Rickey McNalley - Cold Spray Action Team

Report
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Status of Cold Spray Repair
Efforts for Magnesium
Transmission Components
Approved for public release; distribution unlimited. 10JUN2014, Doc ID 305 Control
Number 0849
Presented by:
Names: Ricky McNalley.
Date: 6/3/2014
Materials Engineer, Materials Branch,
Aviation Engineering Directorate,
U.S. Army Aviation and Missile Research, Development, and Engineering Center
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Cold Spray Efforts - Introduction
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•
The Materials Branch of the Aviation Engineering Directorate (AEF-M)
has notionally approved the use of cold spray repairs as developed by
the Army Research Laboratory (ARL) for the repair of magnesium
housings and gearboxes used in our aviation platforms. These repairs
can address a significant portion of the $3.5M in magnesium housings
currently considered BER in the Storage, Analysis, Failure evaluation,
and Reclamation (SAFR) inventory at CCAD.
•
Groups involved in repair process approval and implementation.
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UH-60 Sump Repair Status
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AH-64 Intermediate Gear Support Repair Status
•
The Path to Structural Repairs – UH-60 Lower Housing
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Summary
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PEO Aviation
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AMRDEC Public Release: FN3832
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Aviation Engineering Directorate
(AED)
Director
Program Support Assistant
Program Executive Officer
)
Associate Director of
Programs
Deputy Director
Technical Director
)
Associate Director of
Technology
Acquisition Business Mgr (AE-Z)
)
Rapid Response Initiative Manager
Aeromechanics (AE-A)
Sustainment Engineering(AE-K)
Standardization Manager
Structures and Materials(AE-F)
Maintenance Engineering(AE-M)
Test & Integration Manager
Aviation Systems (AE-B)
Cargo (AE-C)
Propulsion (AE-P)
Mission Equipment (AE-S)
Apache (AE-D)
Aviation Chief (SED)
Non Standard Rotary Wing (AE-N)
Armed Scout (AE-R)
562 Army Civilians
Special Ops (AE-T)
Utility (AE-U)
UAS (AE-V)
4
~
350 FTE Support Contractors
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Aviation Engineering Directorate in Cold Spray
Approval - Roles and Definitions
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PMO- Each aircraft has its own Program Management Office; for sump
repairs the cognizant organization is the Utility Helicopter Program
Office, UH-PO; for the intermediate gear support the Apache Program
Office has cognizance. As the “owners” of the aircraft platforms, these
offices establish priorities for implementation of new repairs such as
cold spray.
•
Systems Engineering: this group acts as a liaison between the PM’s
and AED platform and functional groups. Systems Engineers organize
task assignments and consolidate the input of platform and functional
groups into a single AED position memo.
•
DMWR – Depot Maintenance Work Requirements: A document that
provides step by step instructions for depot level maintenance efforts.
•
MEO – Maintenance Engineering Order: Written by AEM, once
approved it revises the DMWR.
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Aviation Engineering Directorate in Cold
Spray Approval - Roles and Definitions
(continued)
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AEF Materials: has cognizance for all new materials and processes
and evaluates them in terms of airworthiness and sustainability.
•
AEP Propulsion: has structural cognizance for transmission
components; in this case, magnesium housings.
•
MED Maintenance Engineering Division: Identifies repair opportunities
in the SAFR inventory and submits MEO’s for approval to revise
DMWR’s when new processes are approved.
•
CCAD: The Corpus Christi Army Depot is responsible for executing
approved repairs either in house or via approved contractors. They
also work closely with units and PMO’s to determine emerging needs.
•
Summary: the efforts of seven separate organizations (including ARL)
must be coordinated just for the approval of a specific cold spray
repair. The logistics for returning a repaired part to active inventory
involves many other organizations.
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UH-60 Main Transmission Sump
Repair P/N 70351-48140-042
The O’Ring groove
on the large diameter
is the focal point of
the sump repair
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UH-60 Main Transmission Sump Repair
P/N 70351-48140-042
•
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The First Article Test Report for the Cold Spray Repair of UH-60
Sumps has been approved by the AED Utility Division and two parts
have been forwarded to MED / CCAD for fit and bench testing.
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AH-64 Intermediate Gear Support P/N 7311310015-5.
The arrow shows the contact surface
with witness marks left by the gear
teeth. This area is also susceptible to
pitting corrosion and fretting damage
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Apache Intermediate Gear Support P/N
7-311310015-5.
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AEF and AEP have approved this cold spray repair of the top land with
defects up to .050” in depth.
•
Current Status: ARL has completed the cold spray repair of two gear
supports from the SAFR inventory and the first article test (FAT)
inspection has been completed by ARL and CCAD. Review and
approval by AEF and AEP will be conducted via the tasking system.
•
An MEO will follow review and approval of the FAT test report.
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UH-60 PN 70351-38134-42
Main Gearbox Lower Housing Assy
Candidate for First Structural Cold Spray Repair
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PN 70351-38134-42
Main Gearbox Lower Housing Assy
Typical Packing Groove Corrosion
No Current Repair
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PN 70351-38134-42
Main Gearbox Lower Housing Assy
Liner Bore Seat Damage
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.
Main Gearbox Lower Housing Assembly
PN 70351-38134-42
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•
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Current Status: A test article has been identified from the SAFR
inventory and is being forwarded to ARL/MOOG for review and
proposed repair parameters.
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Cold Spray Efforts - Summary
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The efforts to approve and implement cold spray repairs for Army Aviation
assets are progressing with two non structural repairs approved by AEF &
AEP.
•
ARL has completed the cold spray repair of two AH-64 intermediate gear
supports. First Article Testing by ARL and CCAD is complete. AED will review
these results vis the tasking system.
•
The First Article Test Report for the Cold Spray Repair of UH-60 Sumps has
been approved by the AED Utility Division and awaits fit and bench testing.
•
Successful implementation of the two currently approved non structural repairs
will build momentum for the approval of other more complex applications with
structural aspects such as the UH-60 lower housing.
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