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ElectroSpark DepositionElectroSpark Deposition

Hard Chrome Alternatives TeamJoint Cadmium Alternatives Team

Canadian Hard Chrome Alternatives TeamJoint 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 Center859 Convention Center Blvd

New Orleans, LA 70130

Report Documentation Page Form ApprovedOMB 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 andmaintaining 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, ArlingtonVA 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 itdoes not display a currently valid OMB control number.

1. REPORT DATE JAN 2007 2. REPORT TYPE

3. DATES COVERED 00-00-2007 to 00-00-2007

4. TITLE AND SUBTITLE ElectroSpark Deposition

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) Advanced Surfaces And Processes, Inc.,85 N 26th Ave,Cornelius,OR,97113

8. PERFORMING ORGANIZATIONREPORT NUMBER

9. SPONSORING/MONITORING AGENCY NAME(S) AND ADDRESS(ES) 10. SPONSOR/MONITOR’S ACRONYM(S)

11. SPONSOR/MONITOR’S REPORT NUMBER(S)

12. DISTRIBUTION/AVAILABILITY STATEMENT Approved for public release; distribution unlimited

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 Same as

Report (SAR)

18. NUMBEROF PAGES

53

19a. NAME OFRESPONSIBLE PERSON

a. REPORT unclassified

b. ABSTRACT unclassified

c. THIS PAGE unclassified

Standard Form 298 (Rev. 8-98) Prescribed by ANSI Std Z39-18

January 25, 2007January 25, 2007Advanced Surfaces And Processes, Inc.Advanced Surfaces And Processes, Inc.

22

IntroductionsIntroductions

Norma PriceNorma Price

Advanced Surfaces And Processes, Inc.Advanced Surfaces And Processes, Inc.

ElectroSpark Deposition (ESD)ElectroSpark Deposition (ESD)Results of Materials Testing and Technology InsertionResults of Materials Testing and Technology Insertion


33

What is ESD?What is ESD?

The ESD process is comprised of generating an arc through The ESD process is comprised of generating an arc through a consumable electrode via capacitive discharge. The a consumable electrode via capacitive discharge. The electrode and substrate materials are melted, rapidly electrode and substrate materials are melted, rapidly solidify, and buildsolidify, and build--up occurs incrementally.up occurs incrementally.

Metallurgical bondMetallurgical bondLow heat inputLow heat inputRapid solidificationRapid solidificationNo preNo pre--ESD preparationESD preparationNo postNo post--ESD processingESD processingEnvironmentally benignEnvironmentally benignPortablePortableApplicable for NLOSApplicable for NLOS


44

HistoryHistory


55

ProjectProject ObjectiveObjective

The goals of this project were to The goals of this project were to demonstrate and validatedemonstrate and validate

ElectroSpark Deposition (ESD) ElectroSpark Deposition (ESD) as technically feasible and as technically feasible and commercially viable for a commercially viable for a productionproduction--scale process, and scale process, and to perform the tests to perform the tests necessary to transition ESD necessary to transition ESD for use on gas turbine engine for use on gas turbine engine components.components.


66

ESTCP/HCATESTCP/HCATPEWGPEWGPortland State UniversityPortland State UniversityEdison Welding InstituteEdison Welding InstituteGeneral Electric Aircraft Engines General Electric Aircraft Engines Pacific Northwest National LabPacific Northwest National Lab

ParticipantsParticipants

Air Force Research LabAir Force Research LabMetcut Metcut Hamilton SundstrandHamilton SundstrandPratt & WhitneyPratt & WhitneyTinker AFBTinker AFBRowan Technology GroupRowan Technology Group


77

!! Optimization of ESD (Material Studies)Optimization of ESD (Material Studies)!! Joint Test Protocol (IN 718)Joint Test Protocol (IN 718)!! Joint Test Protocol (three more materials)Joint Test Protocol (three more materials)

–– 410 Stainless Steel410 Stainless Steel–– TiTi--6Al6Al--4V4V–– ChromeChrome--plated IN 718plated IN 718

!! ESD/Robotics/UITESD/Robotics/UIT!! ComponentsComponents

MilestonesMilestones


88

www.HCAT.orgwww.HCAT.org

HCAT Member WorkSpace HCAT Member WorkSpace

→→Projects and Partners Projects and Partners

→→Hard Chrome Alternative Team Hard Chrome Alternative Team

→→ ESD ESD -- Electrospark Deposition for Repair (mostly GTEs) Electrospark Deposition for Repair (mostly GTEs) ––PEWGPEWG--HCAT Project EPP 0202 HCAT Project EPP 0202 –– COMPLETED Reports COMPLETED Reports

→→ Final Report Final Report

→→ ESD Final Report Draft.docESD Final Report Draft.doc (updated 8/17/2006)(updated 8/17/2006)

MilestonesMilestones


99

410 Stainless Steel410 Stainless Steel

TiTi--6Al6Al--4V4V

ChromeChrome--plated IN 718plated IN 718

Joint Test ProtocolJoint Test ProtocolFor Three Other MaterialsFor Three Other Materials


1010

OptimizationOptimization

–– Deposition RateDeposition Rate

–– MicrohardnessMicrohardness

–– DiscontinuitiesDiscontinuities

FatigueFatigue

TensileTensile

CorrosionCorrosion

Joint Test ProtocolJoint Test ProtocolFor Three Other MaterialsFor Three Other Materials


1111

410 Stainless Steel410 Stainless Steel


1212

OptimizationOptimization410 Stainless Steel410 Stainless Steel


1313

OptimizationOptimization410 Stainless Steel410 Stainless Steel

Run Order

Coupon Number

Pulse Rate(Hz)

Voltage(V)

Capacitance(mF)

Electrode Speed(rpm)

1 410-34 300 100 30 8002 410-35 300 150 40 12003 410-36 300 200 50 14004 410-37 500 150 30 14005 410-38 500 200 40 8006 410-39 500 100 50 12007 410-31 700 200 30 12008 410-32 700 100 40 14009 410-33 700 150 50 800


1414

410 Stainless Steel410 Stainless SteelOptimizationOptimization

Deposition Rate of 410SS Coupons

0.000

0.005

0.010

0.015

0.020

0.0250

200

400

600

800

1000

1200

Energy (kJ)

Dep

ositi

on R

ate

(g/m

in)


1515


Microhardness in 410SS Coupons

0

100

200

300

400

5000

200

400

600

800

1000

1200

Energy (kJ)

Mic

roha

rdne

ss (K

noop

)

ESD Interface Substrate


1616


Discontinuities in 410SS Coupons

0.00

1.00

2.00

3.00

4.00

5.00

6.00

7.000

200

400

600

800

1000

1200

Energy (kJ)

Dis

cont

inui

ties

(% A

rea)


1717

Parameters SelectedParameters Selected410 Stainless Steel410 Stainless Steel

ESD Parameters ESD Parameters –– Based on DOE results: Based on DOE results: 500 Hz Pulse Rate500 Hz Pulse Rate40 mF Capacitance40 mF Capacitance150 volts Voltage150 volts Voltage1100 rpm electrode rotation speed1100 rpm electrode rotation speed


1818

FatigueFatigue410 Stainless Steel410 Stainless Steel

ASTM E466ASTM E466


1919

FatigueFatigue410 Stainless Steel410 Stainless Steel


2020

TensileTensile410 Stainless Steel410 Stainless Steel

ASTM E8ASTM E8


2121

Tensile Strength

195

196

197

198

199

Baseline Divot ESD 32 ESD V4 Bead-on-Plate

UIT

Ave

rage

Ten

sile

Str

engt

h (k

si)

Yield Strength

168

169

170

171

172

173

174


UIT

Ave

rage

Yie

ld S

treng

th (k

si)


Elongation

15

20

25

30


UIT

Aver

age

Elon

gatio

n (%

)

Reduction in Area

25

30

35

40


UIT

Ave

rage

Red

uctio

n in

Are

a (%

)

Method 22

Method 22Method 22

Method 22


2222


410 All Conditions

0

20

40

60

80

100

120

140

160

0 1 2 3 4 5 6 7 8 9 10 11 12

Strain, ε (%)

Stre

ss, σ

(ksi

)

Baseline with Defect

Baseline

Bead On Plate

ESD

ESD with UITMethod 2


2323

CorrosionCorrosion410 Stainless Steel410 Stainless Steel

ASTM B117ASTM B117

Performed by Performed by Cascade Technical Sciences, Inc.Cascade Technical Sciences, Inc.

Hillsboro, OregonHillsboro, Oregon


2424


Before TestBefore Test


2525


After TestAfter Test


2626

TiTi--6Al6Al--4V4V


2727

TiTi--6Al6Al--4V4V

TiTi--6Al6Al--4V Specimens Prepared in a Glove Box4V Specimens Prepared in a Glove Box


2828

Run Order

Coupon Number

Pulse Rate(Hz)

Voltage(V)

Capacitance(mF)


1 Ti-21 500 130 50 8002 Ti-19 300 130 40 12003 Ti-11 300 170 50 14004 Ti-15 400 130 30 14005 Ti-13 400 170 40 8006 Ti-20 400 90 50 12007 Ti-17 500 170 30 12008 Ti-14 500 90 40 14009 Ti-12 300 90 30 800

Run Order

Coupon Number

Pulse Rate(Hz)

Voltage(V)

Capacitance(mF)


1 Ti-21 500 130 50 8002 Ti-19 300 130 40 12003 Ti-11 300 170 50 14004 Ti-15 400 130 30 14005 Ti-13 400 170 40 8006 Ti-20 400 90 50 12007 Ti-17 500 170 30 12008 Ti-14 500 90 40 14009 Ti-12 300 90 30 800

OptimizationOptimizationTiTi--6Al6Al--4V4V


2929

Deposition Rate of Ti-6Al-4V Coupons

-0.005

0.000

0.005

0.010

0.015

0.020

0.0250

100

200

300

400

500

600

700

800

Energy (kJ)

Dep

ositi

on R

ate

(g/m

in)

TiTi--6Al6Al--4V4VOptimizationOptimization


3030

Microhardness in Ti-6Al-4V Coupons

0

100

200

300

400

5000

100

200

300

400

500

600

700

800

Energy (kJ)

Mic

roha

rdne

ss (K

noop

)




3131

Discontinuities in Ti-6Al-4V Coupons

0.00

1.00

2.00

3.00

4.00

5.00

6.00

7.000

100

200

300

400

500

600

700

800

Energy (kJ)

Dis

cont

inui

ties

(% A

rea)



3232

ESD Parameters ESD Parameters –– Based on DOE results: Based on DOE results: 500 Hz Pulse Rate500 Hz Pulse Rate50 mF Capacitance50 mF Capacitance130 volts Voltage130 volts Voltage1400 rpm electrode rotation speed1400 rpm electrode rotation speed

Parameters SelectedParameters SelectedTiTi--6Al6Al--4V4V


3333

FatigueFatigueTiTi--6Al6Al--4V4V


3434

Tensile Strength

130.0

135.0

140.0

145.0

150.0

Baseline Baselinewith Defect

ESD Bead-on-Plate

ESD withUIT

Ave

rage

Ten

sile

Stre

ngth

(ksi

)

Yield Strength

168

169

170

171

172

173

174


UIT

Ave

rage

Yie

ld S

treng

th (k

si)

TensileTensileTiTi--6Al6Al--4V4V

Elongation

0.00

10.00

20.00

30.00

40.00

50.00

Baseline Baselinewith Defect

ESD Bead-on-Plate

ESD withUIT

Ave

rage

Elo

ngat

ion

(%)

Reduction in Area

0.0

5.0

10.0

15.0

20.0

25.0

30.0

Baseline Baseline withDefect

ESD Bead-on-Plate

ESD with UIT

Ave

rage

Red

uctio

n in

Are

a (%

)

Method 22

Method 22Method 22

Method 22


3535

TensileTensileTiTi--6Al6Al--4V4V

Ti-6Al-4V All Conditions

0

20

40

60

80

100

120

140

0 2 4 6 8 10 12 14 16 18 20

Strain, ε (%)

Stre

ss, σ

(ksi

)

Baseline with DefectBaselineBead On PlateESDESD with UITMethod 2


3636

CorrosionCorrosionTiTi--6Al6Al--4V4V



3737

CorrosionCorrosionTiTi--6Al6Al--4V4V



3838

ChromeChrome--Plated IN 718Plated IN 718


3939

Run Order

Coupon Number

Pulse Rate(Hz)

Voltage(V)

Capacitance(mF)


1 Chrome-1 300 100 10 8002 Chrome-2 300 125 20 12003 Chrome-3 300 150 30 14004 Chrome-4 400 100 20 14005 Chrome-5 400 125 30 8006 Chrome-6 400 150 10 12007 Chrome-7 500 100 30 12008 Chrome-8 500 125 10 14009 Chrome-9 500 150 20 800

OptimizationOptimizationChromeChrome--Plated IN 718Plated IN 718


4040

ChromeChrome--Plated IN 718Plated IN 718OptimizationOptimization

Deposition RateDeposition Rate

Because of the difficulty with depositing material on Because of the difficulty with depositing material on chrome plated coupons, and with some areas of chrome plated coupons, and with some areas of chrome plate debonding (or having been debonded), chrome plate debonding (or having been debonded), the weight gain measurements, and therefore, the the weight gain measurements, and therefore, the deposition rates were not determined.deposition rates were not determined.


4141

Microhardness in Cr-Plated IN718 Coupons

0

100

200

300

400

5000 10 20 30 40 50 60 70 80

Energy (kJ)

Mic

roha

rdne

ss (K

noop

)




4242

Discontinuities in Cr-Plated IN718 Coupons

0.00

1.00

2.00

3.00

4.00

5.00

6.00

7.000 10 20 30 40 50 60 70 80

Energy (kJ)

Dis

cont

inui

ties

(% A

rea)



4343

Parameters SelectedParameters SelectedChromeChrome--Plated IN 718Plated IN 718


4444

Parameters SelectedParameters SelectedChromeChrome--Plated IN 718Plated IN 718

ESD Parameters ESD Parameters –– Based on Metallographic results: Based on Metallographic results: 300 Hz Pulse Rate300 Hz Pulse Rate30 mF Capacitance30 mF Capacitance150 volts Voltage150 volts Voltage1400 rpm electrode rotation speed1400 rpm electrode rotation speed


4545

FatigueFatigueChromeChrome--Plated IN 718Plated IN 718


4646

Tensile Strength

140.0

145.0

150.0

155.0

160.0


ESD Bead-on-Plate

Ave

rage

Ten

sile

Stre

ngth

(ksi

)

Yield Strength

120.0

125.0

130.0

135.0

140.0


ESD Bead-on-Plate

Ave

rage

Yie

ld S

treng

th (k

si)

TensileTensileChromeChrome--Plated IN 718Plated IN 718

Elongation

0.00

10.00

20.00

30.00

40.00

50.00


ESD Bead-on-Plate

Ave

rage

Elo

ngat

ion

(%)

Reduction in Area

0.0

5.0

10.0

15.0

20.0

25.0

30.0

35.0


ESD Bead-on-Plate

Ave

rage

Red

uctio

n in

Are

a (%

)


4747

TensileTensileChromeChrome--Plated IN 718Plated IN 718

Chrome Plated IN718 - All Conditions

0

50

100

150

200

250

0 1 2 3 4 5 6 7 8 9 10

Strain, ε (%)

Stre

ss, σ

(ksi

)

Baseline with Defect

Baseline

Bead on Plate

ESD


4848




4949




5050

Project CompleteProject Complete

Addendum to Final Report sent to Addendum to Final Report sent to ESTCP on December 12, 2006.ESTCP on December 12, 2006.


5151

From Material PropertiesFrom Material Properties……

#5 Bearing Housing (410 SS)Stator Segment (IN 718)Compressor Rear Shaft (Chrome Plate)

To ComponentsTo Components


5252

Other Projects and ApplicationsOther Projects and Applications

Army Army –– Anniston Anniston –– Abrams TankAbrams Tank

Navy Navy –– Carderock Carderock –– Nuclear SubNuclear Sub

Army Army –– Watervliet/Benet Watervliet/Benet -- RailRail

ElectroSpark DepositionElectroSpark Deposition

Advanced Surfaces And Process, Inc.Advanced Surfaces And Process, Inc.

503.640.4072503.640.4072www.advancedwww.advanced--surfaces.comsurfaces.com

FAA Repair facility # V9PR575YFAA Repair facility # V9PR575Y

P.O. Box 729P.O. Box 729 85 N 2685 N 26thth AveAveForest Grove, OR 97116Forest Grove, OR 97116 Cornelius, OR 97113Cornelius, OR 97113

http://www.advanced-surfaces.com/

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