OC-ALC Chrome
Plate Reduction 20 FEB 2002
OKLAHOMA CITY OKLAHOMA CITY AIR LOGISTICS CENTERAIR LOGISTICS CENTER
Johnny Tsiao
OC-ALC/LPARR
(405)736-3481
I n t e g r i t y - S e r v i c e - E x c e l l e n c e
TEAM TINKER
2
OVERVIEW
• CHROME WORKLOAD AT TINKER
• HVOF AS ALTERNATIVE
• TF33 HVOF QUALIFICATION
• TINKER HVOF CAPABILITY
• FUTURE TASKS
3
CY2000
70%
10%
16%
4%
TINKER CHROME PLATE TINKER CHROME PLATE WORKLOADWORKLOAD
CY 2001
40%
18%
39%
3%
TF33
F100
F110 AND F101
OTHERS
• 2063 total parts in CY 2001– constant average of 172 parts per month– 29% increase from CY 2000
• F110/101 increase due to ENSIP schedule• F100 increase due to organic repair qualifications• TF33 decrease due to C141 a/c retirement
4
NEED FOR CHROME REDUCTION
• CURRENTLY TINKER IS A BIG USER OF HEXAVALENT CHROME FOR REPAIR OF ENGINE COMPONENTS
• INCREASED RESTRICTIONS ON CHROME USAGE WILL SIGNIFICANTLY IMPACT MISSION READINESS FOR AIR FORCE PROPULSION
• IDENTIFY CHROME PLATE FEATURES TO DETERMINE BEST ALTERNATIVES– Review tech data for all chrome callouts
– Categorize by location and geometric features
5
HVOF AS ALTERNATIVE
• LP HAS IDENTIFIED HIGH VELOCITY OXYGEN FUEL (HVOF) COATING AS THE LEADING TECHNOLOGY TO REPLACE CHROME PLATING AT TINKER AFB– TF33 HVOF substitutions provide the greatest initial reduction in
chrome usage – F110/101 Aft Shaft is bulk of chrome usage. Chrome repair also
used for #4 Seal Housing on as needed basis to support DLA shortage. HVOF alternative is currently available for Aft Shaft.
– Currently few F100 components identified for HVOF substitution. However, continual efforts for repair qualifications will identify additional needs
• OEMs ALSO SPECIFIES HVOF IN THEIR DESIGNS
• LP HAS IDENTIFIED COMPONENTS HAVING SUBSTRATES AND GEOMETRY SUITABLE FOR HVOF APPLICATION
6
HVOF CANDIDATES
• TF33 COMPONENTS:– AMS 5613, #1 Bearing Support; #2, #4, #5 and #6 Bearing Housing – AMS 5616, #6 Hub– AMS 5660, Rear Compressor Rear Hub – AMS 6280, #2 Bearing . Housing Alternate– AMS 6304, LPT Shaft; HPT Shaft – AMS 6322, #4.5 Bearing . Retaining Nut– AMS 6415, #2 Hub; #2.5 Bearing . Housing
• F110/101 COMPONENTS:– INCO 718, HPT Aft shaft– A-286, #4 Carbon Seal Seat (recent addition)– SAE 8740, #5 Carbon Seal Seat (may be planned)
• F100 COMPONENTS:– AMS 6265, Impeller shaft– AMS 6265, Gear shaft
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TF33 HVOF QUALIFICATION
• TF33 IS THE LEAD PROGRAM FOR CHROME REPLACEMENT VIA HVOF– F100 agrees to pattern qualification methodology after
TF33– T56 will qualify thermal spray based on Joint Materials
Test Protocol
• 7 COMPONENTS IDENTIFIED FOR ENGINE TEST– Remaining 5 to be qualified by similarity
• FUNCTIONAL TEST PROCEEDS ENDURANCE TEST– Fit Check completed– Metallurgical analysis by PW– Need Wright Lab assistance for sonic testing
8
TF33 HVOF COMPONENTS FOR ENGINE TEST
#1 brg hsg
#2 hub
#4 hub
HPT shaftLPT shaft
#5 brg hsg #6 brg hsg
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TF33 HVOF COMPONENTS FOR ENGINE TEST
• ENGINE TEST PROBLEMS– Hardware installed on test engine
– Engine at PW test facility
– Significant delay due to technical and financial problems unrelated to this effort
– Project completion of test by Aug 02
• POST ENGINE TEST MATERIAL ANALYSIS IS REQUIRED BEFORE PARTS ARE VALIDATED
17
TINKER HVOF CAPABILITY KEY PARAMETERS
• Booth Installation– Purchased and installed one Sulzer-Metco DJ system– Bio-environmental, safety certification– Long term Oxygen supply
• Training– Classroom and practical – PW, Engelhard, Metco support
• LP Quality Plan– Amend LPP process order to include HVOF
• Coating Parameter – Sampling method– Evaluation standards– Masking Tools
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TINKER HVOF CAPABILITY KEY PARAMETERS
• Finishing – Fine finish required for oil wetted parts– Tinker has not developed finishing capability– Engelhard support
• Coating Removal– Need to determine removal method for subsequent repairs– Chemical vs mechanical
• OEM Qualification– Two part PW source approval: General Process and Part
Specific– Working on establishing PW support for source approval– Need to address GE components
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TINKER INHOUSE HVOF ROADMAP
Tinker and Englehard
See PWA Flowsheet
SprayEquipment
InstallationJan '02
Bio, FireSafety
Approval
FacilityOperational
TrainingDevelopeTraining Manual
OJTClassroom
Testing
TIESV Met Lab
RDE Contract
EvaluationStandards
CoatingPolishing
Procedures
Hands onw/
MCL Lab
QualityDocuments
Revision
Coatings
PreliminaryQualification
PWAProgram
Plan
Quality Plan
LPOI 21-166
ProcessOrder
LPP 85-11
LPA/ LPF/ LPQ
Approval
Bulk OxygenHQ
ApprovalFundedFy '02
BulkOxygen
Installation
ParametersPWA
36206-1
RoboticPrograms
PartSpecific
Qualification
LabSamples
Masking/Tooling
Coating meetsSpecification
Requirements?
HVOFRoadmap
Proceed to the nextpart requiring qualification
Tinker Englehard PWA MetcoEnglehard
andMetco
ApprovalGranted
Program PlanRequirements
Met?
No
Yes
Legend:
Yes
START
END
SEE PAGE 12
20
PW QUALIFICATION PROCESS
QualificationGranted
- Creates Replog EntrySee Note 2
- Review Resultsand Communicate to
Source- Provide Results to
MME
- Identifies NecessarySteps for Qualification
Process
- Notifies Requester
- Submits Material ForMCL Review and
Approval toSpecifications
- Review of ProcessQualification
Requirements andPlans
See Note 4
Rework Process
QualificationRequest
See Note 1
Preparation ofRequested
Material
See Note 3
Submittal ofRequested
Material
- MCL Prepares theMaterial for Review and
Compares Samples toSpecifications
SamplesFail
ImproveProcess
Schedule Meetingto Review
Qualificationrequirements
Process ProcessQualification
Samples
- Review Resultsand Communicate to
Source- Provide Results to
MME
- Submits Material ForMCL Review and
Approval toSpecifications
Rework Process
Submittal ofQualification
Samples
- MCL Prepares theMaterial for Review and
Compares Samples toSpecifications
SamplesFail
SamplesPass
Samples &Document
Review Acceptable
PRELIMINARY
PARTSSPECIFIC
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FUTURE TASKS
• New part numbers and Tech Data must be introduced
– Class I Engineering Changes required for configuration control
– Additional funding for OEM through CIP needed
• More extensive process quality control requirements
– Standardized evaluation of process qualification– Process tech data incorporation to T O 2-1-111
• Particle liberation in oil wet areas– Design requirements defined by OEM
• JOAP trending impacts– Atomic absorption limitations with tungsten
– AMT engine will define criteria
program specific issue
joint issue
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