1. HVOF CONCERNS Ogden Air Logistics Center

2. HVOF CONCERNS HVOF CONCERNS Hill AFB concerns 0Thick Coatings 0Spalling 0Corrosion 0Spraying Parameters Sensitivity 0Almen Measurement Non-concerns for Hill AFB 0Fatigue Debit 0Grinding 0Finish Hill AFB concerns 0Thick Coatings 0Spalling 0Corrosion 0Spraying Parameters Sensitivity 0Almen Measurement Non-concerns for Hill AFB 0Fatigue Debit 0Grinding 0Finish

3. Ogden Air Logistics Center SPALLING TEST Spalling testing 02 A-10 NLG pistons(300M) coated with WC-Co >Tafa Powder >JP5000 system (6 inch barrel) >Parameters supplied by Jerry Schell >Grinding accomplished by Hill AFB (8-9 RA) Pistons were not superfinishedPistons were not superfinished >One piston.009 inches thick after grind >One piston.015 inches thick after grind Spalling testing 02 A-10 NLG pistons(300M) coated with WC-Co >Tafa Powder >JP5000 system (6 inch barrel) >Parameters supplied by Jerry Schell >Grinding accomplished by Hill AFB (8-9 RA) Pistons were not superfinishedPistons were not superfinished >One piston.009 inches thick after grind >One piston.015 inches thick after grind

4. Ogden Air Logistics Center SPALLING TESTS A-10 Test protocol 0FPI 0Ultra-sonic immersion test 0Loading sequence, R=-.33 A-10 Test protocol 0FPI 0Ultra-sonic immersion test 0Loading sequence, R=-.33

5. Ogden Air Logistics Center SPALLING TEST Spalling Testing 0Test conducted at U of Penn 0FPI and Ultra-Sonics Immersion testing >Prior to testing >After each 500 cycle test 0If coating still intact after final loading sequence then continue testing up to Yield Strength of material in 10 cycle increments Spalling Testing 0Test conducted at U of Penn 0FPI and Ultra-Sonics Immersion testing >Prior to testing >After each 500 cycle test 0If coating still intact after final loading sequence then continue testing up to Yield Strength of material in 10 cycle increments

6. Ogden Air Logistics Center CORROSION WC-Co coating is susceptible to corrosion as shown by HCAT testing 0Is it more susceptible than chrome? >Conflicting data 0Hill AFB corrosion testing plan >Coat round bars and flat plates as follows: Cad plateCad plate Chrome/HVOF coatChrome/HVOF coat Prime and paint exposes ends/edgesPrime and paint exposes ends/edges Some will be placed in salt spray chambersSome will be placed in salt spray chambers Some placed in outside locationsSome placed in outside locations Bars and plates will be processed identical to real life partsBars and plates will be processed identical to real life parts Report at next HCATReport at next HCAT WC-Co coating is susceptible to corrosion as shown by HCAT testing 0Is it more susceptible than chrome? >Conflicting data 0Hill AFB corrosion testing plan >Coat round bars and flat plates as follows: Cad plateCad plate Chrome/HVOF coatChrome/HVOF coat Prime and paint exposes ends/edgesPrime and paint exposes ends/edges Some will be placed in salt spray chambersSome will be placed in salt spray chambers Some placed in outside locationsSome placed in outside locations Bars and plates will be processed identical to real life partsBars and plates will be processed identical to real life parts Report at next HCATReport at next HCAT

7. Ogden Air Logistics Center SPRAYING PARAMETES Spraying parameters critical to coating success 0Each spraying system must be optimized >What does this really mean for production facilities? >Who does the DOE? >Do the new AMS specs address all critical issues >Booth qualification requirements Standardize requirementsStandardize requirements »Fatigue testing »Spalling testing »Corrosion testing Spraying parameters critical to coating success 0Each spraying system must be optimized >What does this really mean for production facilities? >Who does the DOE? >Do the new AMS specs address all critical issues >Booth qualification requirements Standardize requirementsStandardize requirements »Fatigue testing »Spalling testing »Corrosion testing

8. Ogden Air Logistics Center ALMEN STRIP Almen Strip Concerns 0Residual Stress requirements >Is the Almen strip the correct method to use >Is the AMS spec too lenient(.003-.012) >If spallation is a concern should we be investigating higher almen numbers Almen Strip Concerns 0Residual Stress requirements >Is the Almen strip the correct method to use >Is the AMS spec too lenient(.003-.012) >If spallation is a concern should we be investigating higher almen numbers

9. Ogden Air Logistics Center AS SPRAYED A-10 Piston as Sprayed

10. Ogden Air Logistics Center GRINDING

11. GRINDING

12. SPALLING TEST RIG

13. Ogden Air Logistics Center SPALLING TEST RIG