NAVAIR Cold Spray Initiative Update Cold Spray Action

NAVAIR Cold Spray Initiative Update Cold Spray Action TEAM Presented to: CSAT 2014 TIM; Worcester Polytechnic Institute Presented by: Frederick A. Lancaster AIR 4. 3. 4 S&T Lead June 2014

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 Engineer 1 Ground Support Engineer 8, Tech 1; Low Pressure unit Engineer 4 Tech 1; Low/High Pressure units Engineer 3 Tech 1; Low Pressure, 2 Robotic High pressure units 1911 -2011 100 Years of Naval Aviation Engineer 4 3 Tech 1; Low Pressure 3/17/2018

NAVAIR Cold Spray Timeline Pre-Section 219 Timeframe (5 Years) FY-05 FY-06 FY-08 FY-07 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 FY-09 FY-10 FY-11 FY-12+ Section 219 S&T Investment Gearbox CS Repaired Part Repair Approval Initiate Army Contact Army Collaboration (Demval, Testing, Information Exchange, Project Teaming, DOD Vision) SME FRC-East Trained SME 4 Low pressure CS units Operational All FRC’s 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 Trai Modeling ned Pax River MIL-STD-3021 Cold Spray Spec SME FRC-SW Specifications Trained SME MIL-PRF-XXXX Aerospace Powder Spec 3 -------------4 ---------5 -------TRL Level-------6 ----7 -----------8 --9 1911 -2011 100 Years of Naval Aviation Trained

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 -T 73651 Plate, 7075 -T 76511 Extruded, 7075 -T 6 sheet/clad skin, 2024 -T 3 – sheet/cladskin, A 356 -T 61 Cast, – Steel alloys used for naval aviation applications – – – AISI 4130 & AISI 4340, Stainless Steel PH 13 -8 Mo, High Strength Steels (landing gear, arresting hooks), 300 M, Aermet 100, AF 1410 – Magnesium alloys (AZ-91, ZE 41 A) – Titanium (Ti 6 -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

FY 12 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. FY 13 Progress Key Milestones Achieved – Continued flight time for AMAD repairs – Upgrade of CGT-4000 @ FRC-E w/ 47 k. W heater – OSD Corrosion Office sponsorship for continued working relation with Australian DSTO. – (overall, slow due to sequestration)

FY 14 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 $220 K each tot $4. 4 M • IVD Repair: – H-60 • Canted bulkhead repair (bushing alternative) • Gearbox repair (SAC & Australian DSTO) – V-22 • V-22 Sills est $80 K+ 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 FRC’s 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 F/A-18 E/F AMAD Main Housing (hydraulic pad restoration) LPS F/A-18 E/F AMAD Main Housing (gear failure repair) LPS F/A-18 E/F AMAD Hydraulic Gearshaft (seal surface repair) LPS F/A-18 E/F Main Landing Gear Brake Carrier F/A-18 A-D AMAD Housing PTS Axis (fretting repair) Mature 1. 2. 3. 4. 5. 6. F/A-18 E/F Radar Rack Assembly (dimensional restoration) 7. F/A-18 A-D GCU Tube Flange (pitted repair) 8. F/A-18 E/F GCU PMG Shaft (dimensional restoration) 9. F/A-18 E/F Wing Panel Fastener Holes (dimensional restore) 10. F/A-18 A-D Center Pylon (dimensional restoration) In-Process 10. F/A-18 E/F Steering Collar Cover (HSS dimensional restore) 11. F/A-18 E/F Arresting Hook Pivot (HSS dimensional restore) Recently Identified 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

FRC-E Cold Spray Apps & Repairs 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 In-Process 4. V-22 Window Sill Corrosion Repair (dimensional) LPS 5. H-60 Gearbox Pad Restoration; 1. Intermediate, 2. Tail, 3. Combining, & 4. Main Mature 1. H-60 Sump (wear restoration, dimensional repair) SAC ORI 2. H-53 – Five SAC ORI’s for various drivetrain parts. (detail coming) 3. H-1 Combining Gearbox Chafing repair (dimensional) LPS * 1. First Operational Level Repair

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 Mature 3. IVD Aluminum repair In-Process 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

Current & Future Projects Yr-10 Yr-11 Yr-12 Yr-13 Aircraft Component &Transition(s) Timeline Repair of Cad & Al Coatings (OSD) Dimensional Repair/Aerospace Powder Spec(DLA) Repair of IVD(DLA) Repair of Cad Alt to Brush Plate (DLA) UH-1 N/AH-1 W RING GEAR High Pressure (Section 219) FRC-E F-18 E/F/G AMAD Transmission Housing High Pressure Fretting/Dim Rep(Section 219) FRC-SW H-60 Gearbox repairs – Australian Navy/USN/US Army/SAC UH-1 N/AH-1 W COMBINING GEARBOX HOUSING REPAIR – PORTABLE (TIPS) FRC-E PSU-ARL Repairability, F-18 (REPTECH) Key Corrosion Future Dimensional/Non -structural Structural (Repair within struct limits) H-53 MGB Pad Mounts ( POM 15) F-18 EMI REPAIR – PORTABLE (TBD) UH-1 N/AH-1 W SUPPORT CASE PAD MOUNT – PORTABLE (TBD) UH-1 N/AH-1 W CAD ALTERNATIVE ELECTTRICAL CONNECTORS – PORTABLE (TBD) 14

Current & Future Projects Yr-14 Yr-15 Yr-16 Yr-17 Aircraft Component &Transition(s) Timeline Repair of Cad Alt to Brush Plate (DLA) Aerospace Powder Spec(DLA) Repair of IVD(DLA) Repair of Cad Alt to Brush Plate (DLA) Portable Robotic CS - H-60 Intermediate Gearbox repairs – Australian Navy DSTO/USN NAVAIR (OSD Corrosion) F-18 Wing Spar Fastener Hole Elongation Repair(AERMIP) UH-1 N/AH-1 W COMBINING GEARBOX HOUSING REPAIR – PORTABLE (TIPS) FRC-E (Deployment to O-Level) PSU-ARL Repairability, F-18 (REPTECH) Key Portable Robotic Cold Spray Application Corrosion/Coat Dimensional/Non-structural F-18 EMI REPAIR – PORTABLE (TBD) Structural (Repair within struct limits) UH-1 N/AH-1 W CAD ALTERNATIVE ELECTTRICAL CONNECTORS – PORTABLE (TBD) To Be Proposed (wish list) 15

Future: Field/FRC Deployable Robotic Systems 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

S&T Analysis Issues for all materials of interest to the Navy/NAVAIR – 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 Need to tie fundamental understanding of process parameters/operating envelope to coating properties

CORROSION & DIMENSIONAL NONSTRUCTURAL CAPABILITIES STRUCTURAL $COST$ ADVANCED POWDER/ALLOY DEVELOPMENT RISK/COMPLEXITY Hierarchy of Cold Spray Application Projects

Approach Establish Procedure(s) Develop – 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 Qualify Check Assure

Take-Aways – All Fleet Readiness Centers are capable of Cold Spray repairs • Hardware in place • Personnel trained, SME’s 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