aeromat 2004 june 10, 2004 ralph m. tapphorn and howard gabel aeromat 2004 june 10, 2004 ralph m....
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AeroMat 2004June 10, 2004
Ralph M. Tapphorn and Howard Gabel
AeroMat 2004June 10, 2004
Ralph M. Tapphorn and Howard Gabel
Kinetic
Metallization
Kinetic
Metallization
Application of Alternative Wear-Resistant Metallic Coatings for Landing Gear and Aerospace Components
Application of Alternative Wear-Resistant Metallic Coatings for Landing Gear and Aerospace Components
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Alternatives for Hard Chrome Coatings
Introduction to Kinetic Metallization
Overview of Process
Technical and Cost Advantages
Kinetic Metallized WC-Co Coatings
Kinetic Metallized MCrAlY Coatings
Alternatives for Hard Chrome Coatings
Introduction to Kinetic Metallization
Overview of Process
Technical and Cost Advantages
Kinetic Metallized WC-Co Coatings
Kinetic Metallized MCrAlY Coatings
OverviewOverview
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HC AlternativesHC Alternatives
Executive Order EO13148
All Federal Agencies
Toxic Chemials, Hazardous Substances, and Pollutants Reduced by 50% by 12/31/2006
Applies to Hard Chrome and Chromate Conversion Coatings
Executive Order EO13148
All Federal Agencies
Toxic Chemials, Hazardous Substances, and Pollutants Reduced by 50% by 12/31/2006
Applies to Hard Chrome and Chromate Conversion Coatings
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US OrganizationsUS OrganizationsHard Chrome Alternatives
PEWG & JPCC (DoD)
Propulsion Environmental Working Group
Joint Propulsion Coordinating Committee
HCAT (Hard Chrome Alternative Team)
PEWG, ESTCP
JG-PP (Joint Group-Propulsion Prevention)
SERDP (DoD, DoE, EPA)
Strategic Environmental R&D Program
Hard Chrome Alternatives
PEWG & JPCC (DoD)
Propulsion Environmental Working Group
Joint Propulsion Coordinating Committee
HCAT (Hard Chrome Alternative Team)
PEWG, ESTCP
JG-PP (Joint Group-Propulsion Prevention)
SERDP (DoD, DoE, EPA)
Strategic Environmental R&D Program
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HC AlternativesHC Alternatives
Potential Alternatives for Wear Resistance
Coatings: WC-Co and MCrAlY
HVOF Process
Spark Etch and EB-PVD Process
Kinetic Metallization Process
Potential Alternatives for Wear Resistance
Coatings: WC-Co and MCrAlY
HVOF Process
Spark Etch and EB-PVD Process
Kinetic Metallization Process
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Impact Consolidation ProcessFeed-stock: fine powder
Accelerant: inert light gas
Solid-state ConsolidationNo Bulk Melting
No Liquid Chemicals
Environmentally InnocuousNo Particle or Hazardous Gas Emission
Impact Consolidation ProcessFeed-stock: fine powder
Accelerant: inert light gas
Solid-state ConsolidationNo Bulk Melting
No Liquid Chemicals
Environmentally InnocuousNo Particle or Hazardous Gas Emission
Kinetic Metallization
Kinetic Metallization
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KM Process FlowKM Process FlowPowder fluidized using
pressurized He gas (PFU)
Powder/gas mix thermally conditioned to improve deposition efficiency (TCU)
Deposition nozzle produces highly collimated spray pattern
Area coverage using X-Y rastering of nozzle and/or rotation of substrate
Powder fluidized using pressurized He gas (PFU)
Powder/gas mix thermally conditioned to improve deposition efficiency (TCU)
Deposition nozzle produces highly collimated spray pattern
Area coverage using X-Y rastering of nozzle and/or rotation of substrate
HeHe
PFUPFU
TCUTCU
DepositionNozzle
DepositionNozzle
SubstrateSubstrate
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Coating Development System
Desk sized
Production unit
Same footprint
Remove spray enclosure
Coating Development System
Desk sized
Production unit
Same footprint
Remove spray enclosure
KM–CDSKM–CDSFirst KM-CDS Shipped!!Buyer: US Naval AcademyLocated: NAVSEA-Carderock
First KM-CDS Shipped!!Buyer: US Naval AcademyLocated: NAVSEA-Carderock
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KM Critical ComponentsKM Critical
ComponentsPowder Fluidizing Unit
Closed-loop mass-loss control
Thermal Conditioning Unit
Low power
Deposition Nozzle
Friction compensated
Powder Fluidizing Unit
Closed-loop mass-loss control
Thermal Conditioning Unit
Low power
Deposition Nozzle
Friction compensatedHeHe
TCUTCU
PFUPFU
DNDN
PFUPFU
TCUTCU
DNDN
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KM Virtual Control Panel
KM Virtual Control Panel
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Compatible with any robot
5-pin connector provides
All KM power/control interface
Compatible with any robot
5-pin connector provides
All KM power/control interface
KM Robotic Control
KM Robotic Control
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KM Nozzle DesignKM Nozzle Design
Nozzle Anatomy
Friction Compensated Sonic Nozzle
Reference: Session 2: AeroMat 2004
“Kinetic Metallization Process and Coating Development System” Howard Gabel
Nozzle Anatomy
Friction Compensated Sonic Nozzle
Reference: Session 2: AeroMat 2004
“Kinetic Metallization Process and Coating Development System” Howard Gabel
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Wear and Corrosion Resistant Coatings
WC-Co on High Strength Steels & Al Alloys
MCrAlY on Steel and Superalloys
Wear and Corrosion Resistant Coatings
WC-Co on High Strength Steels & Al Alloys
MCrAlY on Steel and Superalloys
KM ExamplesKM Examples
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KM
WC-Co
Quality
KM
WC-Co
Quality
Highly Uniform
WC 3-m Average
Smooth Interface
Highly Uniform
WC 3-m Average
Smooth Interface
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KM
WC-Co
Quality
KM
WC-Co
Quality
25 m
KM WC-CoKM WC-Co HVOF WC-CoHVOF WC-Co
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PEWG
Review
PEWG
Review
Endorsed by OC-ALC and DoD JPCC
Assess and verify KM for
Repair and manufacturing GTE components
GEAE Specification F50TF71
Request AF Materiel Command, FY05 environmental funding
Endorsed by OC-ALC and DoD JPCC
Assess and verify KM for
Repair and manufacturing GTE components
GEAE Specification F50TF71
Request AF Materiel Command, FY05 environmental funding
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KM WC-Co Coatings
KM WC-Co Coatings
Wear ApplicationPump Guide Facing
Aluminum Alloy Disk
5-6 mils Thick
Grind/Polish 32 Ra
Aerospace Customer
Parker Aerospace
Wear ApplicationPump Guide Facing
Aluminum Alloy Disk
5-6 mils Thick
Grind/Polish 32 Ra
Aerospace Customer
Parker Aerospace
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KM
WC-Co
Coatings
KM
WC-Co
Coatings
Wear Application
Demo of Oblique Angle
KM Applied at 45
5 mils Thick
Ti & Al Alloy Substrates
Aerospace Customer
Hamilton Std. UTC
Wear Application
Demo of Oblique Angle
KM Applied at 45
5 mils Thick
Ti & Al Alloy Substrates
Aerospace Customer
Hamilton Std. UTC
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KM
WC-Co
KM
WC-Co
Borehole Drill Bit Heads
Wear resistant WC-Co
Applied to steel surfaces
Improved adhesion over Detonation Gun Coatings
Borehole Drill Bit Heads
Wear resistant WC-Co
Applied to steel surfaces
Improved adhesion over Detonation Gun Coatings
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NiCrAlY on Cu Alloy
NiCrAlY on Cu Alloy
KM ProcessLow Temperature on Cu
Inert Gas Applicator
Rocket Engine Coating
Oxidation Resistant
KM ProcessLow Temperature on Cu
Inert Gas Applicator
Rocket Engine Coating
Oxidation Resistant
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CoNiCrAlY- WaspaloyCoNiCrAlY- Waspaloy
KM ProcessLow Temperature
No Grit Blast
No Masking
Low Cost
KM ProcessLow Temperature
No Grit Blast
No Masking
Low Cost
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The KM Alternative
The KM AlternativeKM NiCrAlYKM NiCrAlY HVOF CoNiCrAlYHVOF CoNiCrAlY
SiC particle(from gritblasting)
SiC particle(from gritblasting)
Process
Coating Composition
Substrate Material
PorosityAdhesion Strength
KMNi-16Cr-6Al-
0.5YSteel 2.3%
>10.5 ksi (1)
HVOFCo-Ni-Cr-Al-
YWaspaloy 5.4% ~10ksi (2)
(1) Failure in epoxy (Sebastian stud-pull test per ASTM C 633)(2) Failure in coating (1.0” dia. epoxied loading fixture per ASTM C 633)(1) Failure in epoxy (Sebastian stud-pull test per ASTM C 633)(2) Failure in coating (1.0” dia. epoxied loading fixture per ASTM C 633)
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Process Simplification
Process Simplification
Pre-HeatPre-Heat
KM
KM
GritBlastGritBlast CoatCoat Cool
DownCoolDownH
VO
FH
VO
F ProcessCool
ProcessCool
CoatCoat
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KM WC-Co SummaryKM WC-Co Summary
Eliminates EnhancedGrit Blast Fatigue resistancePreheat ThroughputHigh temperature overheating
Permits long spray dwell times
Cool-down ThroughputHeat distortion UsabilityMasking ThroughputSharp transitions Fatigue resistancePorosity Ductility
Oxide inclusionsDuctility, corrosion resistance
Explosive Gases Safety
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KM vs.
HVOF
Costs
KM vs.
HVOF
Costs
Hypothetical Actuator
Dimensions 36” x 4” OD
Labor Rate @ $17/hr
60% Deposition Efficiency
Capital Equip - 7 Yr Life
Adv. Materials & Processing
May 2004 Issue
Tech Spotlight
Hypothetical Actuator
Dimensions 36” x 4” OD
Labor Rate @ $17/hr
60% Deposition Efficiency
Capital Equip - 7 Yr Life
Adv. Materials & Processing
May 2004 Issue
Tech Spotlight
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Phase II AFRL Material Command
KM of WC-Co Selected in FY03 by AFRL
Material Performance per GEAE Specification F50TF71
Fatigue Evaluations in FY04
Qualification Testing for Future Customers
Hamilton Std. UTC
Parker Aerospace
Conval, Inc.
Woodward Governor Co.
Phase II AFRL Material Command
KM of WC-Co Selected in FY03 by AFRL
Material Performance per GEAE Specification F50TF71
Fatigue Evaluations in FY04
Qualification Testing for Future Customers
Hamilton Std. UTC
Parker Aerospace
Conval, Inc.
Woodward Governor Co.
KM Future WC-CoKM Future WC-Co
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Qualification Testing for Future Customers
Pratt and Whitney
Honeywell Aviation Services
HiTempCo
Solar Turbines
Qualification Testing for Future Customers
Pratt and Whitney
Honeywell Aviation Services
HiTempCo
Solar Turbines
KM Future MCrAlYKM Future MCrAlY