– Commercial Technologies for Maintenance Activities Next Generation Inspection System (NGIS III) April 19, 2005 Jeffrey A. Calkins Manufacturing Resources Inc. (MRI)

2 – Commercial Technologies for Maintenance Activities NGIS III Project Team NCMS Program Manager: Bill Waddell Technology Partners End User: NADEP Cherry Point, NC Other Industry and Government Participants Solar Turbines Philadelphia Naval Foundry and Propeller Center NIST

3 – Commercial Technologies for Maintenance Activities NGIS III Objectives Perform on-machine inspection and repair of turbine engine blades and impellers.

4 – Commercial Technologies for Maintenance Activities NGIS III Objectives Perform on-machine inspection and repair of turbine engine blades and impellers. Dramatically reduce the amount of hand blending of airfoil surfaces under repair. Achieve “near net shape” blend on airfoil surfaces. Weld Areas

5 – Commercial Technologies for Maintenance Activities NGIS III Objectives Perform on-machine inspection and repair of turbine engine blades and impellers Dramatically reduce the amount of hand blending of airfoil surfaces under repair. Achieve “near net shape” blend on airfoil surfaces Reduce blending labor by 60% Eliminate rework Prevent scrap loss

6 – Commercial Technologies for Maintenance Activities NGIS III Objectives Perform on-machine inspection and repair of turbine engine blades and impellers Dramatically reduce the amount of hand blending of airfoil surfaces under repair: Achieve “near net shape” blend on airfoil surfaces Reduce blending labor by 60% Eliminate rework Prevent scrap loss Provide NADEP Cherry Point with a viable tool that can be also be adopted by other Depots and Industry users

7 – Commercial Technologies for Maintenance Activities NGIS III Objectives Perform on-machine inspection and repair of turbine engine blades and impellers Dramatically reduce the amount of hand blending of airfoil surfaces under repair: Achieve “near net shape” blend on airfoil surfaces Reduce blending labor by 60% Eliminate rework Prevent scrap loss (“killed” parts) Provide NADEP Cherry Point with a viable tool that can also be adopted by other Depots and Industry users Lay groundwork for additional future capabilities (e.g integrate material deposition process within the cell to eliminate welding).

8 – Commercial Technologies for Maintenance Activities NGIS III 5-Axis Cell X 5-axis machine and fixtures (MRI) Open architecture control (Delta Tau) Scanning algorithm and hardware (API, Mitutoyo) Surfacing and machine program generation software (RapidForm, Delcam) Key Subsystems and Technology Providers

9 – Commercial Technologies for Maintenance Activities NGIS III 5-Axis Cell Z Y X Z 3 Linear and 2 Rotary Axes (plus Rotary Tool Changer) B C

10 – Commercial Technologies for Maintenance Activities NGIS III 5-Axis Cell X Scanning Probe and Spindle Scanning Probe and Spindle are Mounted Concentrically on the B (Rotary) Axis

11 – Commercial Technologies for Maintenance Activities NGIS III Scanning Probe and Spindle Spindle Contact Scanning Probe Scanning Probe and Spindle are Mounted Concentrically on the B (Rotary) Axis

12 – Commercial Technologies for Maintenance Activities NGIS III 5-Axis Cell X Blade Fixture Blade and Impeller Fixtures are mounted on the C (Rotary) Axis

13 – Commercial Technologies for Maintenance Activities Part Set-Up (once per P/N) NGIS III Process Overview Adaptive Part Probing 5-Axis Cell Probe To Verify Final Bench and Inspection Ship Master or Model Part Part Machining Design Fixture Part Geometry Create Surface Model NC Tool Path Generation (Unique to Part Undergoing Repair) Machine to Nominal +.005”

14 – Commercial Technologies for Maintenance Activities Part Geometry Part Set-Up (once per P/N) Design Fixture NGIS III Process Overview Adaptive Part Probing Probe To Verify Final Bench and Inspection Ship Master or Model Part Part Machining Part Probing 5-Axis Cell Create Surface Model NC Tool Path Generation (Unique to Part Undergoing Repair) Machine to Nominal +.005”

15 – Commercial Technologies for Maintenance Activities Scan Data From A Welded Impeller

16 – Commercial Technologies for Maintenance Activities Detail of Scan Data From Welded Impeller

17 – Commercial Technologies for Maintenance Activities Scan Data From A Welded Blade Weld Areas

18 – Commercial Technologies for Maintenance Activities Part Geometry Part Set-Up (once per P/N) Design Fixture NGIS III Process Overview Adaptive Part Probing Probe To Verify Final Bench and Inspection Ship Master or Model Part Part Machining Part Probing 5-Axis Cell Create Surface Model NC Tool Path Generation (Unique to Part Undergoing Repair) Machine to Nominal +.005”

19 – Commercial Technologies for Maintenance Activities Creating Blade Surface Model 1.Triangulate the set of points from scan data to convert it to a polygon mesh 2.Use volumetric polygon offset to account for the probe tip radius 3.Clean up the polygon mesh using RapidForm’s “polygon healing” toolset Scan Processing Suite

20 – Commercial Technologies for Maintenance Activities Part Geometry Part Set-Up (once per P/N) Design Fixture NGIS III Process Overview Adaptive Part Probing 5-Axis Cell Probe To Verify Final Bench and Inspection Ship Master or Model Part Part Machining Create Surface Model NC Tool Path Generation (Unique to Part Undergoing Repair) Machine to Nominal +.005”

21 – Commercial Technologies for Maintenance Activities NC Tool Path For Blade Machining Tool Path

22 – Commercial Technologies for Maintenance Activities Part Geometry Part Set-Up (once per P/N) Design Fixture NGIS III Process Overview Adaptive Part Probing 5-Axis Cell Probe To Verify Final Bench and Inspection Ship Master or Model Part Part Machining Create Surface Model NC Tool Path Generation (Unique to Part Undergoing Repair) Machine to Nominal +.005”

23 – Commercial Technologies for Maintenance Activities Machining the Weld Bead NGIS III Tool Evaluation Study at MRI Helical Burr Tool

24 – Commercial Technologies for Maintenance Activities Part Geometry Part Set-Up (once per P/N) Design Fixture NGIS III Process Overview Adaptive Part Probing 5-Axis Cell Probe To Verify Final Bench and Inspection Ship Master or Model Part Part Machining Create Surface Model NC Tool Path Generation (Unique to Part Undergoing Repair) Machine to Nominal +.005”

25 – Commercial Technologies for Maintenance Activities Part Geometry Part Set-Up (once per P/N) Design Fixture NGIS III Process Overview Adaptive Part Probing 5-Axis Cell Probe To Verify Final Bench and Inspection Ship Master or Model Part Part Machining Create Surface Model NC Tool Path Generation (Unique to Part Undergoing Repair) Machine to Nominal +.005”

26 – Commercial Technologies for Maintenance Activities NGIS III Project Status (April, 2005) Major Project ElementStatus 5-Axis MachineComplete Open-Architecture Control IntegrationComplete Blade and Impeller FixturesComplete Tooling EvaluationComplete Probe & Scanning Software1. API is continuing scanning algorithm development with the original “on-machine” approach 2. Mitutoyo is developing a “stand-alone” scanning capability as another path to a technical solution Machining Programs“Proof-of-concept” demonstration completed User Interface and ProcessTo be completed upon successful demonstration of Automationscanning capability

27 – Commercial Technologies for Maintenance Activities Crysta-Apex CMM MP-100 Scanning Probe MCOSMOS Software Alternative Scanning Approach Mitutoyo is providing equipment and technical support to develop an alternative to the project’s original scanning approach Evaluation work is under way with blade samples provided in March, 2005 Key Elements

28 – Commercial Technologies for Maintenance Activities Industry Participant Contacts Mr. Jeff Calkins Tel: X103 Cell: Fax: Website:

29 – Commercial Technologies for Maintenance Activities Dr. Kam Lau Tel: Fax: Website: Industry Participant Contacts

30 – Commercial Technologies for Maintenance Activities Mr. Neal Kearney Tel: Website: Industry Participant Contacts

31 – Commercial Technologies for Maintenance Activities Mr. Tony Gable Tel: Website: Industry Participant Contacts

32 – Commercial Technologies for Maintenance Activities Mr. Tom Charron Tel: Fax: Website: Industry Participant Contacts

33 – Commercial Technologies for Maintenance Activities Mr. Larry Maggiano Tel: X4508 Cell: Website: Industry Participant Contacts