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Hard Chrome Replacement NADEP Jacksonville

Hard Chrome Replacement NADEP Jacksonville. February, 2002 Michael Linn Materials Engineering. Hard Chrome Replacement TF34 Affordable Readiness Initiative. ARI POA&M Develop fixturing/masking including drawings Complete Prototype HVOF repairs Complete Complete

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Hard Chrome Replacement NADEP Jacksonville

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  1. Hard Chrome ReplacementNADEP Jacksonville February, 2002 Michael Linn Materials Engineering

  2. Hard Chrome ReplacementTF34 Affordable Readiness Initiative • 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

  3. Hard Chrome ReplacementTF34 Affordable Readiness Initiative • Identified Parts / Replacement Coating - Highlighted parts have been prototyped and installed in test engine. Parts Currently in production at NADEP Jacksonville

  4. Hard Chrome ReplacementTF34 Navy & Air Force Engines • 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)

  5. TF34 Axis-B Bevel Gearshaft P/N 6008T48P01 S/N HPC 01271 T800 HVOF Diamalloy 3001 After 50 hr. engine run

  6. TF34 B-Sump Housing P/N 6018T02G03 S/N GGM00204 T800 Plasma Spray Metco 68F-NS After 50 hr. engine run

  7. TF34 HPC Rear Shaft P/N 6016T83P01 S/N GAT 17106T800 T800 HVOF Diamalloy 3001 After 50hr. engine run

  8. TF34 No. 5 Carbon Seal Runner P/N 4019T60G01 HVOF Tungsten Carbide/Cobalt Diamalloy 2005 - 83/17 After 50 hr. engine run

  9. TF34 No. 6 Carbon Seal Runner P/N 4020T02G02 S/N BJW 00494 HVOF Tungsten Carbide/Cobalt Diamalloy 2005 - (WC/Co 83/17 After 50 hr. engine run

  10. TF34 No. 7 Carbon Seal Runner after 50 hr. engine run Note minute flat-line chatter marks from grinding operation with corresponding wear marks from mating part

  11. HVOF as a Hard Chrome Replacement 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

  12. Multi-Coat Cell #7 Powder Feeder “Teach Pen” Process Controller

  13. Multi-Coat Cell #7 NADEP Jacksonville Witness Specimens Exhaust plenum TF-34 Bevel Gear Fanuc 5 Axis Robot Sulzer Metco Hybrid Diamond Jet

  14. 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

  15. Prototype Produced in June, 1999 - Approval Pending J52 Rear Compressor Drive Turbine Shaft One of 3 remaining Cr Plated Engine Parts, NADEP Jax

  16. Development of Navy PositionJOAP • 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. Data from 47,770 JOAP Samples: -

  17. 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.

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