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MOOG ISS / CSSI /TAG

Repair Technology Development Projects
May 17-18, 2011
Presented by:
Bob Bierk, Gen Mgr, MOOG Integrated Support Solutions
Greg Addison, President, Cold Spray Services International, Inc.
Bill Elmquist, President, Technology Application Group
PROPRIETARY TO MOOG INC. 2011
Worcester Polytechnic Institute
Host: Victor K. Champagne, Army Research Lab
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Repair Project Goals
Technology integration of existing and new technologies
into the repair of aircraft and rotorcraft components
Utilize cross cultural repairs to gain acceptance (FAA to MIL and
vice versa)
Establish vendor base to support small and large projects
Provide quick, cost effective solutions even for the most costly,
awkward or large component designs
Maximize the use of FAA DER approved repairs on commercial
equivalent platform hardware
Develop mindset, tools, systems necessary to support the
customer needs and repair efforts
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Vendor Base Repair Processes
TRADITIONAL
Machining and grinding (MIL-STD-866)
Shot Peening (AMS-S-13165)
Nondestructive testing (ASTM E1417, E1444)
Electroplating (AMS-QQ-C-320, AMS-QQ-N-290)
NEW
Cold Spray on Mg and Al (MIL-STD-3021)
Metal Spray and HVOF (AMS 2477, MIL-STD-1687)
Hybrid Mg and Al Anodizing (AMS 2466)
Inertia Welding of Dissimilar Metals (MIL-STD-1252)
Mg and Al Welding (AWS D17.1, AMS2219)
Integration of techniques
PROPRIETARY TO MOOG INC. 2011 3
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Repair Project Examples
B707 Derivative Components
FD Emergency Housing (Mg), FD Tee Box Housing (Mg)
Same parts used on KC135, E3A, B720
Utilize cold spray and Tagnite to repair defects in functional areas
Certification basis FAA DER approval
B1B Wingsweep GSA Components
PDU Angle Gearbox, Bearing Support Covers
Parts need to have repairs developed or be manufactured new
Use cold spray, welding and Tagnite to repair defects in functional areas
Certification basis Similarity to B52 and KC135 program mandated repairs
using Tagnite and Rockhard processes for corrosion protection
B727, B737, B747, B757, B767, B777, B787, MD80, MD90, DC10, KC10,
L100, C130, A300, A310, A320, A330, A340. Various Components
Certification basis FAA DER approval
PROPRIETARY TO MOOG INC. 2011 4
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Cold Spray/Tagnite Operations
Moog Integrated Support Solutions (ISS)
Webster, MA
Pueblo, CO
Grand Forks, ND
West Fargo, ND, FAA 145 Repair Station
Cold Spray Services International (CSSI)
Webster, MA
Pueblo, CO
Technology Applications Group (TAG)
Grand Forks, ND
PROPRIETARY TO MOOG INC. 2011
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Cold Spray/Tagnite Operations (Cont)
Moog ISS/CSSI/TAG
Product Line Engineering
FAA DER on Staff
FAA DER Major Repairs Sys/Equip, Propulsion Accy, Repair Specs
Delegations for ALL fixed wing and rotorcraft (Parts 23, 25, 27, 29)
Experienced Cold Spray Engineers
All Degreed engineers with at least 4 years cold spray experience
Metallurgical Engineer Ph.D. on Staff
AS9100 and AS9110 Certified
FAA 145 Repair Station Certificate
Cold Spray Equipment - CGT HPCS, Plasma Giken HPCS, Centerline
LPCS
Other 5-Axis CNC, 3-Axis CNCs, Tooling Fixtures, CNC Lathes,
NDT Capability, Full Lab Facilities
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KC135 Flap Drive Emergency Housing (MG)
Typical corrosion present before and after coating removal
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KC135 Flap Drive Tee Box (MG)
Typical corrosion before and after coating removal
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B1B Angle Gearbox Housing (AL)
Typical impact damage, FOD inclusions, seal area damage
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B1B Bearing Support Cover (AL)
Typical dings, surface corrosion
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B1B Bearing Support Cover (AL)
Typical FOD, inclusions, deformation
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Premachined Parts
PROPRIETARY TO MOOG INC. 2011
Premachined Tee Box Housing
Premachined Flap Drive Emergency Housing
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Premachined Parts
PROPRIETARY TO MOOG INC. 2011
Bearing Support Covers
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Cold Spray Applications
PROPRIETARY TO MOOG INC. 2011
Any aluminum, magnesium, steel, titanium components
Engine gearbox housings, generator casings, pilot yoke column parts, covers,
actuator housings, actuator cylinders, pistons, wheels, etc.
Potential: IDG main and cover housings, CSD main and output housings,
ECS exhaust covers, pneumatic valves, etc
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Premachined and Welded Parts
PROPRIETARY TO MOOG INC. 2011
These particular parts are typically very badly damaged due
to left and right hand interchangeability issues.
Incorrect installation results in destroyed gears which send
shrapnel and internal gears spinning into the aluminum
housing.
These units had structural issues so welding was utilized to
restore strength.
Power Drive Unit Angle Gearbox
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Cold Sprayed Parts
PROPRIETARY TO MOOG INC. 2011 16
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More Cold Sprayed Parts
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Flap Drive Tee Box Housing
PROPRIETARY TO MOOG INC. 2011
Defective TBH Machined TBH Cold Sprayed TBH
Finish ground
TBH surfaces
TBH protected by TAGNITE TBH Finished w/Rockhard
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Rotorcraft Frame Repair
Corrosion
on all 3 feet
Corrosion
removed
After
Cold spray
Reworked
to print
Frame
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Additional Finished Parts
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MOOG ISS CONTACTS
PROPRIETARY TO MOOG INC. 2011
Any questions please contact Don Clavell or Walter Mroch
at MOOG ISS for assistance.
Don Clavell (801) 554-5062 or
Walt Mroch FAA DER (310) 357-7423
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Tagnite Process Compatibility with
Ferrous Metal Inserts and Cold Spray Repair
Bill Elmquist, President
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TAGNITE Process
PROPRIETARY TO TECHNOLOGY APPLICATIONS GROUP, INC. 2011
Tagnite is a proprietary process developed by the Technology
Applications Group that complies with AMS 2466B
Tagnite Has Been Protecting New Magnesium
Aerospace and Defense Parts since 1994
Recently, Tagnite has been selected to protect difficult to
replace magnesiumparts during their repair process.
This allows repair depots to avoid using environmentally
harmful hexavalent chromium based conversion coatings
which have been the standard for magnesium castings for
decades.
Tagnite is now approved and actively coating 27 Unique
Aerospace Magnesium Part Numbers as Part of Their Repair
Cycle
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Superior Corrosion Resistance
TAGNITE HAE
DOW 17
Magnesium alloy ZE41 after 168 hours of salt spray fog test
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Three Most Commonly Used Anodic Coatings for Magnesium Alloys
These Coatings Are Not Used at Repair Depots Due to Incompatibility
with Ferrous Metal Inserts
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USMC EFV
AH-64 Apache
MD 500/600
CH-53
F-35 Fighter
F-22 Fighter
AH-6
Wi del y Spec i f i ed
B-52 Bomber KC-135 Tanker
Pratt & Whitney Canada 308 Engine Pratt & Whitney Canada PT6 Engine
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Sample TAGNITE Parts
SIMPLE
COMPLEX
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Tagnite Has Been Applied to Hundreds of Vintage B-52 Magnesium Components
MOOGs West Fargo, ND Division, as Part of an Overhaul Program with Tinker Air
Force Base, Ships Magnesium Castings to TAG for TAGNITE Coatings. Average
Casting Age is Estimated at 48 Years old
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PROPRIETARY TO TECHNOLOGY APPLICATIONS GROUP, INC. 2011
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MOOG Overhaul and Repair
Program Magnesium Treated
with Tagnite
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Tagnite is regularly applied to
repaired magnesium castings
on the B-52
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48 Year Old+ Magnesium
Castings
Better Protected in 2011 Than
When They Were Factory New
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Tagnite Has Been Applied to Hundreds of Vintage KC-135 Magnesium
Components
Average Casting Age is Estimated at 48 Years old
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Magnesium Flap Drive Gearbox Housings
Old Coatings Removed
Ferrous Metal Masked As Required
Tagnite Anodize Applied
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Do These Look Like 49 year Old Magnesium
castings?
KC-135 Magnesium Flap Drive Components Racked
in Preparation for Tagnite Anodize (above),
and then Tagnite anodized (right ).
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45 Year Old+ Magnesium
Castings
Re-Coated with Tagnite
and Paint and Ready to
Return to Service
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Successfully Tagnite Coated After Masking:
6 Steel Bearing Liners
42 Helicoils
52 Studs
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During overhaul, expensive
magnesium castings are
commonly coated with
inexpensive, poor performing
chromate conversion coatings.
These coatings, which offer very
little corrosion resistance, are
employed because they are
compatible with the multiple
ferrous metal inserts found in
most magnesium castings.
The ability to isolate the ferrous
material opens the doors to highly
corrosion resistant anodize
coatings such as Tagnite. This
would allow castings to leave
overhaul with equal or better than
OEM protection.
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3 of the 6
Bearing Liners
had Core
Passageways
Going Through
Them Which
Would Allow
Electrolyte to
Penetrate to
The Steel Liner.
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Complex Ferrous Metal Masking Prior to Tagnite Anodize is Possible
PROPRIETARY TO TECHNOLOGY APPLICATIONS GROUP, INC. 2011
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Complex Ferrous Metal Masking
Prior to Tagnite Anodize is
Possible
PROPRIETARY TO TECHNOLOGY APPLICATIONS GROUP, INC. 2011
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Approved by Many Aerospace and
Defense Companies, Brush Tagnite is
an Effective Method to Touch-up
Magnesium Castings Without Using
Hexavalent Chromium
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Tagnite Compatibility with Cold Spray
PROPRIETARY TO TECHNOLOGY APPLICATIONS GROUP, INC. 2011
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Casting Repaired Using Cold Spray &
Then Tagnite Coated
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Tagnite Compatibility with Cold Spray
Water Immersion Testing
A limited amount of
water immersion testing
per ASTM D870-02 have
been conducted using
Rockhard 576-450-002
Over Tagnite. Tagnite
was applied over CP-AL
cold spray and an AL
Matrix cold spray. Panels
were exposed for 96
hours then grid pattern
was scratched on to the
surface, followed by tape
pulling on the grid. Both
the CP-AL and the Al
Matrix had had perfect
adhesion.
CP-Al Al Matrix
Test plate alloy ZE41A
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Tagnite Compatibility with Cold Spray
Salt Fog Corrosion
Testing
A limited amount of
scribed salt fog corrosion
testing has been
conducted using
Rockhard 576-450-002
Over Tagnite. Tagnite
was applied over CP-AL
cold spray and an AL
Matrix cold spray. Panels
were scribed to base
metal and exposed for
500 hours. Both the CP-
AL and the Al Matrix had
had perfect adhesion.
Tagnite Thickness 0.33 mil Cold Spray Thickness 1 mm
Above the Line: Tagnite Over ZE41A
Below the Line: Tagnite Over Cold Spray
500 Hours Salt
Fog Exposure
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TAGNITE
168 Hours
Dow 7
12 Hours
Dow 19
9 Hours
Why Repair A Part With Cold Spray and Then Apply an
Ineffective Chromate Conversion Coating?
Tagnite Vs. Common Repair Depot Paint Base Coatings for Magnesium
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View of 1 of Many Magnesium
Helicopter Housing for Which
TAG is Presently Developing
Ferrous Metal Isolation Tools to
Allow The Tagnite Coating to
Applied
Repair The Part with Cold Spray
Make It Last Longer & Decrease
Lifecycle Cost with Tagnite
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Cold Spray Solutions International (CSSi)
Webster, MA
Pueblo, CO
Greg Addison, President
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What is CSSi?
WHAT IS CSSi?
A combination of experienced solution providers with an advanced understanding of
commercial production technologies, new manufacturing techniques, defense industry
concerns and the ability to convert new manufacturing capabilities into sustainable
production processes.
A partnership between two groups offering decades of experience providing
manufacturing solutions to industries (aerospace, defense, automotive, communications,
etc) comprising the heart of American manufacturing.
HOW DO WE DO IT?
CSSi and our partner, Moog ISS, leverage specific core competencies to better address
customer needs.
FAA Certified Repair Specialists
Emerging Technologies (e.g. Cold Spray & Tagnite)
By combining R&D Capability with Production Manufacturing Expertise (Commercial
and Defense)
In-depth understanding of aerospace
22 Town Forest Drive, Webster MA 01570 Phone: (816) 519.9690 Fax:
www.cssillc.com
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CSSi Cold Spray Example
Successful replacement of coating technology with copper
cold spray solution for automotive engine
22 Town Forest Drive, Webster MA 01570 Phone: (816) 519.9690 Fax:
www.cssillc.com
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CSSI Cold Spray Example (Cont)
Advantages of the Copper Cold Spray Alternative:
Excellent binding between substrate and coating
Very good thermal shock resistance
Excellent corrosion resistance
Uniform heat distribution
Optimal induction characteristics / energy
efficiency
No sand blasting before coating necessary
22 Town Forest Drive, Webster MA 01570 Phone: (816) 519.9690 Fax:
www.cssillc.com
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CSSi/MOOG ISS
Webster, MA Facility
22 Town Forest Drive, Webster MA 01570 Phone: (816) 519.9690 Fax:
www.cssillc.com
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CSSi/MOOG ISS
Webster, MA Facility (Cont)
22 Town Forest Drive, Webster MA 01570 Phone: (816) 519.9690 Fax:
www.cssillc.com
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CSSi Contacts
Greg Addison
President CSSi
(816) 519-9690
gaddison@cssillc.com
gaddison@ti-kc.com
Larry Kuberski
Vice President CSSi
(314) 731-9363
lkuberski@cssillc.com
lkuberski@gimsllc.com
22 Town Forest Drive, Webster MA 01570 Phone: (816) 519.9690 Fax:
www.cssillc.com