ElectroSpark Deposition Hard Chrome Alternatives Team Joint Cadmium Alternatives Team Canadian Hard Chrome Alternatives Team Joint Group on Pollution Prevention Propulsion Environmental Working Group Replacement of Hard Chrome Plating Replacement of Cadmium Plating Program Review Meeting 23-25 January 2007 Marriott New Orleans at the Convention Center 859 Convention Center Blvd New Orleans, LA 70130
Report Documentation Page Form Approved OMB No. 0704-0188 Public reporting burden for the collection of information is estimated to average 1 hour per response, including the time for reviewing instructions, searching existing data sources, gathering and maintaining the data needed, and completing and reviewing the collection of information. Send comments regarding this burden estimate or any other aspect of this collection of information, including suggestions for reducing this burden, to Washington Headquarters Services, Directorate for Information Operations and Reports, 1215 Jefferson Davis Highway, Suite 1204, Arlington VA 22202-4302. Respondents should be aware that notwithstanding any other provision of law, no person shall be subject to a penalty for failing to comply with a collection of information if it does not display a currently valid OMB control number. 1. REPORT DATE JAN 2007 4. TITLE AND SUBTITLE ElectroSpark Deposition 2. REPORT TYPE 3. DATES COVERED 00-00-2007 to 00-00-2007 5a. CONTRACT NUMBER 5b. GRANT NUMBER 5c. PROGRAM ELEMENT NUMBER 6. AUTHOR(S) 5d. PROJECT NUMBER 5e. TASK NUMBER 5f. WORK UNIT NUMBER 7. PERFORMING ORGANIZATION NAME(S) AND ADDRESS(ES),85 N 26th Ave,Cornelius,OR,97113 8. PERFORMING ORGANIZATION REPORT NUMBER 9. SPONSORING/MONITORING AGENCY NAME(S) AND ADDRESS(ES) 10. SPONSOR/MONITOR S ACRONYM(S) 12. DISTRIBUTION/AVAILABILITY STATEMENT Approved for public release; distribution unlimited 11. SPONSOR/MONITOR S REPORT NUMBER(S) 13. SUPPLEMENTARY NOTES 27th Replacement of Hard Chrome and Cadmium Plating Program Review Meeting, January 23-25, 2007, New Orleans, LA. Sponsored by SERDP/ESTCP. 14. ABSTRACT 15. SUBJECT TERMS 16. SECURITY CLASSIFICATION OF: 17. LIMITATION OF ABSTRACT a. REPORT unclassified b. ABSTRACT unclassified c. THIS PAGE unclassified Same as Report (SAR) 18. NUMBER OF PAGES 53 19a. NAME OF RESPONSIBLE PERSON Standard Form 298 (Rev. 8-98) Prescribed by ANSI Std Z39-18
Introductions Norma Price ElectroSpark Deposition (ESD) Results of Materials Testing and Technology Insertion 2
What is ESD? The ESD process is comprised of generating an arc through a consumable electrode via capacitive discharge. The electrode and substrate materials are melted, rapidly solidify, and build-up up occurs incrementally. Metallurgical bond Low heat input Rapid solidification No pre-esd preparation No post-esd processing Environmentally benign Portable Applicable for NLOS 3
History 4
Project Objective The goals of this project were to demonstrate and validate ElectroSpark Deposition (ESD) as technically feasible and commercially viable for a production-scale process, and to perform the tests necessary to transition ESD for use on gas turbine engine components. 5
Participants ESTCP/HCAT PEWG Portland State University Edison Welding Institute General Electric Aircraft Engines Pacific Northwest National Lab Air Force Research Lab Metcut Hamilton Sundstrand Pratt & Whitney Tinker AFB Rowan Technology Group 6
Milestones! Optimization of ESD (Material Studies)! Joint Test Protocol (IN 718)! Joint Test Protocol (three more materials) 410 Stainless Steel Ti-6Al 6Al-4V Chrome-plated IN 718! ESD/Robotics/UIT! Components 7
Milestones www.hcat.org HCAT Member WorkSpace Projects and Partners Hard Chrome Alternative Team ESD - Electrospark Deposition for Repair (mostly GTEs) PEWG-HCAT Project EPP 0202 COMPLETED Reports Final Report ESD Final Report Draft.doc (updated 8/17/2006) 8
Joint Test Protocol For Three Other Materials 410 Stainless Steel Ti-6Al 6Al-4V Chrome-plated IN 718 9
Joint Test Protocol For Three Other Materials Optimization Deposition Rate Microhardness Discontinuities Fatigue Tensile Corrosion 10
410 Stainless Steel 11
410 Stainless Steel Optimization 12
410 Stainless Steel Optimization Run Order Coupon Number Pulse Rate (Hz) Voltage (V) Capacitance (mf) Electrode Speed (rpm) 1 410-34 300 100 30 800 2 410-35 300 150 40 1200 3 410-36 300 200 50 1400 4 410-37 500 150 30 1400 5 410-38 500 200 40 800 6 410-39 500 100 50 1200 7 410-31 700 200 30 1200 8 410-32 700 100 40 1400 9 410-33 700 150 50 800 13
410 Stainless Steel 0.025 Optimization Deposition Rate of 410SS Coupons 0.020 0.015 0.010 0.005 0.000 0 200 400 Deposition Rate (g/min) 600 800 1000 1200 Energy (kj) 14
410 Stainless Steel 500 Optimization Microhardness in 410SS Coupons Microhardness (Knoop) 400 300 200 100 ESD Interf ace Substrate 0 0 200 400 600 800 1000 1200 Energy (kj) 15
410 Stainless Steel 7.00 Optimization Discontinuities in 410SS Coupons 6.00 5.00 4.00 3.00 2.00 1.00 0.00 0 200 400 600 800 Discontinuities (% Area) 1000 1200 Energy (kj) 16
410 Stainless Steel Parameters Selected ESD Parameters Based on DOE results: 500 Hz Pulse Rate 40 mf Capacitance 150 volts Voltage 1100 rpm electrode rotation speed 17
410 Stainless Steel Fatigue ASTM E466 18
410 Stainless Steel Fatigue 19
410 Stainless Steel Tensile ASTM E8 20
410 Stainless Steel Tensile 174 Yield Strength 199 Tensile Strength Average Yield Strength (ksi) 173 172 171 170 169 Average Tensile Strength (ksi) 198 197 196 168 Baseline Divot ESD 32 ESD V4 Bead-on- Plate Method UIT 2 195 Baseline Divot ESD 32 ESD V4 Bead-on- Plate Method UIT 2 40 Reduction in Area 30 Elongation Average Reduction in Area (%) 35 30 Average Elongation (%) 25 20 25 Baseline Divot ESD 32 ESD V4 Bead-on- Plate Method UIT 2 15 Baseline Divot ESD 32 ESD V4 Bead-on- Plate Method UIT 2 21
410 Stainless Steel Tensile 410 All Conditions 160 140 120 Stress, σ (ksi) 100 80 60 40 20 0 0 1 2 3 4 5 6 7 8 9 10 11 12 Strain, ε (% ) Baseline with Defect Baseline Bead On Plate ESD ESD with UIT Method 2 22
410 Stainless Steel Corrosion ASTM B117 Performed by Cascade Technical Sciences, Inc. Hillsboro, Oregon 23
410 Stainless Steel Corrosion Before Test 24
410 Stainless Steel Corrosion After Test 25
Ti-6Al 6Al-4V 26
Ti-6Al 6Al-4V Ti-6Al 6Al-4V Specimens Prepared in a Glove Box 27
Ti-6Al 6Al-4V Optimization Run Order Coupon Number Pulse Rate (Hz) Voltage (V) Capacitance (mf) Electrode Speed (rpm) 1 Ti-21 500 130 50 800 2 Ti-19 300 130 40 1200 3 Ti-11 300 170 50 1400 4 Ti-15 400 130 30 1400 5 Ti-13 400 170 40 800 6 Ti-20 400 90 50 1200 7 Ti-17 500 170 30 1200 8 Ti-14 500 90 40 1400 9 Ti-12 300 90 30 800 28
Ti-6Al 6Al-4V Optimization Deposition Rate of Ti-6Al-4V Coupons 0.025 Deposition Rate (g/min) 0.020 0.015 0.010 0.005 0.000 0 100 200 300 400 500 600 700 800-0.005 Energy (kj) 29
Ti-6Al 6Al-4V Optimization Microhardness in Ti-6Al-4V Coupons 500 Microhardness (Knoop) 400 300 200 100 ESD Interf ace Substrate 0 0 100 200 300 400 500 600 700 800 Energy (kj) 30
Ti-6Al 6Al-4V Optimization Discontinuities in Ti-6Al-4V Coupons 7.00 Discontinuities (% Area) 6.00 5.00 4.00 3.00 2.00 1.00 0.00 0 100 200 300 400 500 600 700 800 Energy (kj) 31
Ti-6Al 6Al-4V Parameters Selected ESD Parameters Based on DOE results: 500 Hz Pulse Rate 50 mf Capacitance 130 volts Voltage 1400 rpm electrode rotation speed 32
Ti-6Al 6Al-4V Fatigue 33
Ti-6Al 6Al-4V Tensile 174 Yield Strength 150.0 Tensile Strength Average Yield Strength (ksi) 173 172 171 170 169 Average Tensile Strength (ksi) 145.0 140.0 135.0 168 Baseline Divot ESD 32 ESD V4 Bead-on- Plate Method UIT 2 130.0 Baseline Baseline with Defect ESD Bead-on- Plate ESD with Method 2 UIT 30.0 Reduction in Area 50.00 Elongation Average Reduction in Area (%) 25.0 20.0 15.0 10.0 5.0 Average Elongation (%) 40.00 30.00 20.00 10.00 0.0 Baseline Baseline with Defect ESD Bead-on- Plate ESD Method with 2UIT 0.00 Baseline Baseline with Defect ESD Bead-on- Plate ESD Method with2 UIT 34
Ti-6Al 6Al-4V Tensile Ti-6Al-4V All Conditions Stress, σ (ksi) 140 120 100 80 60 40 20 0 0 2 4 6 8 10 12 14 16 18 20 Strain, ε (% ) Baseline with Defect Baseline Bead On Plate ESD ESD with UIT Method 2 35
Ti-6Al 6Al-4V Corrosion Before Test 36
Ti-6Al 6Al-4V Corrosion After Test 37
Chrome-Plated IN 718 38
Chrome-Plated IN 718 Optimization Run Order Coupon Number Pulse Rate (Hz) Voltage (V) Capacitance (mf) Electrode Speed (rpm) 1 Chrome-1 300 100 10 800 2 Chrome-2 300 125 20 1200 3 Chrome-3 300 150 30 1400 4 Chrome-4 400 100 20 1400 5 Chrome-5 400 125 30 800 6 Chrome-6 400 150 10 1200 7 Chrome-7 500 100 30 1200 8 Chrome-8 500 125 10 1400 9 Chrome-9 500 150 20 800 39
Chrome-Plated IN 718 Optimization Deposition Rate Because of the difficulty with depositing material on chrome plated coupons, and with some areas of chrome plate debonding (or having been debonded), the weight gain measurements, and therefore, the deposition rates were not determined. 40
Chrome-Plated IN 718 500 Optimization Microhardness in Cr-Plated IN718 Coupons Microhardness (Knoop) 400 300 200 100 ESD Interf ace Substrate 0 0 10 20 30 40 50 60 70 80 Energy (kj) 41
Chrome-Plated IN 718 7.00 Optimization Discontinuities in Cr-Plated IN718 Coupons Discontinuities (% Area) 6.00 5.00 4.00 3.00 2.00 1.00 0.00 0 10 20 30 40 50 60 70 80 Energy (kj) 42
Chrome-Plated IN 718 Parameters Selected 43
Chrome-Plated IN 718 Parameters Selected ESD Parameters Based on Metallographic results: 300 Hz Pulse Rate 30 mf Capacitance 150 volts Voltage 1400 rpm electrode rotation speed 44
Chrome-Plated IN 718 Fatigue 45
Chrome-Plated IN 718 Tensile 140.0 Yield Strength 160.0 Tensile Strength Average Yield Strength (ksi) 135.0 130.0 125.0 Average Tensile Strength (ksi) 155.0 150.0 145.0 120.0 Baseline Baseline with Defect ESD Bead-on-Plate 140.0 Baseline Baseline with Defect ESD Bead-on-Plate 35.0 Reduction in Area 50.00 Elongation Average Reduction in Area (%) 30.0 25.0 20.0 15.0 10.0 5.0 Average Elongation (%) 40.00 30.00 20.00 10.00 0.0 Baseline Baseline with Defect ESD Bead-on-Plate 0.00 Baseline Baseline with Defect ESD Bead-on-Plate 46
Chrome-Plated IN 718 Tensile Chrome Plated IN718 - All Conditions 250 200 Stress, σ (ksi) 150 100 50 0 0 1 2 3 4 5 6 7 8 9 10 Strain, ε (%) Baseline with Defect Baseline Bead on Plate ESD 47
410 Stainless Steel Corrosion Before Test 48
410 Stainless Steel Corrosion After Test 49
Project Complete Addendum to Final Report sent to ESTCP on December 12, 2006. 50
From Material Properties To Components #5 Bearing Housing (410 SS) Stator Segment (IN 718) Compressor Rear Shaft (Chrome Plate) 51
Other Projects and Applications Army Anniston Abrams Tank Navy Carderock Nuclear Sub Army Watervliet/Benet - Rail 52
ElectroSpark Deposition Advanced Surfaces And Process, Inc. P.O. Box 729 85 N 26 Ave Forest Grove, OR 97116 Cornelius, OR 97113 503.640.4072 www.advanced-surfaces.com FAA Repair facility # V9PR575Y