CSAT 2019 - Chinook Young - Ken PDF

Engineering, Test & Technology
Boeing Research & Boeing Research

Technology | Chinook&Cold
Technology
Spray Repair
Development
Chinook Cold Spray Repair

Development
Presented at Cold Spray Action Team (CSAT)
2019 Workshop
WPI, Worcester, MA
June 25, 2019
Ken Young
The Boeing Company
Boeing Research & Technology
This research was partially funded by the Government under Agreement No. W911NF-15-2-0034. The U.S. Government is authorized to reproduce
and distribute reprints for Government purposes notwithstanding any copyright notation thereon.
The views and conclusions contained in this document are those of the authors and should not be interpreted as representing the official policies,
either expressed or implied, of the Aviation Applied Technology Directorate or the U.S. Government.
Distribution Statement A: Approved for Public Release. Distribution is Unlimited.
Acknowledgements
Boeing Research & Technology | Chinook Cold Spray Repair
Development
• OSD ManTech Phase 3 Funding, W911NF-15-2-0034

 HF Webster (Rob Hrabe)
 Army Research Laboratory (Vic Champagne)
• Boeing-CCAD Partnership Funding

 AMRDEC (AEM, AED)
 Boeing Liaisons (Greg Lincoln)
• ARL Aberdeen Cold Spray Lab (Gehn Ferguson, Aaron Nardi)
• Boeing
 Philadelphia BR&T Metals Lab (Abe Calvin, Bryce Bowman, Charles Griffith)
 Philadelphia Design & Stress (Jim Choi, Don Johnson, Steve Carbaugh)
 Huntsville BR&T (Bruno Zamorano)
Copyright © 2019 Boeing. All rights reserved. 2

Overview
Development
• CH-47 Chinook Part Candidates

 Boeing approach
 Primary focus on structural repairs
 SAFR inventory
• Boeing Repair Classifications & Criteria

 Repair types and limits
 Structural criticality ratings
• Repair Development
 Coupon testing to down-select process and mitigate risks
 Part specific applications – representative coupons and part repair demos
• Path to Qualification
 Part requirements, stress analysis, component testing, customer approval
 Repair implementation/documentation
Boeing Cold Spray Repair Approach
Development
MAI Baseline
• Material and Process Development Repair Test
• Specific powder and process (MAI) Coupons
• Multiple approach to optimize for specific repairs (OSD)
• Part Repairs Deposit Depth,

• Target for aluminum structural/non-critical (MAI) Blend Ratio, etc.
• Part specific – Chinook rotor system component (OSD) Broad Applications Approach
vs. Specific Part Repair Need
• Repair and Test Configurations
OSD ManTech Example
• Common test repair geometries (MAI)
• Representative configurations / repair type (OSD)
• Qualification Requirements
• Allowables vs. point qualification
• Extensive applications vs. target part or family of parts
• Repair Implementation
• Specifications and repair documents
Chinook CS Repair Part Candidates
Development
Part Name Part Type Damage Type Substrate Material

Al 2014-T652
Rotating Ring Swashplate Rotor System Corrosion/Other
Al 7050-T7452
Forward Stationary Ring Rotor System Corrosion/Other Al 2014-T6
Forward Slider Shaft Rotor System Al 2014-T6
Aft Slider Shaft Rotor System Al 2014-T6
Pitch Varying Housing Rotor System Corrosion/Wear Al 7075-T73
Swashplate Drive Collar Rotor System Steel 4340
Integrated Lower Control Actuator, Lower Boost Manifold Hydraulic Corrosion Al 7075-T73
Lag Damper Housing Hydraulic Corrosion Al 7075-T73
Combiner Transmission Sump Cover Transmission Corrosion Mg ZE41A-T5

Main Transmission Housing, Aft Transmission Transmission Corrosion Mg ZE41A-T5
Aft Transmission Housing, Accessory Transmission Corrosion Mg ZE41A-T5
Combiner Transmission Housing Assembly Transmission Corrosion Mg ZE41A-T5
Main Housing, Combiner Transmission Transmission Corrosion Mg ZE41A-T5
Impeller Fan, Cooling Fan Drive System Mg EZ33A-T5
Aft Rotor Shaft Upper Extension Drive System Steel 9310
Canted Longeron Assembly Airframe Cracking Al 7050-T7451

Sta 160 Crown Frame Airframe Cracking/Corrosion Al 7050-T7451
OSD ManTech and Boeing Global Services funded

through Boeing-CCAD Partnership

SAFR Chinook Rotating Ring Inventory
Development
GOVERN
AIRCRAFT MENT
NOMEN AIRCRAFT TYPE SYSTEM TYPE D_REC SERIAL NUMBER QTY C CODE TSN MOAT DISCREPANCY CODE DISCREPANCY LOC
Parts
RING, ASSY ROTATING
FWD CH-47, MH-47 ROTOR SYSTEM Army 12/16/2011 W14178956 1 F 3083 UNLIMITED PITTED
RING, ASSY ROTATING
FWD
RING, ASSY ROTATING
CH-47, MH-47 ROTOR SYSTEM ARMY 12/17/2013 C00236 1 F 395 UNLIMITED CRACKED NDT
Under
Evaluation
FWD CH-47, MH-47 ROTOR SYSTEM Army 5/8/2014 BCW1866 1 F 2415 UNLIMITED CORRODED
RING, ASSY ROTATING
FWD CH-47, MH-47 ROTOR SYSTEM Army 3/3/2014 GA-0587 1 F 1501 UNLIMITED PITTED BEYOND LIMITS
RING, ASSY ROTATING
FWD CH-47, MH-47 ROTOR SYSTEM Army 8/15/2012 C00640 1 F 0 UNLIMITED OUT OF LIMITS
RING, ASSY ROTATING
FWD CH-47, MH-47 ROTOR SYSTEM Army 8/31/2012 GA0688 1 F 0 UNLIMITED OUT OF LIMITS MEC T147654
RING, ASSY ROTATING
FWD CH-47, MH-47 ROTOR SYSTEM ARMY 8/31/2012 GA0678 1 F 0 UNLIMITED OUT OF LIMITS MEC T147650
RING, ASSY ROTATING
RING, ASSY ROTATING
RING, ASSY ROTATING
RING, ASSY ROTATING
BEYOND SPECIFIED TOLERANCES
RING, ASSY ROTATING PERP=.00790 PARA=.00589
FWD CH-47, MH-47 ROTOR SYSTEM ARMY 10/2/2012 C00544 1 F 1245 UNLIMITED FLATNESS=.00560 MEC D153668 POC KELLY JACKSON
RING, ASSY ROTATING
FWD CH-47, MH-47 ROTOR SYSTEM Army 5/24/2012 C00343 1 F 919 UNLIMITED OUT OF LIMITS MEC T146143 A
RING, ASSY ROTATING
FWD CH-47, MH-47 ROTOR SYSTEM ARMY 5/25/2012 tz0992 1 F 731 UNLIMITED OUT OF LIMITS MEC T146260
PARALLELISM @ .00557" AND
RING, ASSY ROTATING BEYOND SPECIFIED TOLERANCE FLATNESS @ .00535" HOLD AS REPAIR
FWD CH-47, MH-47 ROTOR SYSTEM ARMY 6/3/2013 BCW1506 1 F 3145 UNLIMITED PENDING MEC D162940 CANDIDATE PENDI
RING, ASSY ROTATING BEYOND SPECIFIED TOLERANCE PARALLELISM @ .00511"PENDING
FWD CH-47, MH-47 ROTOR SYSTEM ARMY 6/3/2013 C00688 1 F 543 UNLIMITED PENDING MEC D162951 REPAIR CANDIDATE
RING, ASSY ROTATING REF MEC D162933 PARALLELISM=
FWD CH-47, MH-47 ROTOR SYSTEM ARMY 4/1/2013 TZ1010 1 F 1180 UNLIMITED BEYOND SPECIFIED TOLERANCE .00641 AND FLATNESS= .00554
RING, ASSY ROTATING ALL DIAMETER READINGS ARE BELOW
FWD CH-47, MH-47 ROTOR SYSTEM ARMY 4/1/2013 C00106 1 F 695 UNLIMITED BEYOND SPECIFIED TOLERANCE MINIMUM REF MEC D162946
RING, ASSY ROTATING ALL DIAMETER READINGS ARE BELOW
FWD CH-47, MH-47 ROTOR SYSTEM ARMY 4/1/2013 C00737 1 F 1053 UNLIMITED BEYOND SPECIFIED TOLERANCE MINIMUM REF MEC D161750
REF MEC D161336 PARALLELISM=
Business/logistics considerations in additional to technical requirements:

RING, ASSY ROTATING .00636 AND FLATNESS= .00578 PERP =
FWD CH-47, MH-47 ROTOR SYSTEM ARMY 4/1/2013 BCW1297 1 F 2913 UNLIMITED BEYOND SPECIFIED TOLERANCE .00645
REF MEC D161346 ALL DIAMETER
 Part replacement cost and lead time

RING, ASSY ROTATING READINGS BELOW MINIMUM
FWD CH-47, MH-47 ROTOR SYSTEM ARMY 4/1/2013 GA0713 1 F 1193 UNLIMITED BEYOND SPECIFIED TOLERANCE TOLERANCE
ALL DIAMETER READINGS BELOW
RING, ASSY ROTATING
FWD CH-47, MH-47  Repair limitations, life and non-recurring investment
ROTOR SYSTEM ARMY 4/1/2013 GA0540 1 F 0 UNLIMITED BEYOND SPECIFIED TOLERANCE
MINIMUM REF MEC D161360
PARALLELLISM= .00509
 Mission/aircraft availability metrics

Repair Types and Limits
Development
Type & Description Summary Risk and Requirements

Least amount of testing for non-structural
Discrete repairs or multiple applications. Depth and proximity to part
Type I Blend and Fill
defects at single repair site features drive structural impact where
applicable.
Multiple defects and/or Generally increased removal of parent

Type II Machine and Rebuild location limitations preclude material. Leverage existing capabilities and
discrete repairs expand testing to cover requirements.
Type III
Type IV
Depth and
Type I example blend ratio
x
Distance from
Type II example Area critical feature
Repair Classifications
Development
Criticality Rating Spectrum A

Classification Description
A Coating restoration:
• Cold Spray does not carry load
Short-Term
• Replace surface finish with cold spray
Ni CS
Repair
B
B Non-structural dimensional restoration:
• Cold Spray does not have to carry load
• Could be structural part in benign location
C Non-critical structural:
Intermediate-
• Cold Spray carries load
• Platform will still operate/fly if repaired
C
Term
part fails
D Semi-critical structural:
• Failure results in damage to aircraft and
mission
E Structural Critical: D-E
Long-
Term
• Failure results in loss of platform
Repair ratings may represent whole part or within a part.

Determinations made by Boeing Design and Stress.
C-D
Copyright © 2019 Boeing. All rights reserved.
8
Rotor System Component Background
Development
Rotor Head Swashplate Assembly

• Repair Candidate #1
 Rotating Ring
 2 per aircraft, Fwd and Aft
 Life unlimited
• Materials
 2014-T652 aluminum forging
 7050-T7452 added to Engineering
• Candidates for Cold Spray Repair Trials:

 Corrosion pitting identified and parts dispositioned into SAFR
 Total of 4 Rotating Rings identified as process development articles and
shipped to Boeing from 2018
 Parts include other discrepancies such as crack indications and dimensional
non-conformances
CH-47 Swashplate Rotating Ring
Development
Lug #1
(0°)
Clevis #2
(LH) Clevis #1
(RH)
Part Shown Upside

Down to show Bearing
Retention Shoulder
Lug #3 Lug #2
(240°) (120°)

Repair Areas of Interest
Development
Damage Assessment / Review Repairs for Complexity & Priority

1) Surface pitting – bottom, top, side surfaces
2) Lug exterior surfaces
2
3) Clevis lug exterior surfaces
4) Lug bores 1
5) Clevis lug bores
6) Retention shoulder 3
Potential “Round 1” 6
Repair Evaluations
5
Potential “Round 2”
Repair Evaluations
Part is Flight Critical and Process Sensitive.

Repair classifications are estimates only for 4
development assessment.
Rotating Lug and Clevis Pitting Damage
Development
Corrosion Pit Max
Corrosion
Pitting
Note: 0.050 inch maximum depth from blended surface
Replication of Corrosion Pit

Approx 0.055
inch depth

Rotating Bearing Retention Shoulder
Development
NDI Crack Indication
Retention Shoulder
Bearing Diameter:
Indications and
Dimensional OOT
FPI/Crack
Retention Shoulder
Repair Development Process
Development
Rotating Ring Parts

• Used for full scale repair process assessment
End Here at Part
Verification/Validation
Pathfinder Specimens
• Repair process trials of part elements
 Lug, Clevis, and Shoulder Intermediate Step,
Process Trials and Lab
Evaluation Feedback
Aluminum Test Coupons

• Part specific application drives coupon configuration
Start Here Based on
Part Configuration,
Iterative/Evolving
Repair Development Process
Development
Rotating Ring Parts Status: NDI of candidate 4

• Used for full scale repair process assessment completed, down-selected
• NDI, document and categorize damage/locations part for full-scale repair trial
• Destructive test and structural bench articles
Pathfinder Specimens Status: Round 1 complete,

• Repair process trials of part elements review & incorporate
 Lug, Clevis, and Shoulder
improvements
• Document before, during and after – blend out, spray and post-process
• Boeing NDI and destructive evaluations to assess repairs
Aluminum Test Coupons Status: 20 trial tensiles

• Part specific application drives coupon configuration completed
• Down-select repair process: powder options, bond preparation, spray conditions
• Establish mechanical property capabilities and fine tune to match part repair
Pathfinder Repair Trials
Development
Lab Evaluations after Cold Spray and Post-Machining

Pre-heat treated 7050
powder on 2014 Al
part specimens

Pathfinder Repair Trials – Lug
Development
Pre-Spray Blended Cold Sprayed Post-Machined Cross-Section

1
2
3
4
Masking
induced porosity
1
Porosity adjacent to
lug bore diameter 2 3 4
Methodology for Strength Calculations
Development
1) Load Carrying Credit:

• Normalized load = adjusted for cross sectional area (% area factor applied)
• Normalized load of CS coupon = CS raw load x Baseline area / CS area
• CS normalized load / Baseline load x 100%
Control
Baseline Full cross section
Minimum cross section
10:1 configuration evaluated, 0.115 deep, 46% repair cross section
2) Strength Delta:
• Knockdown vs. Control = CS strength / control strength x 100%
or
• Credit vs. Baseline = calculated based on baseline knockdown from control
= CS strength / [baseline strength x % area of control]
Tensile Test Trials – Load Capacity
Development
Tensile Repair Geometry

Knockdown from Control
Increase over
Baseline
DIC Results Time Evolution, Trial #12

100% of Control Load
Baseline (Blended/Unfilled)

Tensile Test Trials – Stress & Elongation
Development

Testing – Tensile Trial 3 (7050/7050)
Development
Failure Progression:
• Cold spray deposit fractures first (least strain to fracture)
• Substrate fractures last (most strain  necking)
• Deposit to substrate adhesive strength drives failure mode
Deposit
Substrate
1 2 3 4 5
Post-Test Evaluation (7050/7050)
Development
7050 Deposit
7050 Deposit
7050-T7451
(Repair Side)
Edge Face 1
7050-T7451
Substrate
(Back Side)
Edge Face 2
Tensile Test Fractures Elongations at Fractures
7050 Deposit 3.5% “Repair System”
1% “Deposit”
7050 Substrate 3%
“Substrate”
Copyright © 2019 Boeing. All rights reserved. Trials 1-12: Best = 7%, Avg = 4.5%, Worst = 3% 22
Metallurgical Evaluation
Development
7050 Deposit 70507050

Deposit
Deposit
Pre-Blasted Substrate Pre-Blasted Substrate
(example 1) (example 2) 0.0006 to 0.0012
0.0003
7050-T7451 Substrate
Less than ideal mixing
0.0050 7050-T7451 Substrate 0.0050
7050 Deposit 7050 Deposit

Grit Blasted Substrate 0.0006 Pre-Blast and 0.0019
Mixed Bond Coat
Improve surface preparation  Increase interfacial mixing 

0.0050 Increase bond and overall strength 0.0050
7050 Repair Conclusions To Date
Development
Trial Tensile Results

• Helium sprayed heat treated powder repairs increased load carrying capability
vs. blended/unfilled baselines:
 7050 HT powder  30 to 40% increased load carrying capability
 6061 HT powder  20% increased load carrying capability
• Nitrogen repairs evaluated to date did not increase load carrying capability
• Net strength of repaired coupons 20% lower than 7050 controls (expected)
Opportunities for Improvements

• Surface preparation vital to deposit adhesion to maximize mechanical properties
• Combine shot peening, blasting, and/or mixed bond coat to improve bond
• Match test coupon repair configurations with parts to better demonstrate repair
(e.g. repair type, depth, location relative to part features, etc.)

Part Design & Requirements Approach
Development
Evaluated to Date Risk / Issue Path Forward

Pre-blasted with aluminum Evaluate alternate blasting methods for
Surface Optimize interfacial mixing for
powder/N2, grit blast, and/or increased adhesion. Incorporate shot
Preparation mixed powder bond coat
sufficient deposit adhesion
peening for part requirement.
Deposit powders and substrates
7050 Al substrate (coupons) Evaluate substrate combinations for
Substrate 2014 Al substrate (parts)
must address all part material
equivalence, identify process adjustments
configurations
HT powder may be too soft vs. Evaluate mix of powders to compare

Powder 7050 and 6061 pre-HT powders
substrate for deposit adhesion ductility vs. adhesion
Higher cost with helium, nitrogen Evaluate He/N2 gas mixture if properties
Feed Gas Helium and nitrogen
aligned with non-structural repair support cost reduction
Machined finish, no protective FPI and visual observed machining Assess machinability, incorporate protective
Finishing coatings pull outs finishes in corrosion testing
Incorporate ultrasonic or other methods for

NDI Limited to FPI Need to establish acceptance criteria
defect detection
Repair depth on 0.250" substrate Assess part repairs based on

Tensile based on fixed 0.115
results in large % cross-section. classification/type, adjust test coupon
Testing depth, lug shear, metallurgical,
Tests limited to unixaxial loading of configuration accordingly. Identify and
and preliminary corrosion
Type I repairs. execute required tests and analysis.

Fatigue Testing & Stress Analysis
Development
Loading
Configuration
Dependent
2
Coupon Configuration and 4
Testing Representative of Part
Type I
Damage Repair Component

Type II
Structural
Test

Path to Qualification
Development
• Understand Part Engineering and Repair Requirements

• Dimensional, functional, and structural (new vs. repaired part)
• Revise repair design limits and acceptance criteria where applicable (repaired part)
• Satisfy all Testing Required

• Static and fatigue coupon testing based on approved test plan
• Stress analysis to evaluate against design margins
• Component structural and/or functional testing
• Follow Establish Repair Approval Process

• Boeing IPT buy-in
• Customer approvals
• Repair Implementation
• Material and process specifications
• Update and release repair documents/procedures (DMWRs and MEOs)
Success based on aligning repairs with engineering requirements,

repair acceptance criteria, and IPT/USG approval based on expectations
Development
Questions

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Engineering, Test & Technology

Boeing Research & Boeing Research

Chinook Cold Spray Repair

• OSD ManTech Phase 3 Funding, W911NF-15-2-0034

• Boeing-CCAD Partnership Funding

• ARL Aberdeen Cold Spray Lab (Gehn Ferguson, Aaron Nardi)

Copyright © 2019 Boeing. All rights reserved. 2

• CH-47 Chinook Part Candidates

• Boeing Repair Classifications & Criteria

• Part Repairs Deposit Depth,

Part Name Part Type Damage Type Substrate Material

Lag Damper Housing Hydraulic Corrosion Al 7075-T73

Combiner Transmission Sump Cover Transmission Corrosion Mg ZE41A-T5

Canted Longeron Assembly Airframe Cracking Al 7050-T7451

OSD ManTech and Boeing Global Services funded

Copyright © 2019 Boeing. All rights reserved. 5

Business/logistics considerations in additional to technical requirements:

 Part replacement cost and lead time

 Mission/aircraft availability metrics

Type & Description Summary Risk and Requirements

Multiple defects and/or Generally increased removal of parent

Criticality Rating Spectrum A

E Structural Critical: D-E

Repair ratings may represent whole part or within a part.

Rotor Head Swashplate Assembly

• Candidates for Cold Spray Repair Trials:

Part Shown Upside

Copyright © 2019 Boeing. All rights reserved. 10

Damage Assessment / Review Repairs for Complexity & Priority

Part is Flight Critical and Process Sensitive.

Corrosion Pit Max

Note: 0.050 inch maximum depth from blended surface

Replication of Corrosion Pit

Copyright © 2019 Boeing. All rights reserved. 12

NDI Crack Indication

Rotating Ring Parts

Aluminum Test Coupons

Rotating Ring Parts Status: NDI of candidate 4

Pathfinder Specimens Status: Round 1 complete,

Aluminum Test Coupons Status: 20 trial tensiles

Lab Evaluations after Cold Spray and Post-Machining

Copyright © 2019 Boeing. All rights reserved. 16

Pre-Spray Blended Cold Sprayed Post-Machined Cross-Section

1) Load Carrying Credit:

Tensile Repair Geometry

DIC Results Time Evolution, Trial #12

Copyright © 2019 Boeing. All rights reserved. 19

Copyright © 2019 Boeing. All rights reserved. 20

Tensile Test Fractures Elongations at Fractures

7050 Deposit 3.5% “Repair System”

7050 Deposit 70507050

7050 Deposit 7050 Deposit

Improve surface preparation  Increase interfacial mixing 

Trial Tensile Results

Opportunities for Improvements

Copyright © 2019 Boeing. All rights reserved. 24

Evaluated to Date Risk / Issue Path Forward

HT powder may be too soft vs. Evaluate mix of powders to compare

Incorporate ultrasonic or other methods for

Repair depth on 0.250" substrate Assess part repairs based on

Copyright © 2019 Boeing. All rights reserved. 25

Damage Repair Component

Copyright © 2019 Boeing. All rights reserved. 26