2011 100 Years of Naval Aviation
NAVAIR Workforce Development
7/1/2014
3
Engineer 8,
Tech 1; Low Pressure unit

Engineer 4
Tech 1; Low Pressure

Engineer 3
Tech 1; Low Pressure, 2
Robotic High pressure units

Engineer 4
Tech 1; Low/High Pressure
units

Engineer 1 Ground
Support
1911-2011 100 Years of Naval Aviation
FY-05 FY-06 FY-07 FY-08 FY-09
FY-10 FY-11 FY-12+
FRC-East
Pax River
FRC-SE
FRC-SW
Part Repair Approval
MIL-STD-3021
Cold Spray
Spec
Specifications
MIL-PRF-XXXX
Aerospace Powder
Spec
8 F-18 parts back in service
3 H-1 parts back in service
2 approved repair processes
2 new process pending/local approval
5 parts OEM approved (SAC) for rework
4 Low pressure CS units Operational
All FRCs w/ full repair capability
Technical staff trained @ all sites
2 sites high pressure capable
Cold spray specifications for
process Approved
Aerospace Powder Spec
Developing
SME
SME
SME
SME Trai
ned
Trained
Trained
Trained
SME
SME
Modeling
Section 219 S&T Investment
Initiate
Army
Contact
Army Collaboration (Demval, Testing, Information Exchange, Project Teaming, DOD Vision)
3-------------------------4------------------5-------TRL Level--------------6--------7---------------------8--9
Gearbox CS Repaired
Pre-Section 219 Timeframe (5 Years)
NAVAIR Cold Spray Timeline
Current Navy Cold Spray Capabilities
NAVAIR Facilities
FRC-East. 2 high & 1 low pressure
Pax River, low pressure portable
FRC Southeast (Jax), low pressure portable
FRC Southwest (NI), low pressure portable, 2 high
pressure robotic units (fy 14)
NAVSEA
- NSWCCD Inovati since 2004
- Keyport?
NPS
- Low Pressure cabinet
Technology Assessment
Target Material Applications Air Vehicles
Aluminum alloys used for naval aviation applications
7075-T73651 Plate,
7075-T76511 Extruded,
7075-T6 sheet/clad skin,
2024-T3 sheet/cladskin,
A356-T61 Cast,
Steel alloys used for naval aviation applications
AISI 4130 & AISI 4340,
Stainless Steel PH13-8Mo,
High Strength Steels (landing gear, arresting hooks),
300M,
Aermet 100,
AF1410
Magnesium alloys (AZ-91, ZE41A)
Titanium (Ti6-4)


Partnerships / Collaborations
Direct collaboration with
AIR 4.4.2.3 Power & Propulsion
AIR 4.3.3.2 Structures
AIR 4.3.4.2 NDI (Pax & FRC-SW)
Penn State ARL (REPTECH)
PMA 265, PMA 299
FRC East, Southeast, Southwest
Sikorsky Aircraft, Boeing Aircraft
Australian DSTO
NSWC Carderock & US Naval Postgrad
Partnerships with
USMC Corrosion Program
NSWC Carderock Materials
Engineer/Scientist Rotation
NRL Code 35
US Naval Postgrad School, Monterey
Army Research Lab
AMRDEC
TIPS: H-1 Combining Gearbox Repair
DLA: IVD Aluminum Repair, Cad Alternative, Hard Chrome Alternative
SBIR: Low pressure repairs, two small businesses & academia
AERMIP: Low Pressure Portable Metallization FRC-SE, Hole restoration F-18
OSD Corrosion: Portable Robotic System
REPTECH- PSU ARL Portable Repair and Restoration of Aluminum and Magnesium
Components
OSD Mantech-2012 Cold Spray Repair & Rebuild Technology (automated)
ONR SBA (NSWC Carderock/NPS) Single Particle Impact Study
FY12 Progress
Key Milestones Achieved
All depots operational & workforce trained
DT/OT for AMAD Fretting Corrosion Repair
Parts released back into fleet
DT for AMAD internal damage rebuild repair
FRC-East System Upgrade
Auxiliary heater installed on CGT Unit.
FY13 Progress
Key Milestones Achieved
Continued flight time for AMAD repairs
Upgrade of CGT-4000 @ FRC-E w/ 47kW heater
OSD Corrosion Office sponsorship for continued
working relation with Australian DSTO.
(overall, slow due to sequestration)
FY14 Expectations
Future:
F-18
Radar Racks, AMAD Gear Hard Chrome Alt, Wing/spar fastener hole repair (ie
bushing repair)
20 F-18 Radar Racks est $220K each tot $4.4M
IVD Repair:
H-60
Canted bulkhead repair (bushing alternative)
Gearbox repair (SAC & Australian DSTO)
V-22
V-22 Sills est $80K+ each sending back to CP.
H-1
Cobox O-Level Repairs
FRC independent teams can now perform repairs
Continue S&T work at Pax River with FRCs to expand applications
Refine portable repair process (field and depot roll up to the airframe)
Further Navy & Marine Corps Collaborative projects
Collaborative engineer rotation set-up with NSWC Carderock


Change Authorizations to Date
Local Process Specifications: Authority granted by
the cognizant engineering authority at the Fleet
Readiness Center (With local Materials & involved
competencies concurrence)

Engineering Orders from Sikorsky (ORI/(MEO
Army)): OEM approval. For Cold Spray the parts to
date are for using cold spray aluminum as an
alternative to flame spray aluminum, mainly for
wear areas, 5 applications.
FRC-SW Cold Spray Apps & Repairs
1. F/A-18E/F AMAD Main Housing (hydraulic pad restoration) LPS
2. F/A-18E/F AMAD Main Housing (gear failure repair) LPS
3. F/A-18E/F AMAD Hydraulic Gearshaft (seal surface repair) LPS
4. F/A-18E/F Main Landing Gear Brake Carrier
5. F/A-18A-D AMAD Housing PTS Axis (fretting repair)

6. F/A-18E/F Radar Rack Assembly (dimensional restoration)
7. F/A-18A-D GCU Tube Flange (pitted repair)
8. F/A-18E/F GCU PMG Shaft (dimensional restoration)
9. F/A-18E/F Wing Panel Fastener Holes (dimensional restore)
10.F/A-18A-D Center Pylon (dimensional restoration)

10. F/A-18E/F Steering Collar Cover (HSS dimensional restore)
11. F/A-18E/F Arresting Hook Pivot (HSS dimensional restore)

AMAD = Aircraft Mounted Accessory Drive GCU = Generator Control Unit
PTS = Power Take-Off Shaft PMG = Permanent Magnet Group
HSS = High-Strength Steel LPS = Local Process Specification
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FRC-E Cold Spray Apps & Repairs
1. H-60 Sump (wear restoration, dimensional repair) SAC ORI
2. H-53 Five SAC ORIs for various drivetrain parts. (detail coming)
3. H-1 Combining Gearbox Chafing repair (dimensional) LPS *
1. First Operational Level Repair

4. V-22 Window Sill Corrosion Repair (dimensional) LPS
5. H-60 Gearbox Pad Restoration;
1. Intermediate,
2. Tail,
3. Combining, &
4. Main


AMAD = Aircraft Mounted Accessory Drive
GCU = Generator Control Unit
PTS = Power Take-Off Shaft
PMG = Permanent Magnet Group
HSS = High-Strength Steel
LPS = Local Process Specification
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FRC-SE Cold Spray Apps & Repairs
1. F-18 Bomb Rack Repair (coating repair) LPS
2. GSE Spotting Dolly Pin Coating Repair (coating repair)
Engineering Test

3. IVD Aluminum repair







AMAD = Aircraft Mounted Accessory Drive
GCU = Generator Control Unit
PTS = Power Take-Off Shaft
PMG = Permanent Magnet Group
HSS = High-Strength Steel\
GSE= Ground Support Equipment
LPS= Local Process Specification
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14
Yr-13
Yr-10 Yr-11 Yr-12
Aircraft Component &Transition(s) Timeline
H-60 Gearbox
repairs
Australian
Navy/USN/US
Army/SAC
Repair of Cad & Al Coatings (OSD)
UH-1N/AH-1W COMBINING GEARBOX HOUSING REPAIR
PORTABLE (TIPS) FRC-E
Dimensional Repair/Aerospace Powder Spec(DLA)
UH-1N/AH-1W RING GEAR High Pressure (Section 219) FRC-E
F-18 EMI REPAIR PORTABLE (TBD)
UH-1N/AH-1W SUPPORT CASE PAD
MOUNT PORTABLE (TBD)
UH-1N/AH-1W CAD ALTERNATIVE
ELECTTRICAL CONNECTORS
PORTABLE (TBD)
F-18 E/F/G AMAD Transmission Housing High Pressure Fretting/Dim Rep(Section
219) FRC-SW
H-53 MGB
Pad
Mounts (
POM15)
Corrosion
Dimensional/No
n-structural
Structural (Repair
within struct
limits)
Key
PSU-ARL Repairability, F-18 (REPTECH)
F
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Current & Future Projects
Repair of Cad Alt
to Brush Plate
(DLA)
Repair of IVD(DLA)
15
Yr-17
Yr-14 Yr-15 Yr-16
Aircraft Component &Transition(s) Timeline
Portable Robotic CS - H-60 Intermediate Gearbox repairs
Australian Navy DSTO/USN NAVAIR (OSD Corrosion)
UH-1N/AH-1W COMBINING GEARBOX HOUSING REPAIR
PORTABLE (TIPS) FRC-E (Deployment to O-Level)
Aerospace Powder Spec(DLA)
F-18 EMI REPAIR PORTABLE (TBD)
UH-1N/AH-1W CAD ALTERNATIVE
ELECTTRICAL CONNECTORS
PORTABLE (TBD)
Corrosion/Coat
Dimensional/Non-structural
Structural (Repair within struct limits)
Key
PSU-ARL Repairability, F-18
(REPTECH)
Current & Future Projects
Repair of Cad Alt to Brush Plate (DLA)
Repair of IVD(DLA)
Repair of Cad Alt to Brush Plate (DLA)
F-18 Wing Spar Fastener Hole Elongation Repair(AERMIP)
Portable Robotic Cold Spray Application
To Be Proposed (wish list)
Example: Australian DSTO
has adapted a robotic cold
spray metallization system
for Mobile Repair
Advantage: Ability to apply CS
portably at High Pressures for
structural applications or
precise repair.

Goal: A system that artisan
teams can deploy and repair
aircraft in the field, operational
level, or at the aircraft at the
Intermediate level.

Worked with RAN under a
Coalition Warfare project to
further develop this technology
for structural applications.
Currently awarded an OSD
Corrosion effort to further
collaboration & demonstration
of portable repairs.
*Rosebank Engineering presentation TSS Cold Spray Conference 2010-Cold Spray application in Australian
Aerospace Industries-Neil Matthews DSTO Project
Future: Field/FRC Deployable
Robotic Systems
S&T Analysis
Process parameters
Repair limitations
Coating optimization
Powder
Surface preparation
Spray parameters
Coating bond strength
Coating cohesion
Post-coating preparation
Sealing
Welding
Machining
Microstructural characterization
Metallurgical bond
Dislocation density
Coating formation
Mechanical properties
(comparison to existing
technology)
Residual stress



Fatigue
Corrosion
Evaluation/Development of NDT
Significance of Flaws
Specifications and Requirements
Fitness for service acceptance
criteria & logistics
In-service repair
Safety/Environmental concerns
Application based cost benefit
analysis
Modeling, process & materials
Logistics constraints
Material
Equipment


Issues for all materials of interest to the Navy/NAVAIR
Need to tie fundamental
understanding of process
parameters/operating envelope to
coating properties
Hierarchy of Cold Spray Application
Projects
Approach
Establish Procedure(s)
Develop Process(es) & Equipment
NRL, ARL, NSWC-Carderock, Industry, Academia
Certify Testing & Results (laboratory)
Physical Tests
Corrosion Tests
Non-destructive
Develop Process Certification
Procedures/Methods
System/Process Functional Tests
Apply to aircraft
Flight Test
Develop


Qualify


Check


Assure
Take-Aways
All Fleet Readiness Centers are capable of Cold Spray
repairs
Hardware in place
Personnel trained, SMEs in place
Active S&T portfolio to support new process
applications
Still a significant amount of applications & repairs to develop
New alloy development still an open technology area.
Continue process development, verification & validation,
and qualification of applications
Next Step: Portable Systems for Depot & Field Use
Develop portable repair processes for field and depot
roll up to the airframe in place.

Summary
Responsive to fleet needs with solutions
that keep fleet assets affordable &
maintainable
Establishing for NAVAIR a solid base to grow
from
Material & Process Protocols
Capabilities
Processes
Manpower
Logistics