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Kinetic Metallization

Kinetic Metallization. Joining and Repair of Titanium Aircraft Structures. AeroMat 2004 June 9, 2004 Ralph Tapphorn and Don Ulmer Jim E. Pillars, Boeing Integrated Defense. Overview. Introduction to Kinetic Metallization Applications Powder Selection Coating Microstructure CP Ti Ti-6-4

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Kinetic Metallization

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  1. Kinetic Metallization Joining and Repair of Titanium Aircraft Structures • AeroMat 2004 • June 9, 2004 • Ralph Tapphorn and Don Ulmer • Jim E. Pillars, Boeing Integrated Defense

  2. Overview • Introduction to Kinetic Metallization • Applications • Powder Selection • Coating Microstructure • CP Ti • Ti-6-4 • Coating Properties • Density • Oxygen content

  3. Kinetic Metallization • Impact Consolidation Process • Feed-stock: fine powder • Accelerant: inert light gas • Solid-state Consolidation • No Bulk Melting • No Liquid Chemicals • Environmentally Innocuous • No Particle or Hazardous Gas Emission

  4. He TCU PFU KM Process Flow • 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 Deposition Nozzle Substrate

  5. KM–CDS First KM-CDS Shipped!! Buyer: US Naval Academy Located: NAVSEA-Carderock • Coating Development System • Desk sized • Production unit • Same footprint • Remove spray enclosure

  6. KM Applications • Aerospace • Repair of titanium aircraft structures • Repair of titanium airfoil blades • Near-net shape structural reinforcements • Medical • Biocompatible coatings • Corrosion resistant coatings • Energetic materials

  7. KM Advantages • KM vs. Weld Repairs • Eliminates: • Thermal distortion • Heat affected zone • Degradation of parent material processes • KM vs. Thermal Spray • Eliminates: • Thermal distortion • Grit blasting surface preparation • Oxide inclusions and oxygen pickup • Explosive gases

  8. Repairs & Joining Process • Spray Forming • Fillet repairs • Dings & scratches • Fill small holes and crack grooves • Plug insert with perimeter fill • Thin backing plate • Joining techniques • Add gussets with fillet joining • Spray form small structures • Replace welding techniques

  9. CP Ti Powders • Titanium sponge fines (Hunter process) -100 mesh (-150 microns) -325 mesh (-45 microns) -500 mesh (-25 microns)

  10. -325 mesh (-45 microns) -500 mesh (-25 microns) KM CP Ti Coatings • Titanium sponge fines (Hunter process) -100 mesh (-150 microns)

  11. KM CP Ti Coatings • Significant deformation of CP Ti particles observed during particle impact -500 mesh(-25 micron)

  12. KM Coating Density • KM CP Ti coating density increases with decreasing particle size • Oxygen content has secondary effect

  13. Ti-6-4 Powder • Spherical Ti-6-4 (Inert gas atomized) -500 mesh (-25 micron)

  14. Increasing Gas Temperature + Reduced Particle Size Increasing Gas Temperature KM Ti-6-4 Coatings • Spherical Ti-6-4 powder (Inert gas atomized)

  15. Summary • Kinetic Metallization can achieve >99% dense CP Ti and Ti-6-4 coatings • Coating density is determined primarily by particle size and particle velocity • Kinetic Metallization is the only powder spray process that can produce high density coatings without increasing oxygen content

  16. Future Work • Measure mechanical properties of KM CP Ti and Ti-6-4 coatings • Tensile • Fatigue • Measure joint strength between KM CP Ti and Ti-6-4 coatings and substrate

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