Final Report - Strategic Environmental Research and Development ...

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3.5.2.4. Surface Morphology................................................................................46 3.5.2.5. DOE Analyses.........................................................................................48 3.5.2.5.1. Regression Analysis ..........................................................................48 3.5.2.6. Residual Stresses.....................................................................................53 3.5.2.7. Deposition Rate.......................................................................................56 3.5.2.7.1. Deposition Rate Results.....................................................................56 3.5.3. Improvement with Each Phase.......................................................................59 3.6. Conclusions .......................................................................................................60 4. Application of ESD for Repair of Gas Turbine Engine Components......................63 4.1. Introduction .......................................................................................................63 4.1.1. Background....................................................................................................63 4.1.2. Materials Selection........................................................................................63 4.1.3. Preparation of Test Defects............................................................................64 4.1.4. Welding Procedure Specification ..................................................................66 4.1.5. Post ESD treatments ......................................................................................67 4.1.6. Test St<strong>and</strong>ards................................................................................................68 4.2. ESD Optimization .............................................................................................68 4.2.1. Introduction....................................................................................................68 4.2.2. DOE Inputs ....................................................................................................69 4.2.3. DOE Outputs..................................................................................................71 4.2.3.1. Deposition Rate.......................................................................................73 4.2.3.2. Microhardness .........................................................................................73 4.2.3.3. Discontinuities.........................................................................................74 4.2.3.4. Current.....................................................................................................74 4.2.3.5. Surface Finish..........................................................................................74 4.2.3.6. Microstructure .........................................................................................74 4.2.3.7. Non-Destructive Evaluation (NDE)........................................................75 4.2.4. Validation.......................................................................................................75 4.2.5. DOE Repeated ...............................................................................................76 4.2.6. Optimization Results......................................................................................77 4.2.6.1. Results of ESD applied at two different sites..........................................77 4.2.6.2. Results of Deposition Rate Evaluation....................................................79 4.2.6.3. Results of Microhardness Evaluation......................................................79 ix
4.2.6.4. Results of Discontinuities Evaluation .....................................................81 4.2.6.5. Results of Surface Finish Evaluation ......................................................82 4.2.6.6. Results of Non-Destructive Evaluation (NDE).......................................83 4.2.6.7. Validation Results ...................................................................................87 4.2.6.8. Results of Statistical Analysis.................................................................89 4.2.6.9. Parameters Selected for Test Specimens.................................................96 4.3. Results of Materials Testing..............................................................................97 4.3.1. Introduction....................................................................................................97 4.3.2. Fatigue............................................................................................................97 4.3.2.1. Test Rationale..........................................................................................97 4.3.2.2. Specimen Fabrication..............................................................................97 4.3.2.3. ESD Deposit Methodology .....................................................................99 4.3.2.4. Test Methodology .................................................................................100 4.3.2.5. Acceptance criteria................................................................................100 4.3.2.6. Test Results ...........................................................................................100 4.3.2.7. Failure Analysis.....................................................................................105 4.3.2.8. Conclusion.............................................................................................106 4.3.3. Tensile Testing.............................................................................................107 4.3.3.1. Test rationale.........................................................................................107 4.3.3.2. Specimen Fabrication............................................................................107 4.3.3.3. ESD Deposit Methodology ...................................................................107 4.3.3.4. Test Methodology .................................................................................108 4.3.3.5. Acceptance criteria................................................................................108 4.3.3.6. Test Results ...........................................................................................108 4.3.3.7. Failure Analysis.....................................................................................115 4.3.3.8. Conclusion.............................................................................................117 4.3.4. Wear (Pin-on-Disk)......................................................................................117 4.3.4.1. Test rationale.........................................................................................117 4.3.4.2. Specimen Fabrication............................................................................117 4.3.4.3. ESD Deposit Methodology ...................................................................118 4.3.4.4. Test Methodology .................................................................................119 4.3.4.5. Acceptance criteria................................................................................122 4.3.4.6. Test Results ...........................................................................................122 x
Page 1 and 2: U.S. DEPARTMENT OF DEFENSE Environm
Page 3 and 4: This page intentionally left blank.
Page 5 and 6: In addition NSWC-CD evaluated the p
Page 7 and 8: energy. Cost/Benefit Analysis (CBA)
Page 9: 3.4. Methodology ..................
Page 13 and 14: 4.3.9. Material Testing Conclusions
Page 15 and 16: 8.2.1.1. Test Set Up and Parameters
Page 17 and 18: Figure 3-16 Surface of Automated ES
Page 19 and 20: micrograph confirm this to be the c
Page 21 and 22: Figure 4-83 Post-test of Panel S-1
Page 23 and 24: Figure 5-17 Optical Macrograph Show
Page 25 and 26: Table 3-4 ESD Input Levels in DOE .
Page 27 and 28: Controls Immersed in Quiescent, Nat
Page 31 and 32: IARC ID IN625 IN718 IRR JTP kJ ksi
Page 33 and 34: ACKNOWLEDGMENTS The financial and p
Page 35 and 36: Although results were first reporte
Page 37 and 38: • ANAD/ARL - Army components - Ab
Page 39 and 40: operations at repair facilities. 1.
Page 43 and 44: Boeing Company, Honeywell Engines a
Page 45 and 46: Figure 2-1 RC Circuit in ESD Equipm
Page 47 and 48: component surfaces can be reduced f
Page 49 and 50: Cadmium Plating and IVD-Aluminum wi
Page 51 and 52: inch finish. Applications requiring
Page 53 and 54: UIT equipment to improve surface fi
Page 55 and 56: Figure 3-5 Torch-Leading Progressio
Page 57 and 58: The four-jawed chuck permits specim
Page 59 and 60: Table 3-1 Phase One Text Matrix of
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Figure 3-13 UIT Treatment Process W
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Weight measurements were not taken
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Table 3-8 DOE Experimental Test Mat
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esidual stresses in metals. It uses
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etween each of the phases (i.e. har
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Table 3-10 Discontinuity Values Cou
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3.5.1.4. Deposition Rate Results Au
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Table 3-13 Average % Porosity of ES
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ESD/UIT Hardnesses Microhardness (K
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Figure 3-27 Example of 50% Overlap
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ESD/UIT Surface Roughness after Fin
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Figure 3-31 Effect of Input Paramet
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Figure 3-34 Statistical Interaction
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Figure 3-38 and BL) Residual Stress
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Residual Stress of ESD/UIT on IN718
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Table 3-21 Combined (UIT Number) (E
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At the conclusion of this work two
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This page intentionally left blank.
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evaluated are shown in Table 4-1. T
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Figure 4-4 Type 1 Defect in Coupon
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(UIT) as described in Section 3, wh
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Several types of DOE approaches wer
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Figure 4-9 The ESD Trailer Data She
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Figure 4-10 Location of Microhardne
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Energy Input of DOE Coupons vs. Val
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Table 4-10 ASAP and EWI Hardness an
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Microhardness in the DOE Coupons (A
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Discontinuities in the DOE Coupons
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Figure 4-21 Coupon #36. FPI Indicat
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Figure 4-23 Coupon #45. FPI indicat
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Validation of Total Weld Time Depos
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Discontinuities = - 5.86 - 0.00417(
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The statistical software can be use
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Table 4-14 Minitab Four-Output Opti
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4.2.6.9. Parameters Selected for Te
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Figure 4-34 Fatigue Specimen Specif
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4.3.2.4. Test Methodology The fatig
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Table 4-19 Equations for Fatigue Li
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Fatigue Stress vs. Cycles to Failur
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specimen with no visible defective
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Table 4-22 Tensile Test Matrix for
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174 Yield Strength Average Yield St
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Baseline with Defect (All 6) 250 St
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Bead On Plate (All 3) 250 Stress (K
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Figure 4-59 Typical Fracture of Bas
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0.125”-thick disks were used in t
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Figure 4-67 Implant Sciences Corp.
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To generate a deeper groove and ext
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Figure 4-70 Wear Groove in Disk Bas
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It was possible to hear a differenc
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Figure 4-74 Hamilton Sundstrand Wea
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Figure 4-77 Hamilton Sundstrand Wea
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Load Pin 3000 lb. capacity Flat Cou
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Figure 4-81 Test 1, Panel S-1 and E
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Figure 4-87 illustrates (both in da
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Stroking Wear Testing of IN718 and
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when a higher energy setting (and c
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Figure 4-92 Corrosion Specimens 11-
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Figure 4-94 Corrosion Specimens 20-
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Figure 4-97 Digital Height Gauge fo
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ASTM C 633. Per ASTM C 633, ESD is
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4.3.9. Material Testing Conclusions
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Table 4-36 Candidate Components Ima
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the repair and dimensional restorat
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Figure 4-103 Excavate Damages Area
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The microhardness of the deposit wa
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Figure 4-110 10-12 Stator Segment F
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A metallurgical evaluation was perf
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Figure 4-117 Hot Air Erosion Defect
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Figure 5-2 Cannon Cradle Disassembl
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Figure 5-4 Porosity Around the ESD
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Knoop microhardness measurements (w
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Since the approval of the ESD repai
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Figure 5-13 Photograph of an M1A1 h
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Figure 5-15 Test Samples Used for E
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Figure 5-19 SEM Micrograph of a Cro
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Figure 6-3 Steering/Diving Control
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Figure 6-5 Application of ESD Coati
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Potential (V vs. Ag/AgCl) -0.020 -0
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6.3. ESD on Alloy K500 - Component
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Figure 6-10 Metallographic Cross-Se
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6.4. ESD Deposition on Alloy 625 -
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acetone degreased, and then air dri
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Figure 6-18 Crevice Corrosion Test
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The E corr data (Figure 6-19) showe
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this alternative process at OC-ALC.
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given in subsequent sections of thi
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Rework as Needed Mask Strip Bake Ou
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Table 7-7 Baseline Cost Allocations
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Table 7-8 Annual Operating Costs fo
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Table 7-10 Data and Assumptions Use
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Table 7-11 continued MODULE ESD Sho
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7.4.3. Capital Costs Implementing t
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guidance on the discount rates to b
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materials, waste disposal and envir
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data accumulated. Table 8-1 shows a
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8.2.1.1. Test Set Up and Parameters
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8.2.2. Results 8.2.2.1. Summary of
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2.5 Effect of Audible Feedback Forc
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was strictly a summation of effects
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Figure 8-10 Automated Force Control
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8.3.2.2. Automated Force Control te
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8.3.3. Conclusions on the Automated
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Ease of use of the equipment: Accor
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5 4.5 4 3.5 3 Net Effect of SuSi Th
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usually manual, making it difficult
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applicable to ships and submarines.
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16. “Environmental Cost Analysis
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APPENDIX A 252
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RECLAMATION PROCEDURE - M1A1 Cannon
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RECLAMATION PROCEDURE - M1A1 Cannon
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258
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M1A1 HELICAL (SUN) GEAR RECLAMATION
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RECLAMATION PROCEDURE - M1A1 Helica
Page 297 and 298:
Page 299:
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