MILITARY

PTS

Evaluation of Pulse Thermal Spray (PTS) Process and Coatings; and Incorporation of Automated Moving Mechanism for the PTS Process for Navy Component Application

In collaboration with Perpetual Technologies. Montreal Canada

Office of Naval Research
Dr. Lawrence Kabacoff
Materials Division, Code 332
800 North Quincy
Arlington, Virginia 22217-5660
Tel. 703.696.0283
Fax 703.696.0934

Naval Surface Warfare Center
Ken Scandell

United States Naval Academy
Professor Angela Moran

Submission Date: Revision 1
October 19, 2005

Abstract
SAIC has developed a unique thermal spray process, Pulse Thermal Spray (PTS), which has demonstrated preliminary results indicating unique capabilities such as internal diameter, hard-to-reach or complex geometry, and amorphous deposit spraying. To date, there has not been any thorough or systematic evaluation of the PTS process capabilities and resulting material science to quantify performance and differentiating benefits (i.e. in-flight particle temperatures and velocities). Conducting fundamental investigations will provide necessary understanding of the process parametric boundaries essential to optimizing the system for each application.

As one of the only (or perhaps “few”) industrial based thermal spray companies with experience in beta testing and integrating these systems for industrial applications of developing thermal spray systems, F.W. Gartner Thermal Spray (FWGTS) Company proposes to use its extensive experience and capabilities to evaluate both the Pulse Thermal Spray (PTS) process and its coatings. As well, FWGTS will assist SAIC in identifying critical aspects of building a second PTS system to be integrated into FWGTS’ in-house robotic manipulation system to provide the multi-axial capability necessary to depositing onto a complex-geometry Navy component.

To accomplish these tasks, FWGTS will adapt its real-time, in-flight particle diagnostic system (Accuraspray) to measure the average particle temperature, velocity, and flow rates. These in-flight particle characteristics can be directly correlated to the input spray parameters as well as coating properties. Factors derived from this study cab aide in curtailing a normal protracted parametric optimization process typified by “trial-and-correction” and/or extensive modeling. Coating evaluation will consist of polishing each coating material with established recipes, carrying out light optical microscopy, and performing micro hardness and tensile adhesion tests.

One of the numerous robotic manipulation systems at FWGTS and possibly a numerical control substrate manipulation system will be adapted for the PTS system so as to allow for repeatable, accurate, and reproducible application of deposits onto a complex-shape marine gas turbine engine blade. This will require a great deal of optimization and customization for both the PTS and manipulation systems.