1. Engineered Applications of Electro-Spark Deposition (ESD) for Component Repair
Replacement of Hard Chrome Plating Program Review Meeting
1-2 April 2003
Loews Coronado Bay Resort
COMPONENT REPAIR PROJECTS
Electrospark deposition studies for gas turbine engine component repair
Advanced Surfaces and Processes, Inc.

2. Advanced Surfaces and Processes, Inc.
Introductions
Larry McCarty – President and CEO
John Kelley – VP R&D
Norma Price – Mechanical Engineer, Project Manager
Advanced Surfaces and Processes, Inc.

3. Advanced Surfaces and Processes, Inc.
Project Objective
Advanced Surfaces and Processes, Inc
will identify, evaluate and qualify applications of the Electrospark Deposition (ESD) process for repair of gas turbine engine components.
Advanced Surfaces and Processes, Inc.

4. Advanced Surfaces and Processes, Inc.
Participants
PEWG/ESTCP/HCAT
Portland State University
EWI
Rowan Technology Group
AFRL
GEAE PW
Tinker AFB
PNNL
Advanced Surfaces and Processes, Inc.

5. Advanced Surfaces and Processes, Inc.
The Project Plan
Phase 1
Period of Performance: 10/01/01 – 9/30/02
Objective: Determine the feasibility of using the ESD process to effect repairs on Gas Turbine Engine (GTE) components.
Phase 2
Period of Performance: 9/1/02 – 6/30/03
Objective: Gather and evaluate data regarding the effects of the ESD process on common GTE component materials.
Phase 3
Period of Performance: 7/01/03 – 6/30/04
Objective: Identify GTE components to be processed for performance testing. Develop ESD repair procedures and specifications for these specific components.
Advanced Surfaces and Processes, Inc.

6. Advanced Surfaces and Processes, Inc.
Phase 1
10/01/01 – 9/30/02
Determine the feasibility of utilizing the ESD process to effect cost effective repairs on a wide range of high cost, long lead-time, GTE components for which:
there are no known method of repair
existing repair methods are impractical
replacement parts are no longer available
existing methods of repair involve the utilization of HAZMATS such as electrolytic hard chrome (EHC).
Advanced Surfaces and Processes, Inc.

7. Advanced Surfaces and Processes, Inc.
Phase 1
Tasks:
Identify candidate materials
Select candidate materials
Optimize ESD parameters and specifications for selected substrate/electrode combinations
Identify repair liabilities for the ESD process on GTE materials
Create Process Specification Template
Advanced Surfaces and Processes, Inc.

8. Advanced Surfaces and Processes, Inc.
Phase 1 Task 1
Identify candidate materials
This task involved the identification of substrate materials widely used in GTE’s. DoD and OEM facilities and personnel were contacted and provided input. A wide variety of materials were identified as potential candidate materials.
100% Complete
Advanced Surfaces and Processes, Inc.

9. Electrode Specification Advanced Surfaces and Processes, Inc.
Phase 1 Task 2
Select candidate materials.
Substrate
Specification
Electrode Specification
IN 718
AMS 5663
AMS 5832
IN 625
AMS 5666
AMS 5837
Hastelloy X
AMS 5754
AMS 5798
Haynes 188
AMS 5772
AMS 5801
410 Stainless
AMS 5504
AMS 5823
17-4PH
AMS 5604
AMS 5825
100% Complete
Advanced Surfaces and Processes, Inc.

10. Advanced Surfaces and Processes, Inc.
Phase 1 Task 3
Optimize ESD parameters and specifications for selected materials.
A Design of Experiment (DOE) was created for each of the six materials. 36 coupons would be repaired varying the ESD parameters:
Capacitance
Voltage
Current
Pulse Rate
Based on material testing results, the optimum parameters will be selected. Further parameter optimization may be conducted.
Advanced Surfaces and Processes, Inc.

11. Advanced Surfaces and Processes, Inc.
Phase 1 Task 4
Identify repair liabilities for the ESD process on GTE materials.
This task involves the collection of data related to materials and weld repair (i.e. “specific problems with welding selected materials”) concerns, such as
Susceptibility to HAZ
Micro cracking
Porosity
Phase changes.
Advanced Surfaces and Processes, Inc.

12. Advanced Surfaces and Processes, Inc.
Phase 1 Task 5
Create Process Specification Template
A Welding Procedure Specification format has been developed by EWI, which represents one page of the entire Welding Specification. AFRL provided ASAP with templates that can be used for the development of complete Welding Specs which will be created for each application.
This task is dependant on the completion of component selection and has been moved to Phase 3, Task 4.
Advanced Surfaces and Processes, Inc.

13. Advanced Surfaces and Processes, Inc.
Phase 1
Status
Task 1 and 2 complete
Task 3 in process
Task 4 and 5 need to be revisited
Advanced Surfaces and Processes, Inc.

14. Advanced Surfaces and Processes, Inc.
Phase 2
9/1/02 – 6/30/03
Gather and evaluate information and data regarding the effects of the ESD process on common GTE component materials. This information and data will form the basis for our ESD/GTE compatibility criteria.
Advanced Surfaces and Processes, Inc.

15. Advanced Surfaces and Processes, Inc.
Phase 2
Tasks:
Produce Materials Test Coupons
Identify Materials and Mechanical Testing Protocol
Produce materials testing specimens
Evaluate materials testing results
Produce mechanical testing specimens
Evaluate mechanical testing results
Create candidate part screening requirements
Advanced Surfaces and Processes, Inc.

16. Advanced Surfaces and Processes, Inc.
Phase 2
Tasks:
PSU Contract
EWI Contract
Reclamation Project
Advanced Surfaces and Processes, Inc.

17. Advanced Surfaces and Processes, Inc.
Phase 2 Task 1
Produce Materials Test Coupons
216 coupons have been:
Procured
Heat treated, if necessary
Defects drilled
Pre ESD (surface finish, clean, weigh)
Repaired (defect filled)
Post ESD (surface photograph, weigh)
100% Complete
Advanced Surfaces and Processes, Inc.

18. Advanced Surfaces and Processes, Inc.
Phase 2 Task 1
Produce Materials Test Coupons
Advanced Surfaces and Processes, Inc.

19. Advanced Surfaces and Processes, Inc.
Phase 2 Task 2
Identify Materials and Mechanical Testing Protocol
ASAP will perform qualitative materials testing
PSU will perform material and mechanical testing
EWI will perform mechanical testing
Other facilities will review testing procedures
Working with Keith Legg et al to develop Joint Test Protocol (JTP)
Advanced Surfaces and Processes, Inc.

20. Advanced Surfaces and Processes, Inc.
Phase 2 Task 3
Produce materials testing specimens
216 coupons have been:
Cut and sent to PSU
Mounted, Polished and Etched
Micrographed
3 parameter sets have been duplicated 5 times to confirm repeatability
100% Complete
Advanced Surfaces and Processes, Inc.

21. Advanced Surfaces and Processes, Inc.
Phase 2 Task 4
Evaluate materials testing results
Compare ASAP and PSU analysis
Select optimum parameters for each material
Continue to optimize parameters, if necessary
Revisit material testing after component selection
Additional materials testing, per the JTP
Advanced Surfaces and Processes, Inc.

22. Advanced Surfaces and Processes, Inc.
Phase 2 Task 5
Produce mechanical testing specimens
PSU will address Low Cycle Fatigue testing
EWI will address Low Cycle Fatigue, Tensile and Bend testing
Advanced Surfaces and Processes, Inc.

23. Advanced Surfaces and Processes, Inc.
Phase 2 Task 6
Evaluate mechanical testing results
Compare EWI and PSU analysis
Continue to optimize parameters, if necessary
Revisit mechanical testing after component selection
Additional mechanical testing, per the JTP
Advanced Surfaces and Processes, Inc.

24. Advanced Surfaces and Processes, Inc.
Phase 2 Task 7
Create candidate part screening requirements
Criteria:
1 of the 6 materials
Replace/prevent EHC coatings
Format created,
revise as needed
Advanced Surfaces and Processes, Inc.

25. Advanced Surfaces and Processes, Inc.
Phase 2 Task 8
PSU Contract
Oregon Metal Initiative
Tasks
Advanced Surfaces and Processes, Inc.

26. Advanced Surfaces and Processes, Inc.
Phase 2 Task 8
Quantitative image analysis – optical & SEM
Microhardness – deposit- interface- substrate
Fatigue - Evaluation Capabilities
Axial – tension-tension (room & elevated Temp)
Flex bending – “Krauss”-tapered constant stress
Air & salt water
Rotating bending – “Fatigue Dynamics”- hour glass
Thermal & thermal-mechanical fatigue –controlled atmosphere
Courtesy of Portland State University
Advanced Surfaces and Processes, Inc.

27. Advanced Surfaces and Processes, Inc.
Phase 2 Task 8
Installation of ESD system at PSU
Enhanced characterization facilities
PC based Microhardness
ESD controlled atmosphere chambers being configured
High resolution field emission SEM and TEM installed
Scratch tester
Axial, rotating, and bending fatigue
Collaborative user facility relationships
FEI Co -- Dual Beam FIB/SEM
PNNL & EMSL National laboratory user facility
Courtesy of Portland State University
Advanced Surfaces and Processes, Inc.

28. Advanced Surfaces and Processes, Inc.
Phase 2 Task 8
Introduction Web Page for ESD Research Project (v2.5)
Courtesy of Portland State University
Advanced Surfaces and Processes, Inc.

29. Advanced Surfaces and Processes, Inc.
Phase 2 Task 8
Alloy As polished (100X)
Demonstrating Interference Contrast
Courtesy of Portland State University
Advanced Surfaces and Processes, Inc.

30. Advanced Surfaces and Processes, Inc.
Phase 2 Task 8
ESD voltage-current-porosity relationship
Courtesy of Portland State University
Advanced Surfaces and Processes, Inc.

31. Advanced Surfaces and Processes, Inc.
Phase 2 Task 9
EWI Contract
GEAE Project
Tasks
Advanced Surfaces and Processes, Inc.

32. Advanced Surfaces and Processes, Inc.
Phase 2 Task 8
Workscope for GEAE work
Focus on developing mechanical property data for ESD deposits in IN718
Apply ESD welds in machined grooves
Machine deposits flush and perform tensile, bend and LCF testing
Compare with unwelded specimens
Showed Favorable Results
Courtesy of Edison Welding Institute & GEAE
Advanced Surfaces and Processes, Inc.

33. Advanced Surfaces and Processes, Inc.
Phase 2 Task 8
LCF specimen – before and after
Courtesy of Edison Welding Institute & GEAE
Advanced Surfaces and Processes, Inc.

34. Advanced Surfaces and Processes, Inc.
Phase 2 Task 8
LCF specimen – before and after
Courtesy of Edison Welding Institute & GEAE
Advanced Surfaces and Processes, Inc.

35. Advanced Surfaces and Processes, Inc.
Phase 2 Task 10
Reclamation Project
Reclaim super alloy materials from scrap to be used to manufacture electrodes for the ESD process
Advanced Surfaces and Processes, Inc.

36. Advanced Surfaces and Processes, Inc.
Phase 2
Status
All tasks in process
Advanced Surfaces and Processes, Inc.

37. Advanced Surfaces and Processes, Inc.
Phase 3
7/01/03 – 6/30/04
Identify GTE components in which to effect cost effective ESD repairs. Candidate components will be selected and processed for performance testing as required. ESD repair procedures and specifications will be developed for the specific components in anticipation of deployment in DoD facilities.
Advanced Surfaces and Processes, Inc.

38. Advanced Surfaces and Processes, Inc.
Phase 3
Tasks:
Develop a database of components as candidates
Select candidate parts
Identify performance testing requirements
Create repair instructions and specifications
(From Process Specification Template)
Repair candidate parts for performance testing
Evaluate performance testing results, report findings
Demonstrate process techniques Provide training
Begin Technology Transfer
Final reports
Advanced Surfaces and Processes, Inc.

39. Advanced Surfaces and Processes, Inc.
Phase 3 Task 1
Develop a comprehensive database of GTE components as candidates for ESD repair.
Some prior work completed
Advanced Surfaces and Processes, Inc.

40. Advanced Surfaces and Processes, Inc.
Phase 3 Task 2
Select candidate parts (3-5) for ESD repair development.
Begin immediately (Scheduled to begin July, 2003)
Run parallel with materials and mechanical testing
Advanced Surfaces and Processes, Inc.

41. Advanced Surfaces and Processes, Inc.
Phase 3 Task 3
Identify performance testing requirements for ESD repaired parts.
Per JTP
Advanced Surfaces and Processes, Inc.

42. Advanced Surfaces and Processes, Inc.
Phase 3 Task 4
Create repair instructions and specifications for ESD repair of GTE components.
(From Process Specification Template, Phase 1, task 5)
Advanced Surfaces and Processes, Inc.

43. Advanced Surfaces and Processes, Inc.
Phase 3 Task 6
Repair candidate parts for performance testing.
Conduct Performance testing (execute the JTP)
Advanced Surfaces and Processes, Inc.

44. Advanced Surfaces and Processes, Inc.
Phase 3 Task 7
Evaluate performance testing results, report findings.
Document results in a Joint Test Report (JTR)
Advanced Surfaces and Processes, Inc.

45. Advanced Surfaces and Processes, Inc.
Phase 3 Task 8
Demonstrate process techniques for OEM’s and DoD facilities
Advanced Surfaces and Processes, Inc.

46. Advanced Surfaces and Processes, Inc.
Phase 3 Task 9
Provide training for OEM’s and DoD customers wishing to own/license ESD technology
Advanced Surfaces and Processes, Inc.

47. Advanced Surfaces and Processes, Inc.
Phase 3 Task 10
Begin Technology Transfer
Advanced Surfaces and Processes, Inc.

48. Advanced Surfaces and Processes, Inc.
Phase 3 Task 11
Final reports
Monthly Status Reports (MSR)
Potential Alternatives Report (PAR)
Joint Test Protocol (JTP)
Joint Test Report (JTR)
ESTCP Technology Demonstration Report
Advanced Surfaces and Processes, Inc.

49. Advanced Surfaces and Processes, Inc.
Phase 3
Status
With the exception of “Component Selection”, all tasks should begin July, 2003
Advanced Surfaces and Processes, Inc.

50. Advanced Surfaces and Processes, Inc.
Engineered Applications of Electro-Spark Deposition (ESD) for Component Repair
Questions?
Advanced Surfaces and Processes, Inc.