Hard Chrome Replacement NADEP Jacksonville February, 2002 Michael Linn Materials Engineering

Hard Chrome ReplacementNADEP Jacksonville

February, 2002

Michael Linn

Materials Engineering

• ARI POA&M– Develop fixturing/masking including drawings Complete

– Prototype HVOF repairs Complete Complete

– Perform 50 hour engine test cell endurance run Complete

– Visually and dimensionally evaluate coatings after engine test Complete

– Update repair manuals Complete

– Air Force Approval Complete

– Install new Multi-Coat Cell HVOF Complete

– Implement repairs Complete

Hard Chrome ReplacementTF34 Affordable Readiness

Initiative

• Identified Parts / Replacement Coating

Part Nomenclature Replacement Coating Part Nomenclature Replacement Coating

Seal Runner, #1 HVOF WC -17Co Axis A Gearshaft HVOF Tribaloy 800

Seal Runner, #3 HVOF WC -17Co Axis B Bevel Gear HVOF Tribaloy 800

Seal Runner, #4 HVOF WC -17Co Axis BB Gearshaft HVOF Tribaloy 800

Seal Runner, #5 HVOF WC -17Co Axis C Gearshaft HVOF Tribaloy 800

Seal Runner, #6 HVOF WC -17Co Axis D Gear Shaft HVOF Tribaloy 800

Seal Runner, #7 HVOF WC -17Co Axis E Gearshaft HVOF Tribaloy 800

B Sump Housing Plasma – Tribaloy 800 Axis F Gearshaft HVOF Tribaloy 800

No. 6 Bearing Hsg Plasma – Tribaloy 800 Axis G Spur Gear HVOF Tribaloy 800

No. 7 Bearing Hsg Plasma – Tribaloy 800 Axis H Gearshaft HVOF Tribaloy 800

C-Sump Cover Plasma – Tribaloy 800 Axis J Gearshaft HVOF Tribaloy 800

LPT Rear Shaft HVOF Tribaloy 800 Axis K Gearshaft HVOF Tribaloy 800

HPC Rear Shaft HVOF Tribaloy 800 Axis L Gearshaft HVOF Tribaloy 800

HPC Forward Shaft HVOF Tribaloy 800 Axis P Gearshaft HVOF Tribaloy 800

Hard Chrome ReplacementTF34 Affordable Readiness Initiative

- Highlighted parts have been prototyped and installed in test engine.

Parts Currently in production at NADEP Jacksonville

• Production Status– 100% of fixturing/masking completed including drawings

– Gained AF approval

– New Multi-coat cell is complete

– Approximate Number of Parts Processed by Production:

50 Axis B Bevel Gears

30 B-Sump Housing & # 6, #7 Bearing Housings

20 # 5, 6, & 7 Carbon seal runners

5 Years processing # 3 Bearing Housing (APS T800)

Hard Chrome ReplacementTF34 Navy & Air Force Engines

TF34 Axis-B Bevel GearshaftP/N 6008T48P01S/N HPC 01271

T800 HVOFDiamalloy 3001

After 50 hr. engine run

TF34 B-Sump HousingP/N 6018T02G03S/N GGM00204

T800 Plasma SprayMetco 68F-NS

After 50 hr. engine run

TF34 HPC Rear ShaftP/N 6016T83P01

S/N GAT 17106T800T800 HVOF

Diamalloy 3001After 50hr. engine run

TF34 No. 5 Carbon Seal RunnerP/N 4019T60G01

HVOF Tungsten Carbide/CobaltDiamalloy 2005 - 83/17After 50 hr. engine run

TF34 No. 6 Carbon Seal RunnerP/N 4020T02G02S/N BJW 00494

HVOF Tungsten Carbide/CobaltDiamalloy 2005 - (WC/Co 83/17

After 50 hr. engine run

TF34 No. 7 Carbon Seal Runner after 50 hr. engine runNote minute flat-line chatter marks from grinding operation

with corresponding wear marks from mating part

Status of New HVOF Cell at NADEP JAX

Specification for HVOF Cell Complete

Contract Award - March 29, 2000 Complete

Natural Gas Line Stubbed-out at Service Pad Complete

Blast cabinets for Cell #7 Installed & Operational Complete

Sound-proof enclosed room Complete

Exhaust plenum & Air Handling System Complete

FANUC 5-Axis Robot System for Cell #7 Complete

Multi-Coat Process Control Unit Installed Complete

System functional checks Complete

HVOF as a Hard Chrome Replacement

Multi-Coat Cell #7

“Teach Pen” Process Controller

Powder Feeder

Multi-Coat Cell #7 NADEP Jacksonville

Witness Specimens

TF-34 Bevel Gear Fanuc 5 Axis Robot Sulzer Metco Hybrid Diamond Jet

Exhaust plenum

Conclusion

• NADEP Jacksonville now Chrome free on TF-34, F 404, F414, F1D2

• NADEP Jacksonville has 3 J-52 parts remaining to be Chrome free on all engines

- Rear Compressor Drive Turbine Shaft

#5 Bearing Journal

- No. 4 Bearing Housing

- Spur Gear shaft

J52J52

Rear Compressor Drive Rear Compressor Drive Turbine ShaftTurbine Shaft

One of 3 remaining Cr One of 3 remaining Cr Plated Engine Parts, Plated Engine Parts,

NADEP JaxNADEP Jax

Prototype Produced in June, 1999 - Approval Pending

Development of Navy Position

JOAP

• Concern regarding replacement of Cr:Once Cr is replaced, should the JOAP Program add an element (W or Co) as a replacement for Wear

Metal Analysis ? • Assumption: The JOAP program currently uses [Cr] to indicate wear on

Cr Plated Wear Surfaces; [Cr] used to indicate potential failures.

-

compsn compmod dt_sample labrec fe ag al cr cu ni eimod71498 J52-P-6B 2/7/1997 91 69 92 110 82 120 UNINSTALLED660673 J52-P- 8B 6/6/1995 F 4 0 0 8 0 1 A-6660673 J52-P- 8B 6/12/1995 T 4 0 0 9 0 1 A-6636689 J52-P- 6C 7/23/1996 T 45 1 0 8 0 1 A-4696959 J52-P-408 1/11/1994 C 3 0 0 8 1 0 A-4696959 J52-P-408 1/16/1994 C 3 1 0 9 1 0 A-4696959 J52-P-408 3/21/1994 A 2 0 0 8 1 1 A-4696959 J52-P-408 12/17/1993 C 2 0 0 8 1 0 A-4696959 J52-P-408 1/25/1994 A 3 1 0 9 2 0 A-4661049 J52-P- 8B 11/16/1994 T 3 1 0 8 0 0 A-6678396 J52-P-408 1/7/1997 126 127 135 127 114 123 A-6660661 J52-P- 8B 3/6/1996 A 3 0 0 8 8 0 A-6678384 J52-P-408 6/17/1998 T 142 3 10 15 1 2 A-6678200 J52-P-408 6/14/1999 93 89 97 104 91 97 0678252 J52-P-408 9/18/2001 B 10 1 0 8 0 6 TEST CELL678469 J52-P-408 12/28/2001 T 53 1 0 9 0 1 UNINSTALLED

Data from 47,770 JOAP Samples:

Development of Navy PositionJOAP

• Data from 47,770 J-52 JOAP Samples indicates:

• 2 engines were removed for high Cr (8-9PPM) without the presence of high Fe. Those engines were 660673 (A-6) and 661049 (A-4 Aircraft). Engine 696959 was closely monitored around June, 1995 and was returned to normal after the Cr failed to increase.

NAVAIR Site Jacksonville Materials Engineering position: No evidence that Cr by itself provides utility for JOAP,at least not for the J-52.

Cr Data provided to FST for final determination.