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OC-ALC Chrome Plate Reduction 20 FEB 2002

OKLAHOMA CITY AIR LOGISTICS CENTER. OC-ALC Chrome Plate Reduction 20 FEB 2002. TEAM TINKER. Johnny Tsiao OC-ALC/LPARR (405)736-3481 Johnny.tsiao@tinker.af.mil. I n t e g r i t y - S e r v i c e - E x c e l l e n c e. OVERVIEW . CHROME WORKLOAD AT TINKER HVOF AS ALTERNATIVE

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OC-ALC Chrome Plate Reduction 20 FEB 2002

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  1. OKLAHOMA CITY AIR LOGISTICS CENTER OC-ALC Chrome Plate Reduction 20 FEB 2002 TEAM TINKER Johnny Tsiao OC-ALC/LPARR (405)736-3481 Johnny.tsiao@tinker.af.mil I n t e g r i t y - S e r v i c e - E x c e l l e n c e

  2. OVERVIEW • CHROME WORKLOAD AT TINKER • HVOF AS ALTERNATIVE • TF33 HVOF QUALIFICATION • TINKER HVOF CAPABILITY • FUTURE TASKS

  3. TINKER CHROME PLATE WORKLOAD • 2063 total parts in CY 2001 • constant average of 172 parts per month • 29% increase from CY 2000 • F110/101 increase due to ENSIP schedule • F100 increase due to organic repair qualifications • TF33 decrease due to C141 a/c retirement

  4. NEED FOR CHROME REDUCTION • CURRENTLY TINKER IS A BIG USER OF HEXAVALENT CHROME FOR REPAIR OF ENGINE COMPONENTS • INCREASED RESTRICTIONS ON CHROME USAGE WILL SIGNIFICANTLY IMPACT MISSION READINESS FOR AIR FORCE PROPULSION • IDENTIFY CHROME PLATE FEATURES TO DETERMINE BEST ALTERNATIVES • Review tech data for all chrome callouts • Categorize by location and geometric features

  5. HVOF AS ALTERNATIVE • LP HAS IDENTIFIED HIGH VELOCITY OXYGEN FUEL (HVOF) COATING AS THE LEADING TECHNOLOGY TO REPLACE CHROME PLATING AT TINKER AFB • TF33 HVOF substitutions provide the greatest initial reduction in chrome usage • F110/101 Aft Shaft is bulk of chrome usage. Chrome repair also used for #4 Seal Housing on as needed basis to support DLA shortage. HVOF alternative is currently available for Aft Shaft. • Currently few F100 components identified for HVOF substitution. However, continual efforts for repair qualifications will identify additional needs • OEMs ALSO SPECIFIES HVOF IN THEIR DESIGNS • LP HAS IDENTIFIED COMPONENTS HAVING SUBSTRATES AND GEOMETRY SUITABLE FOR HVOF APPLICATION

  6. HVOF CANDIDATES • TF33 COMPONENTS: • AMS 5613, #1 Bearing Support; #2, #4, #5 and #6 Bearing Housing • AMS 5616, #6 Hub • AMS 5660, Rear Compressor Rear Hub • AMS 6280, #2 Bearing . Housing Alternate • AMS 6304, LPT Shaft; HPT Shaft • AMS 6322, #4.5 Bearing . Retaining Nut • AMS 6415, #2 Hub; #2.5 Bearing . Housing • F110/101 COMPONENTS: • INCO 718, HPT Aft shaft • A-286, #4 Carbon Seal Seat (recent addition) • SAE 8740, #5 Carbon Seal Seat (may be planned) • F100 COMPONENTS: • AMS 6265, Impeller shaft • AMS 6265, Gear shaft

  7. TF33 HVOF QUALIFICATION • TF33 IS THE LEAD PROGRAM FOR CHROME REPLACEMENT VIA HVOF • F100 agrees to pattern qualification methodology after TF33 • T56 will qualify thermal spray based on Joint Materials Test Protocol • 7 COMPONENTS IDENTIFIED FOR ENGINE TEST • Remaining 5 to be qualified by similarity • FUNCTIONAL TEST PROCEEDS ENDURANCE TEST • Fit Check completed • Metallurgical analysis by PW • Need Wright Lab assistance for sonic testing

  8. LPT shaft HPT shaft #4 hub #1 brg hsg #2 hub #5 brg hsg #6 brg hsg TF33 HVOF COMPONENTS FOR ENGINE TEST

  9. TF33 HVOF COMPONENTS FOR ENGINE TEST • ENGINE TEST PROBLEMS • Hardware installed on test engine • Engine at PW test facility • Significant delay due to technical and financial problems unrelated to this effort • Project completion of test by Aug 02 • POST ENGINE TEST MATERIAL ANALYSIS IS REQUIRED BEFORE PARTS ARE VALIDATED

  10. TF33 HVOF Functional Test #1 Bearing Housing As finished by Engelhard 2/01

  11. TF33 HVOF Functional Test #5 Bearing Housing As finished by Engelhard 2/01

  12. TF33 HVOF Functional Test #6 Bearing Housing & Seal Runner As finished by Engelhard 2/01

  13. TF33 HVOF Functional Test #2, 2.5 and 3 Bearing Journals As finished by Engelhard 2/01

  14. TF33 HVOF AMT HPC Rear Hub As received by Engelhard 2/01

  15. TF33 HVOF Functional Test #4.5 Bearing & Seal Journals As finished by Engelhard 2/01

  16. TF33 HVOF Functional Test #5 Bearing & Seal Journals As finished by Engelhard 2/01

  17. TINKER HVOF CAPABILITY KEY PARAMETERS • Booth Installation • Purchased and installed one Sulzer-Metco DJ system • Bio-environmental, safety certification • Long term Oxygen supply • Training • Classroom and practical • PW, Engelhard, Metco support • LP Quality Plan • Amend LPP process order to include HVOF • Coating Parameter • Sampling method • Evaluation standards • Masking Tools

  18. TINKER HVOF CAPABILITY KEY PARAMETERS • Finishing • Fine finish required for oil wetted parts • Tinker has not developed finishing capability • Engelhard support • Coating Removal • Need to determine removal method for subsequent repairs • Chemical vs mechanical • OEM Qualification • Two part PW source approval: General Process and Part Specific • Working on establishing PW support for source approval • Need to address GE components

  19. TINKER INHOUSE HVOF ROADMAP SEE PAGE 12

  20. PRELIMINARY Qualification Request - Creates Replog Entry See Note 2 See Note 1 Preparation of - Identifies Necessary Requested Steps for Qualification Material Process See Note 3 - Notifies Requester - MCL Prepares the - Submits Material For Submittal of Material for Review and MCL Review and Requested Compares Samples to Approval to Material Specifications Specifications Improve Process - Review Results Samples Rework Process and Communicate to - Provide Results to Fail Source MME PARTS SPECIFIC Samples Pass - Review of Process Schedule Meeting Qualification to Review Requirements and Qualification Plans requirements See Note 4 Process Process Qualification Samples - MCL Prepares the - Submits Material For Submittal of Material for Review and MCL Review and Qualification Compares Samples to Approval to Samples Specifications Specifications - Review Results Samples Rework Process and Communicate to - Provide Results to Fail Source MME Samples & Document Review Acceptable Qualification Granted PW QUALIFICATION PROCESS

  21. New part numbers and Tech Data must be introduced Class I Engineering Changes required for configuration control Additional funding for OEM through CIP needed More extensive process quality control requirements Standardized evaluation of process qualification Process tech data incorporation to T O 2-1-111 Particle liberation in oil wet areas Design requirements defined by OEM JOAP trending impacts Atomic absorption limitations with tungsten AMT engine will define criteria joint issue FUTURE TASKS program specific issue

  22. TEAM TINKER

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