Advanced Surface Repair Capabilities

Transcription

1 m Advanced Surface Repair Capabilities 1

2 m Moog is a global designer, manufacturer and integrator of precision motion control products and systems. Over the past 60 years, we have developed a reputation for delivering innovative solutions for the most challenging motion control applications. As a result, we have become a key supplier to the world s leading aerospace and defense manufacturers, and are positioned on virtually every platform in the marketplace supplying reliable mission critical products that are highly supportable and add significant value for our customers. A key element of our success has been our corporate culture, which embraces a strong customer focus, process and product innovation, solid work ethic and remarkable attention to purpose of our people. Through Moog s aftermarket services business, we have been providing the same highly responsive, customer-focused support to commercial and military operators around the world. With aircraft staying in service far beyond their intended life, Moog continually strives to develop enhanced repair processes and reliability improvements to keep products on wing longer, thereby increasing fleet availability and lowering lifecycle costs. In addition to providing world-class MRO services, we offer product modification and upgrades, reliability enhancements and technology insertion, obsolescence management, logistics services and public-private partnerships. Over the last decade, Moog has been extending its world-class product support to include both Moog and non-moog parts. Moog s dedicated team provides fast, flexible and responsive repair services for a variety of mechanical, hydraulic and electronic parts. We are continuously investing in the resources needed to extend the depth of our expertise, and this, coupled with our small business style, enables us to provide truly personalized service and a wide spectrum of superior quality products for our customers. 2

3 Advanced Surface Repair Capabilities For decades, both new part manufacturers and end users have tried to find repair solutions for corroded and damaged parts. Replacement parts are expensive and usually have long lead times. As a result, maintainers often prefer repairing versus replacing. Many processes have been developed to repair damaged parts, but these may induce undesirable thermal stresses that can result in premature failure. Over the past several decades, experts from around the world have been looking for alternatives. One innovative solution is a process called Cold Spray an additive manufacturing process that uses metal powders accelerated to supersonic speeds to restore original substrates without inducing thermal stresses. This process is being widely used in the automotive and industrial marketplaces and is ideal for aerospace materials like magnesium, aluminum and titanium, as well as other alloys. Benefits of Cold Spray Repair Significant Total Cost Savings With Cold Spray, avoid replacing the entire damaged unit. Instead, repair the existing part and save on inventory, lead time and labor. Repair Time Reduction By reducing or even eliminating teardown, Cold Spray can be used to repair a part in-situ and eliminate assembly and testing costs. Improved Production Yield Not only can Cold Spray be applied to parts returned from the field, it can also be used to salvage parts with manufacturing defects. Moog has been working with industry experts including the US Army Research Lab at Aberdeen Proving Ground, designated by the DoD as the government expert in Cold Spray, to apply this process to the repair of commercial and military aerospace parts. Moog has successfully demonstrated repairs to corrosion, wear damage, and manufacturing defects on hard to repair magnesium and aluminum parts including transmission gearboxes, flap transmission housings, constant speed drive output housings, nose wheel steering actuators, landing gear components and more. Flap Transmission Tee Box Housing: Defect Repair Damaged Flap Transmission Tee Box Housing Flap Transmission Tee Box Housing Cold Spray applied Repaired Flap Transmission Tee Box Housing Cold Spray is Ideal for Many Situations: n Restoring material from corrosion n Restoring material from wear n Repairing manufacturing defects n Corrosion protection n Product surface build up 3

4 What is Cold Spray? Cold Spray is an advanced additive manufacturing process for metal surfaces that does not induce thermal stresses into the parent or deposited material. Its unique properties are compatible with many aerospace materials. What makes Cold Spray so unique? Unlike other repair processes that use heat to fuse materials together, Cold Spray uses a compressed gas to accelerate metal powders to supersonic speeds and is impinged onto the substrate. The resulting surface can be made comparable in strength to the original substrate. Main Gas Flow Cold Spray Deposition Process Particle Injection Coating n No melting of particles n Negligible oxidation n No decomposition or phase changes of deposited particles or substrate DeLaval Supersonic Nozzle Substrate Cold Spray is a material deposition process in which relatively small particles (ranging in size from approximately 5μm to 100μm in diameter) in solid state are accelerated to a critical high velocity (typically m/s), and are subsequently plastically deformed to develop a deposit on a metallic substrate. How Cold Spray Works Cold Spray repair is generally performed using low, medium or high pressure systems, through the use of a handheld, portable system or a stationary system in a ventilated work chamber. Low or Medium Pressure Systems: These systems are used in the application of lighter materials. Low or Medium pressure Cold Spray systems are typically much smaller, portable, and are limited to m/sec particle velocities. Metallic powder is injected after the nozzle throat (diverging section) to avoid nozzle erosion. Low or medium pressure systems generally utilize readily available air or nitrogen as propellant gases. Flexible, Handheld Low Pressure Cold Spray System High Pressure Systems: These systems are used in the application of more dense or heavy particles. High pressure Cold Spray systems utilize higher pressure gases, are stationary, and are typically generating particle velocities of m/sec. Metallic powder is injected before the nozzle throat after which the gas is expanded through a converging/diverging nozzle. Lower weight gases, such as nitrogen or helium, are the preferred propellant gases. Robotic-Controlled High Pressure Cold Spray System in Dedicated Booth 4

5 Moog s Cold Spray Technology and Services Moog has been actively involved in the development, qualification and certification of Cold Spray and is working to develop and acquire approval on specific repairs for helicopter and aircraft parts. Repairs are developed and conducted by skilled and experienced material specialists (ASM International Certified Thermal Spray Operators in Cold Spray) and a Ph.D. metallurgical engineer. We also have an on-staff FAA Designated Engineer Representative authorized for repair specifications and major repair approvals. Coating Materials As one of the only commercial facilities operating both high pressure and medium pressure systems, Moog has the ability to spray a wide array of coating materials. With a variety of materials comes a variety of critical velocity requirements the more pressure, the more velocity. Our wide array of equipment coupled with our extensive range of coating materials ensures we meet your unique repair requirements. Coating Powders Commonly Used: n Aluminum n Brass n Bronze n Copper n Inconel n Monel n Nickel n Niobium n Silver n Steel n Stainless Steel n Tantalum n Tin n Titanium n Zinc n Zirconium Value-Added Services Moog also has the capability to perform value-added repair services alongside our Cold Spray repair. We operate several FAA Part 145 Repair Stations, which provide turnkey repair and overhaul of aircraft parts. These stations allow us to take damaged LRUs and perform necessary teardown, repair, reassembly, test and recertification. Moog can also address repair, overhaul, reliability and obsolescence issues to improve asset availability and reduce lifecycle costs. Moog Provides a Full Range of Cold Spray Services from Development to Approval: n Experienced materials engineering staff for repair specification development n Surface preparation n Cold Spray build up n Post machining n Final inspection n In-house metallurgical lab for material analysis n Engineering technical package for required customer approvals n Surface finishing n Finishing/Anti-corrosion coating 5

6 Cold Spray Examples Helicopter Tail Rotor Housing Challenge: Corrosion caused severe surface pitting on the magnesium tail rotor casting. Normally theses castings would be scrapped. Solution: Moog repaired the magnesium surface using a Cold Spray aluminum alloy. Customer Benefit: Repairing this part with Cold Spray ensured that the coating is more corrosion and wear resistant. The customer saved a significant amount of lead time and the potential cost savings can be in excess of 70% of a replacement part. Corroded Tail Rotor Housing Cold Spray Aluminum Repaired Tail Rotor Housing 737 Nose Wheel Steering Actuator Barrel Challenge: The nose wheel steering actuator is exposed to harsh environments such as dirt, moisture and water. When the landing gear is engaged, these elements work themselves into the joints, causing the gear to corrode. Solution: Moog removed existing corrosion by pre-machining the barrel. The barrel was then restored using cold sprayed nickel metallic powder and final machined to original part specifications. Customer Benefit: Repairing parts with nickel provided even greater corrosion protection, making the repaired part more dependable than the original. Maintenance costs can be reduced by eliminating the need to purchase an expensive replacement part. 6 Corroded 737 Nose Wheel Steering Actuator Barrel Cold Spray Nickel Repaired 737 Nose Wheel Steering Actuator Barrel

7 Cold Spray Facilities Moog and its Mid-America Aviation subsidiary are performing various Cold Spray processes today. The West Fargo, ND facility is ISO9001/AS9100C certified and also holds an FAA Part 145 Repair Station Certificate. The facility has an on-staff FAA Designated Engineer Representative, authorized for repair specifications and major repair approvals. There is also an in-house Ph.D. metallurgical engineer and several in-house material specialists (experienced ASM International Certified Thermal Spray Operators in Cold Spray). Mid-America Aviation provides teardown and assembly services, and also has satellite offices for development and production purposes. West Fargo Operations (Headquarters) 159 8th Avenue NW West Fargo, ND Tel: Fax: Cage: 0UES3 FAA: VMDR806L EASA: Repair Station Certificate Number: VMDR806L Grand Forks Operations (Satellite Office) th Street NE Grand Forks, ND Tel: Fax: Cage: 0UES3 FAA: VMDR806L EASA: Repair Station Certificate Number: VMDD806L Webster Operations (Satellite Office) 22 Town Forest Road Webster, MA Tel: Fax: Cage: 0UES3 FAA: VMDR806L EASA: Repair Station Certificate Number: VMD2806L pending 7

8 Moog Worldwide Argentina Finland Italy Norway Spain Australia France Japan Philippines Sweden Brazil Germany Lithuania Singapore Switzerland Canada India Luxembourg South Africa United Kingdom Costa Rica Ireland Netherlands South Korea United States For more information contact: Don Clavell, Business Development, Civil Applications Phone: Mike Kizziah, ISS Business Development Director Phone: Moog Inc. All rights reserved