COMMERCIAL ENGINE STANDARD PRACTICES MANUAL GEK9250 - Rev 109, 04/01/2020

TESTING AND QUALITY ANALYSIS

COMMERCIAL ENGINE STANDARD PRACTICES MANUAL Dated: 11/05/2018

SPM 70-70-00 TESTING AND QUALITY ANALYSIS
TASK 70-70-00-700-001
1. General.
This procedure consists of a series of operations. Test specimens and special tools or fixtures
required in the performance of specific tasks are described in the procedures that make use of
them.
2. Thermal Spray Coating Quality Tests.
Subtask 70-70-00-700-011
A. Types of Tests.
All thermal spray deposits shall be visually checked for complete coverage, uniform structure,
freedom from cracks, voids, spalling, chipping, flaking, or other indications of poor adhesion.
The quality of the thermal spray deposit shall be tested, as shown in Table 1, by the following
methods:
(1) Wire brush test.
The technical requirement for this test has been deleted. It no longer needs to be
performed even when specified in the Engine/Shop Manual.
(2) Bend test. Refer to TASK 70-71-08-700-014, Bend Test.
The technical requirement for this test has been deleted. It no longer needs to be
performed even when specified in the Engine/Shop Manual.
(3) Tensile bond test. Refer to TASK 70-71-01-700-002, Bond Strength Tensile Testing of Thermal
Spray Coatings.
The tensile bond test is performed using pull test buttons or adapters in a tensile testing
machine to check adherence of the thermal spray coating. A minimum of three tests shall be
performed for each part. The material used for test specimens/adapters shall be either same
as parts they represent or as stated in Table 2 below.
(4) Lap shear bond test. Refer to TASK 70-71-02-700-003, Bond Strength Lap-Shear Testing of
Thermal Spray Coatings.
The lap shear bond test is performed using a three-piece set of test panels in a tensile
testing machine to check the adherence of the thermal spray coating. The material used for
test specimens shall be either same as parts they represent or as stated in Table 2 below.
Two pieces of each three-piece set are sprayed for a length of 0.50 inch (12.7 mm) along
with the production part, and a minimum of three sets must be sprayed in conjunction with
each part.
(5) Scratch hardness test. Refer to TASK 70-71-03-700-004, Scratch-Hardness Testing of Thermal
Spray Coatings.
The scratch hardness test is performed using a test panel sprayed in conjunction with the
production part.
(6) Metallographic examination. Refer to TASK 70-71-04-700-005, Metallographic Evaluation of
Thermal Spray Coatings.
A test panel or scrap part, sprayed in conjunction with the production part, is sectioned,
polished, and examined microscopically.
(7) Rockwell hardness test.
This test is usually performed on a small coupon sprayed with the part and sometimes on the
same coupon used for metallography. The hardness of the coating is determined in accordance
with TASK 70-34-03-220-009, Rockwell Hardness Testing.
(8) Vickers (microhardness) test.
This test is performed on a mounted cross-section and the same sample prepared for the
metallographic evaluation can be used. The hardness of the coating is determined in
accordance with TASK 70-34-02-220-008, Vickers Hardness Testing.
B. Frequency of Testing.
(1) After the initial coating qualification, part quality testing should begin with evaluation
of all test coupons (at 100% frequency) as required by:
(a) The specific Engine/Shop Manual Repair,
(b) The specific thermal spray procedure [for example, TASK 70-49-10-340-011, Thermal
Spraying Nickel-Aluminum (Powder)],
(c) The general thermal spray requirements in TASK 70-49-00-340-001, Thermal Spraying,
(d) The specific testing procedures (for example, TASK 70-71-04-700-005, Metallographic
Evaluation of Thermal Spray Coatings), and
(e) The general testing requirements in TASK 70-70-00-700-001, Testing and Quality
Analysis.
(2) As spraying continues, passing data should be gathered and analyzed by an acceptable
statistical process control (SPC) system. The frequency of testing may then be reduced (or
the time intervals between quality control testing increased) based on the statistical
analysis if consistent results are obtained. The frequency intervals should all be based on
requirements documented in the repair shop's internal Quality Assurance System.
3. Metal-To-Metal, Film Adhesive Bonding Quality Tests.
Subtask 70-70-00-700-012
NOTE: Test procedure adhesive evaluations can now be found in TASK 70-70-01-700-001, Testing and
Quality Analysis of Metal-to-Metal Bonding.
Test Requirements for Thermal Spray Coating - Table 1

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COMMERCIAL ENGINE STANDARD PRACTICES MANUAL GEK9250 - Rev 109, 04/01/2020
TESTING AND QUALITY ANALYSIS

Coatings Coating Procedure Tensile Bond per Metallo-graphic Hard-ness

70-71-01 psi (MPa) Exam per
70-71-04
Aluminum, Pure 70-49-01 (powder) 1200 (8.3) X
(also see 70-49-23 and
70-49-40)
Alumina 70-49-02 (powder) 1000 (6.9) X
Chromium Carbide 70-49-03 (powder) 3000 (20.7) X Note 1
Copper-Nickel 70-49-04 (powder) 2900 (20.0) X
Copper-Nickel-Indium 70-49-05 (powder) 2000 (13.8) X
(also see 70-49-49)
Magnesium 70-49-06 (powder) X
Molybdenum 70-49-07 (powder) 2500 (17.2) X
(also see 70-49-08 and
70-49-51)
Molybdenum 70-49-08 (wire) 2500 (17.2) X
(also see 70-49-07 and
70-49-51)
Nickel-Aluminide 70-49-09 (powder) 2500 (17.2) X
Nickel-Aluminum 70-49-10 (powder) 4000/5000 X
(also see 70-49-11 and (27.6/34.5)
70-49-38)
Nickel-Aluminum 70-49-11 (wire) 4000/5000 X
(also see 70-49-10 and (27.6/34.5)
70-49-38)
Nickel-Chromium 70-49-12 (powder) X
Nickel-Chromium 70-49-13 (wire) X
Nickel-Graphite (75:25) 70-49-14 (powder) 750 (5.2) X Note 2
Nickel-Graphite (85:15) 70-49-15 (powder) 1200-3000 X Note 3
(8.3-20.7)
Nickel-Silicon-Boron 70-49-16 (powder) 5500 (37.9) X
Silver Alloy (Cu-Zn-Ag) 70-49-17 (wire) 3000 (20.7) X
(also see 70-49-44)
50% Tungsten Carbide 70-49-18 (powder) 5500 (37.9) X Note 1
Tungsten Carbide-Cobalt 70-49-19 (powder) 5500 (37.9) X Note 1
(also see 70-49-28)
Chromium Carbide No. 1 70-49-20 (powder) X
Composite
Nickel-Chromium/Aluminum 70-49-21 (powder) 4000-5000 X
Composite (also see 70-49-39) (27.6-34.5)
Alumina/Nickel-Aluminum 70-49-22 (powder) 2000 (13.8) X
(55:45)
Aluminum, Pure 70-49-23 (wire) 1200 (8.3) X
(also see 70-49-01 and
70-49-40)
75% Tungsten Carbide 70-49-24 (powder) X Note 1
Aluminum-Bronze 70-49-25 (powder) 2000 (13.8) X
(also see 70-49-26 and
70-49-52)
Aluminum-Bronze 70-49-26 (wire) 2000 (13.8) X
(also see 70-49-25 and
70-49-52)
Tribaloy 400 (CoMoCrSi) 70-49-27 (powder) 3100 (21.4) X Note 4
Tungsten Carbide-Cobalt 70-49-28 (powder) 5500 (37.9) X Note 1
(also see 70-49-19)
Chromium Carbide-Nickel 70-49-29A (powder) 5000 (34.5) X Note 1
Chromium
70-49-29B (powder) 5000 (34.5) X Note 5
Tribaloy 800 (CoMoCrSi) 70-49-30 4000 (27.6) X Note 6
(powder)
Nickel Aluminum-Molybdenum 70-49-31 (powder) 2500 (17.2) X
Composite
Inconel 718 70-49-32 (powder) 7000 (48.3) X

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COMMERCIAL ENGINE STANDARD PRACTICES MANUAL GEK9250 - Rev 109, 04/01/2020
TESTING AND QUALITY ANALYSIS

(also see 70-49-45)

Alumina, fine 70-49-33 (powder) 4000 (27.6) X
Aluminum-Silicon-Polyester 70-49-34 (powder) 800 (5.5) X Note 7
NiCrAlY 70-49-35 (powder) 4000 (27.6) X
TBC 70-49-35 (powder) X
Inconel 718 (HVOF) 70-49-36 (powder) 9000 (62.1) X Note 13
Tungsten Carbide-Cobalt 70-49-37 (powder) 10,000 (68.9) X Note 8
(HVOF)
Nickel Aluminum, Electric 70-49-38 (wire) 4000/5000 X
Arc (also see 70-49-10 and (27.6/34.5)
70-49-11)
Nickel Chrome Aluminum, 70-49-39 (wire) 4000/(27.6/34.5) X
Electric Arc (also see 70-49-21)
Pure Aluminum, Electric 70-49-40 (wire) 1200 (8.3) X
Arc (also see 70-49-01 and
70-49-23)
Tribaloy 800 (CoMoCrSi 70-49-43 (powder) 8500 (58.6) X Note 9
Powder) HVOF
Copper Zinc Silver, 70-49-44 (wire) 3000 (20.7) X
Electric Arc (also see 70-49-17)
Inco 718 Wire, Electric 70-49-45 (wire) 7000 (48.3) X
Arc (also see 70-49-32)
Nickel Chrome Silicon 70-49-46 (powder) 10,000 (68.9) X Note 10
Iron, HVOF
Aluminum Silicon Poly 70-49-47 (powder) 800 (5.5) X Note 14
(Cold Process)
Tribaloy 800 (CoMoCrSi 70-49-48 (powder) 8500 (58.6) X Note 11
Powder) HVOF
Cu-Ni-In Electric Arc 70-49-49 (wire) 2000 (13.8) X
(also see 70-49-05)
Ren. 80 (HVOF) 70-49-50 (powder) 9000 (62.1) X Note 12
Molybdenum Electric Arc 70-49-51 (wire) 2500 (17.2) X
(also see 70-49-07 and
70-49-08)
Al-Bronze Electric Arc 70-49-52 (wire) 2000 (13.8) X
(also see 70-49-25 and
70-49-26)
Alumina/Ni-Al (powder) 70-49-53 None X
1. Rockwell hardness test with Rockwell 15-N superficial hardness of 83 (ASTM E18)
NOTE: 2. Rockwell hardness test with Rockwell 15-Y hardness of 30-50 (ASME E18)
NOTE: 3. Rockwell hardness test with Rockwell 15-Y hardness of 50-70 (ASME E18)
NOTE: 4. Rockwell hardness test with Rockwell 15-N superficial hardness of 80 (ASTM E18)
NOTE: 5. Rockwell hardness test with Rockwell 15-N superficial hardness of 75 (ASTM E18)
NOTE: 6. Rockwell hardness test with Rockwell 15-N superficial hardness of 82 (ASTM 18)
NOTE: 7. Rockwell hardness test with Rockwell 15-Y hardness of 65-80 (ASTM E18)
NOTE: 8. Rockwell hardness test with Rockwell 15-N superficial hardness of 89 (ASTM E18) and a Vickers
300 gram load of 950-1200 (ASTM E384)
NOTE: 9. Rockwell hardness test with Rockwell 15-N superficial hardness of 89 (ASTM E18) and a Vickers
300 gram load hardness of 675 (ASTM E384)
NOTE: 10. Rockwell hardness test with Rockwell 15-N superficial hardness of 70 (ASTM E18) and a Vickers
300 gram load hardness of 675 (ASTM E384)
NOTE: 11. Rockwell hardness test with Rockwell 15-N superficial hardness of 83 (ASTM E18) and a Vickers
300 gram load hardness of 500 (ASTM E384)
NOTE: 12. Rockwell hardness test with Rockwell 15-N superficial hardness of 75 (ASTM E18) and a Vickers
300 gram load hardness of 400 (ASTM E384)
NOTE: 13. Rockwell hardness test with Rockwell 15-N superficial hardness of 79 (ASTM E18)
NOTE: 14. Rockwell hardness test with Rockwell 15-Y hardness of 55-80 (ASTM E18)
Test Specimen Material - Table 2
Part Material Test Specimen Material Specification Reference

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COMMERCIAL ENGINE STANDARD PRACTICES MANUAL GEK9250 - Rev 109, 04/01/2020
TESTING AND QUALITY ANALYSIS

Iron-base Alloys 410SS, 321 AMS 5504, AMS5613, AMS5510,

AMS5645
Nickel-base and Cobalt-base Alloys IN718, Hastelloy X AMS5596, AMS5663, AMS5536,
AMS5754
Titanium-base Alloys Ti-6Al-4V AMS4911, AMS4928
Aluminum-base Alloys 6061-T6 Al AMS4027, AMS4117, AMS4127,
AMS4150, AMS4312

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