Hard Chrome Replacement NADEP Jacksonville February, 2002 Michael Linn Materials Engineering

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 Hard Chrome Replacement TF34 Affordable Readiness Initiative

Identified Parts / Replacement Coating Hard Chrome Replacement TF34 Affordable Readiness Initiative - Highlighted parts have been prototyped and installed in test engine. Parts Currently in production at NADEP Jacksonville

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) Hard Chrome Replacement TF34 Navy & Air Force Engines

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

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

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

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

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

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

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 HVOF as a Hard Chrome Replacement

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

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

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

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

Development of Navy Position JOAP 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:

Development of Navy Position JOAP 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 (A-6) and (A-4 Aircraft). Engine 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.