SPD Applications for the Australian Defence Department. Presented by David Wallace Director Future Business and Marketing

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1 SPD Applications for the Australian Defence Department Presented by David Wallace Director Future Business and Marketing

2 Presentation Introduction SPD The Technology Application Successes SPD Certification - Geometry Restoration SPD Structural Integrity Enhancement/Restoration Closing Discussions/Questions 8 July 2013 Slide 2

3 Introduction Rosebank Engineering is a major research centre for the development and application of Supersonic Particle Deposition (Cold Spray) for aerospace and Defence applications globally. This technology provides a number of exciting and cost benefit outcomes particularly in the corrosion protection and restoration of corroded /damaged metallic components/structure to an acceptable level of structural integrity and functionality. To this end the presentation outlines process of evolution of the technology in Australia through local and international collaboration, current SPD application activity to date and the on- going development of this technology for structural repair and restoration. 8 July 2013 Slide 3

4 SPD The Technology 8 July 2013 Slide 4

5 Why High acquisition costs coupled with economic and market forces have resulted in utilisation of commercial and military aircraft beyond their original design life. In many instances environmental degradation of structural components including wing and fuselage panels has resulted in both aviation accidents and significant costs. With respect to the cost of corrosion the June 2007 Report to Congress and US DOD 2009 Report on the Annual Cost of Corrosion estimated cost of corrosion US DoD systems 24 % viz. $10 Billon and 20 $Billon annually with Air Force costs being up to 31% of the total maintenance cost The 2007 Report outlined the need to research into four primary areas one being a process that restores materials to an acceptable level of structural integrity and functionality. This trend coupled with a number of high visible aviation accidents has raised the potential of government/regulators imposing a Limit of Validity on aircraft structural components particularly those that are subject to Multi site Damage (MSD). 8 July 2013 Slide 5

Around Times Up to 13 Months Replacement Cost - US $685,565 To carry out the traditional repair the Gearbox required to be

6 Example - Seahawk Mg Alloy Components Significant corrosion occurs at attachment points where a dissimilar metal is in contact with the coated magnesium component Typical corrosion on mating faces Typical Cost of Repair US $300,000 Repair Turn Around Times Up to 13 Months Replacement Cost - US $685,565 To carry out the traditional repair the Gearbox required to be disassembled and reassembled. So need to add on in house costs. SPD does not we can conduct the repair in situ 8 July 2013 Slide 6

7 8 July 2013 Slide 7 ROSEBANK ENGINEERING/DMTC-IN- CONFIDENCE So what is SPD? Supersonic Particle Deposition (SPD) (also referred to as Cold Spray) is a and additive technology in which metal, composite or polymer powder particles in a supersonic jet of compressed gas impact a solid surface with sufficient energy to cause plastic deformation and bonding with the underlying material and the creation of a reconstituted metal solid. The bonding and reconstitution occurs without the creation of heat affected zones which are typical of other deposition processes (plasma spray) and which are undesirable in many structural applications. Bonding is a result of high strain rate deformation and adiabatic shear instabilities and the bond interface

8 SPD - Science Based Technology Adhesion based on transfer of kinetic energy Kinetic energy can be readily calculated by CFD Critical velocity envelopes exist for various applications Critical Velocities can be calculated. Deposition amounts can be calculated 8 July 2013 Slide 8

9 BONDING MECHANISM Courtesy of T.Schmidt, F.Gaertner H. Kreye, T University of the Federal Armed Forces Germany Cold Spray 2007 Conference, Akron, Ohio 8 July 2013 Slide 9

10 Energy Dispersive X-Ray Analysis of Interface Al on Mg Alloy Continuous interface Movement of Al into Mg substrate Suggests strong metallurgical bond 8 July 2013 Slide 10

11 Technology Engagement Defence Aerospace DEFENCE AEROSPACE NEW COMBAT AIRCRAFT (F35) ALTERNATE COATINGS ( ) SEAHAWK TRANSMISSION RECOVERY AND PROTECTION (2005-) Feasibility study concluded SPD was a potential worthwhile technology for JSF Certification and airworthiness acceptance by the Regulatory Authority( ) Incorporated and flying for geometry restoration and protection ( Numerous collaborative partners through both formal and informal arrangements. In country and international agencies and a range of institutions including Commercial businesses, Defence agencies, Research Organisations and academia. Utilisation for structural Restoration /broader Application 8 July 2013 Slide 13

12 Application Successes 8 July 2013 Slide 15

SPD Transmission Applications RBE has applied SPD to Input module webs and mounting faces (3) RBE has applied SPD to main module sump and Flight control pad (4) RBE has a applied SPD to TRGB feet (4)

13 SPD Transmission Applications RBE has applied SPD to Input module webs and mounting faces (3) RBE has applied SPD to main module sump and Flight control pad (4) RBE has a applied SPD to TRGB feet (4) RBE has applied SPD to Accessory Module mounting faces for corrosion protection and geometry restoration (8) 23 Applications Accrued flight hours > 3000 RBE has applied SPD to IGB feet for corrosion protection and geometry restoration (5) 8 July 2013 Slide 16

14 Main Module Sump (S/N A ) During Before After Corrosion Damage Robotic Deposition Reworked CS deposition CS Deposition 8 July 2013 Slide 17

15 Main Module Aft Vertical Pad (S/N A ) During After Before Robotic Deposition Reworked Fitting Face Tapered Fitting Face Deposited CS Released Configuration Slide 18

16 Accessory Module (S/N A ) Before During After 8 July 2013 Slide 19

17 Seahawk Intermediate Gearbox (S/N A ) Before During After Corrosion Damage Robotic Deposition Reworked Foot Profile Edge Damage Deposition Reworked Foot Profile 8 July 2013 Slide 20

18 Input Module (S/N A ) Before During After 8 July 2013 Slide 21

19 TAIL ROTOR GEAR BOX (S/N A ) During Application After Machining 8 July 2013 Slide 22

20 Quality Assurance Porosity Evaluation Adhesion Evaluation 8 July 2013 Slide 23

21 Other Cold Spray Aerospace Applications P3 NWS Housing P3 Piston SEAHAWK RAST Fitting 8 July 2013 Slide 24

22 Trial Embedded Applications Damaged Main module Replicated damage removal Cold Spray deposition on Replicated damage Repaired Damage 8 July 2013 Slide 25

23 Other Aerospace Applications CH-53 Landing Gear Housing Repair finished pre-machined extensively worn housing coated & partially machined Courtesy of T.Stoltenhoff, Praxair Surface Technologies GmbH, Germany 8 th Colloquium, HVOF Spraying Cold Spray, 2009 Conference, Erding, Germany 8 July 2013 Slide 26

24 Other Aerospace Applications C-160 Propeller Blade Repair extensively worn blade polished/anodized pre-ground coating process shape-ground Courtesy of T.Stoltenhoff, Praxair Surface Technologies GmbH, Germany 8 th Colloquium, HVOF Spraying Cold Spray, 2009 Conference, Erding, Germany 8 July 2013 Slide 27

25 Benefits of SPD Demonstrable cost saver in sustainment costs (RAN Seahawk transmission cost savings 35% 50% ($6M over four years) (US DOD 2009 Report on the Annual Cost of Corrosion as 24 % of maintenance cost Air Force 31%) Can be applied to recover damaged geometry without adversely affecting the substrate Reusable for reclamation of eroded surfaces and application of wear resistant coating. Initial trails have shown that it can be used to enhance structural integrity 8 July 2013 Slide 28

that's designed to prolong the Black Hawk helicopter's service life has won a major environmental award.

26 World Leaders - SPD Rosebank Engineering First SPD Application - September 2009 RAN AIR (NASPO) Accept SPD Repair onto Main Rotor Gear Module S/N A Armed Forces International News - January 2013 Advanced military technology developed by the US Army's Research Laboratory (ARL) and Sikorsky that's designed to prolong the Black Hawk helicopter's service life has won a major environmental award. The ESTCP (Environmental Security Technology Certification Program) award recognises the benefits of this cold spray technique as a costeffective, eco-friendly approach to airframe preservation 8 July 2013 Slide 29

27 SPD Certification - Geometry Restoration 8 July 2013 Slide 30

28 Certification Strategy In order to achieve certification and implementation of powder based technology for structural restoration of damaged aircraft components, a three stage certification will be followed : (1) Laboratory demonstration Complete laboratory program and assess the results from metallurgical and mechanical tests for the chosen clad materials and components. The results will demonstrate the applicability of the technology on a laboratory scale. (2) Application demonstration Define an acceptance strategy based on tests with actual aircraft components with the cladding applied under industrial conditions. Any potential risks will be properly identified and assessed. The specifications or relevant documentations will be also developed at this stage. (3) Implementation Comply with all the acceptance strategy criteria, transfer the technology to an industry partner for inclusion in standard operating procedures and quality management systems. 8 July 2013 Slide 31

29 Aerospace Certification/Acceptance Director General of Technical Airworthiness (DGTA) Sets airworthiness standards for all military aerospace Defence Subject Matter Expert DSTO DMTC Scientific advice and experimentation Authorised Engineering Organisation (AEO) Application and certification on behalf of the DGTA 8 July 2013 Slide 32

30 Structural Integrity Enhancement/ Restoration Question Can SPD be used to enhance/ensure structural integrity???? 8 July 2013 Slide 40

31 Potential Application-Seahawk Pylon Fairing 8 July 2013 Slide 41

32 Potential Application on Seahawk Cockpit Fitting 8 July 2013 Slide 42

33 Structural Integrity Enhancement/Restoration WEAR CORROSION Residual Substrate DAMAGE SEALING 8 July 2013 Slide 43

34 Structural Integrity Enhancement/Restoration Aircraft structures are by necessity multiple, integral and both simple and complex Using FAA/JSSG 2006 definitions Aircraft Structure is a combination of; Primary Structure also known as Structurally Significant Items (SSI) Principal Structural Elements (PSE) which include such elements as Wings, Fuselage, Landing gear. Engine mounts etc. Within the these elements there are many sub-elements such as Skins Frames Bulkheads Webs Splices etc 8 July 2013 Slide 44

Application on Thin Skins Experiment 1 100 mm 2024T3 TEST SPECIMEN AS SUPPLIED 2024T3 TEST SPECIMEN 50mm Material is: Aluminium Alloy 2024T3 AlClad 350 mm x 100 mm x 1.27 mm (0.

35 Application on Thin Skins Experiment mm 2024T3 TEST SPECIMEN AS SUPPLIED 2024T3 TEST SPECIMEN 50mm Material is: Aluminium Alloy 2024T3 AlClad 350 mm x 100 mm x 1.27 mm (0.050 ) 125mm 10 mm 1 mm thick SDP Al Alloy on each side 125mm 75mm 350 mm SDP Al Alloy patch, on both sides centred 70 mm 10 mm 50mm Rivets Geometry of the Single edge notch tension (SENT) panel. An initial 2mm long edge crack Baseline test specimen with notch and no SPD Doubler - Failure at 35,000 cycles Geometry of the panel with an 7075 SPD doubler Applied peak stress was s max = 180 MPa, R = 0.1 MPa For test specimen with notch and the SPD Doubler There was no growth, or damage, after 60,000 cycles. Test stopped 8 July 2013 Slide 47

Application on thin Skins Experiment 2 100 mm 2024T3 TEST SPECIMEN AS SUPPLIED 2024T3 TEST SPECIMEN 50mm Material is: Aluminium Alloy 2024T3 AlClad 350 mm x 100 mm x 1.27 mm (0.

36 Application on thin Skins Experiment mm 2024T3 TEST SPECIMEN AS SUPPLIED 2024T3 TEST SPECIMEN 50mm Material is: Aluminium Alloy 2024T3 AlClad 350 mm x 100 mm x 1.27 mm (0.050 ) 125mm 125mm 75mm 350 mm SDP Al Alloy patch, on both sides centred 10 mm 70 mm 1 mm thick SDP Al Alloy on each side 10 mm 50mm Rivets Geometry of the Single edge notch tension (SENT) panel. An initial 2mm long edge crack Baseline test specimen with notch and no SPD Doubler - Failure at 1,800 cycles 9,300 cycles Note elevation in the stress around crack tip Geometry of the panel with an 7075 SPD doubler Applied peak stress was s max = 270 MPa, R = 0.1 MPa For test specimen with notch and the SPD Doubler Test stopped 13,700 cycles with a crack of 3.7mm 8 July 2013 Slide 48

37 Application on thin Skins Experiment 3 SDP Al Alloy strip, 60 mm long and 10 mm wide on both sides. The strip is 5mm from the edge that has the 2mm EDM edge notch at the centre line, see prior diagram. 5 mm from the edge at the centre line of the specimen 2024T3 TEST SPECIMEN WITH SPD REPAIR 10 mm 60 mm 10 mm scarf region 1 mm thick SDP Al Alloy strip on each side. The SPD strip dimensions to be 60 mm long and 10 mm wide on both sides, please. Geometry of the panel with an 7075 SPD doubler Applied peak stress was s max = 180 MPa, R = 0.1 MPa Baseline specimen (no SPD) failed after ~ 40,000 cycles This test was terminated after ~ 345,000 cycles with no growth from the edge crack or damage in the SPD Note: The SPD is performing structurally and is pulling load from the skin. 8 July 2013 Slide 49

Southwest Boeing Grounding of 79 aircraft Cancellation of almost 700 flights 4 aircraft were found

38 Application to Mechanically Fastened Joints Aloha Airline 737 Oct 1988 Multisite damage (MSD) around fasteners + Local Patch Repairs Southwest Airline 737 April Catastrophic cabin roof failure in Southwest Boeing Grounding of 79 aircraft Cancellation of almost 700 flights 4 aircraft were found with cracks FAA mandated inspection of 175 aircraft above pressure cycles 8 July 2013 Slide 50

as part of the FAA Aging aircraft program and

39 Application to Mechanically Fastened Joints Studies on the ability of SPD to seal mechanical joints from the environment have now been undertaken using a specimen geometry developed as part of the FAA Aging aircraft program and patents lodged 2013 SPD Action Team Meeting 8 July 2013 Slide 51

40 Stress Plots UNCOATED Stresses in MPa at beginning of test Stresses in MPa after 6,500 cycles COATED Stresses in MPa after 29,000 cycles Stresses in MPa at beginning of test Stresses in MPa after 91,000 cycles Stresses in MPa after 104,000 cycles 2013 Cold Spray Action Team Meeting 8 July 2013 Slide 52

41 Application to Mechanically Fastened Joints OUTCOME 1. SPD increased the Limit of Viability (LOV) by a factor of three (3) 2. SPD has the potential to effectively seal lap joints and thereby protect against the onset of corrosion damage 8 July 2013 Slide 53

Applications to seal universal (Dome Head) Rivets Baseline Specimen

27 mm starter crack at the fastener hole as per JSSG2006 damage

Specimen (dome head) rivet sealed using Al Alloy 7075 powder

42 Applications to seal universal (Dome Head) Rivets Baseline Specimen 2 mm thick T6 containing a 1.27 mm starter crack at the fastener hole as per JSSG2006 damage tolerance requirement and a protruding dome head rivet SPD Test Specimen (dome head) rivet sealed using Al Alloy 7075 powder Approximately 1900 flights with no delamination or damage to the SPD and no cracking in the 7075-T6 8 July 2013 Slide 54

Repairs To Corrosion Reworks The unrepaired specimen was subjected to constant amplitude tests at a peak stress of 140 MPa whilst SPD repaired specimens were tested at both 140 and 160 MPa Test

43 Repairs To Corrosion Reworks The unrepaired specimen was subjected to constant amplitude tests at a peak stress of 140 MPa whilst SPD repaired specimens were tested at both 140 and 160 MPa Test Outcome Test at 140 MPa The baseline specimens, i.e. without an SPD repair - 36,800 cycles to failure SPD repaired specimen - 15,000,000 cycles (The SPD repaired specimen did not fail and there was no evidence of cracking in the SPD or in substrate. Test at 160 MPa Two SPD repaired specimens tested. These specimens failed at approximately 640,000 cycles and 1,330,000 cycles... 8 July 2013 Slide 57

44 Spin Off Net Shape Manufacture Near Shape Production Mechanical Feature Recreation 8 July 2013 Slide 64 64

45 Advantages of Cold Spray Ease of application Reduced production & maintenance costs Rapid uniform high growth rate of coating thickness with excellent control over application area Coatings are free from oxides & other inclusions Coatings offer distinct mechanical advantages Corrosion-resistant coatings High thermal & electrical conductivity High hardness, cold work microstructure Improved OH&S Environmentally friendly High density Patents, Additive Manufacturing, IP

46 THANK YOU 8 July 2013 Slide 66

Cold Spray Materials Manufacturing Technology Research

Cold Spray Materials Manufacturing Technology Research Blake Barnett Materials Engineer, Advanced Materials & Processes Team Blake.d.Barnett.civ@mail.mil Outline The Case for Cold Spray: Nonthermal Additive