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• 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 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 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.