Maintaining the operational readiness of military helicopters demands repair solutions that are fast, reliable, and adaptable. This paper presents the integration of Gamma Alloys' advanced metal matrix composites (MMCs) into additive manufacturing (AM) techniques - specifically Cold Spray and Friction Stir Additive Manufacturing (FSAM) - as a transformative approach to helicopter repair and replace for the US Army.

Peabody, Micah, Harrigan, William

Tungsten Carbide-Cobalt Chrome Powder Agglomerated and Sintered

AMS7882D (Current)

10/1/2021

This specification covers tungsten carbide-cobalt chrome in the form of powder.

AMS F Corrosion Heat Resistant Alloys Committee

Electrocoat Compatibilities of Automotive Sealers

J1969_202101 (Current)

1/7/2021

This SAE Recommended Practice sets forth a method for determining the compatibility of automotive sealers with cathodic electrocoat primer.

Materials, Processes and Parts Council

T55 Gas Turbine Engine Bleed Band Actuator Housing Re-Design

F-0076-2020-16281

10/5/2020

The continual replacement of the bleed band actuator caused a supply shortage resulting in production work stoppage. A re-design effort restored the actuator housing through rework modification of a sleeve repair. The re-design substantion is presented along with the qualification test and manufacturing process. Significant value engineering savings and increased supply readiness resulted from the re-design effort for the U. S. Army. However, the re-designed sleeved actuator housing became costly and inefficient over time and subsequently stopped. The overhaul discrepancy is still present on the newer T55 gas turbine engine model. A review of new repair technology available identified another solution that does not generate hazardous industrial waste. That solution is cold spray technology. Cold spray solid state additive technology is evaluated for re-design of the housing as comparison to the existing sleeve re-design. Cost decrease and manufacturing efficiency increase are both a result from this evaluation. Two cold spray powders presented are options for the re-design housing. While both powders provide a better overall solution to the sleeve re-design, the cold spray hard coat powder appears to provide improved wear resistance, e.g. 20 times better than hexavalent chrome plating.

Cass, Wesley

New Coating Process Lights Porous Electronics and Sensors

TBMG-37364

8/1/2020

Researchers have shown how to coat glass and plastic with porous titanium dioxide. The fabrication process is straightforward, the materials are cheap, and the ceramic’s gas sensing performance is considerably improved compared with current devices.

Tungsten Carbide-Cobalt Powder Agglomerated and Sintered

AMS7881B (Current)

5/6/2020

This specification covers tungsten carbide-cobalt in the form of powder.

AMS F Corrosion Heat Resistant Alloys Committee

Tungsten Carbide-Cobalt Chrome Powder Agglomerated and Sintered

AMS7882C (Historical)

4/21/2020

This specification covers tungsten carbide-cobalt chrome in the form of powder.

AMS F Corrosion Heat Resistant Alloys Committee

Development of a Novel Method to Simulate Cavity Preservation in Automotive Industry

2020-01-09004/14/2020

Corrosion protection is a major topic of research for automotive manufacturers and major suppliers. The most critical parts affected by corrosion are the pillars and cavities. Automotive manufacturers spend a lot of effort to improve protection layers as much as possible to increase the longevity of their products. The Electro-Coat Paint Operation (ELPO) or E-Coat process is key in achieving this goal. Unfortunately, often the electric current does not reach all the areas very well and resulting in undercoating. Also, the consequent baking process might see the ovens not achieving the desired temperatures into the cavities. As a fact it often happens that these areas are exposed by undercoating, and hence undermining the quality of corrosion protection. Some car manufacturers investigate one level more to assure a good quality of corrosion protection also within cavities, by applying wax. This wax coating process aims to cover all problematic areas in a way to make cavities more resistant to unfriendly conditions such as rain, snow, and salt. At present, waxing solves those problems quite well. However, the wax is an expensive product and car manufacture investigate to minimize the material cost while keeping quality as high as possible.

Chitneedi, Bhargav Krishna, Schifko, Martin, Verma, Kevin, Menon, Muraleekrishnan, NAIR, Vishal

Hardening Lightweight Metal Foams with Nanocoating

TBMG-358181/1/2020

Bones are strong and stable and can cope with loads almost as well as steel. But despite their strength, they are light enough to be easily moved by humans and animals. The secret lies in the combination of a hard, exterior shell that encases a porous lattice-like network of bone tissue in the interior of the bone. This structure saves on material and reduces weight.

Optimization of RF Magnetron Sputtering Parameters for Deposition of Zinc Oxide Semiconductor Film at Moderate Temperature of 100°C

2019-28-015010/11/2019

Zinc oxide semiconductor thin films are deposited on glass substrate at different RF magnetron sputtering parameters. The deposited films were characterized as a function of substrate - target distance, gas flow ratio, working pressure and RF power. X-ray diffraction, Field emission scanning electron microscopy, and hall measurement were utilized to analyze the effect of the deposition condition on the structure, surface morphology and electrical properties of ZnO thin films. The deposition conditions were optimized to give good quality films suitable for the application of flexible or invisible flat panel display. All the films were deposited at 100°C.

Muthukarappan, Amutha Surabi, Jeyaseelan, Chandradass, Paramathma, Baskara Sethupathi, Park, Seong-Ju

Experimental Study on Tool Wear and Cutting Temperature during Machining of Nimonic C-263 and Waspaloy Based on Taguchi Method and Response Surface Methodology

2019-28-014410/11/2019

Nickel based materials of Nimonic C-263 and Waspaloy are used nowadays for aerospace applications owing to its superior strength properties that are maintained at a higher temperature. Tool wear and cutting temperature in the vicinity of cutting edge are two essential machinability characteristics for any cutting tool. In this regard, this study is pursued to examine the influence of factors on measuring of tool wear (Vba) and cutting temperature (Ts) during dry machining of two alloys studied experimentally based on Taguchi method and response surface methodology. Taguchi’s L16 orthogonal array is used to design the experiment and a PVD (TiAlN), CVD (TiN/Al2O3/TiCN) coated carbide inserts are used on turning of two alloys. The factor effect on output responses are studied using analysis of variance, empirical models, and responses surface 3D plots. To minimize the response and to convert into one single optimum level, responses surface desirability function approach is applied. The results show that progress of flank wear associated with Waspaloy is faster that of Nimonic C-263 due to high cutting temperature for Waspaloy that of Nimonic C-263. Abrasion is active wear mechanism for both the alloys with the investigated cutting parameters. Also, plastic deformation and mechanical fracture are observed for both inserts on turning of two alloys. In overall, PVD tool brings down the cutting temperature (10% for Nimonic C-263 and 4% for waspaloy), and flank wear land (31% for Nimonic C-263 and 41% for waspaloy) than that of CVD tool due to its superior tribological properties.

Kannan, Vetri Velmurugan, Kannan, Venkatesan, Sundararajan, Devendiran

The Challenge of Replacing Hard Chrome

19AERP10_0310/1/2019

The search for a suitable replacement for hard chrome on aerospace components has been a key supply chain priority for aircraft manufacturers. This is because of the documented health risks to workers and the impact on the environment from exposure to hexavalent chromium, a carcinogen that occurs during the chrome plating process and is the most toxic form of chromium. As a result, chromium is a highly regulated chemical in major markets worldwide. In the European Union, hexavalent chromium falls under the domain of the EU regulation, REACH (Registration, Evaluation, Authorization and Restriction of Chemicals), which establishes guidelines for the safe use of chemicals throughout the supply chain. Chromium is also closely regulated in the United States by OSHA.

The Challenge of Replacing Hard Chrome

TBMG-3535910/1/2019

Surface Treatment Could Improve Refrigeration Efficiency

TBMG-351319/1/2019

Unlike water, liquid refrigerants and other fluids that have a low surface tension spread quickly into a sheet when they come into contact with a surface. For many industrial processes, it would be better if the fluids formed droplets that could roll or fall off the surface and carry heat away with them.

Designing Sensors for Hazardous Environments

TBMG-351969/1/2019

Some of the most common applications for hazardous duty sensors are in the oil and gas industry. Rotary encoders are frequently used to provide crucial feedback about moving machinery on the rig. Flammable agents are common in applications near the wellbore, so most electrical components on the rig require special hazardous area certification. Hazardous duty sensors are also used in applications such as paint spray booths because of the volatiles coming off the paint; grain silos because the dust environment is very explosive; chemical factories; explosives factories; and believe it or not, for cosmetics because the very fine powders that are used are highly explosive.

CONNECTOR RECEPTACLE, REVERSE BAYONET COUPLING, DUMMY STOWAGE

AS95234/12 (Current)8/27/2019

AE-8C1 Connectors Committee

Aerospace Work Platforms - More than Meets the Eye

19AERP06_136/1/2019

Today's work platforms are far more complex than the simple designs of the past. For maintenance personnel in the aerospace industry to do their jobs effectively, they need to be able to get physically close to the equipment they are working on. This statement sounds obvious, but in order to meet this requirement, it is very important to utilize quality work platforms. Although most people are familiar with the basic uses of work platforms, there is not always much thought given to everything that goes into their design and fabrication. In years past, simple platforms were widely used for a variety of different work applications, however, much more is demanded of them in modern facilities. These increased demands have forced the work platform fabrication industry to evolve. The design and fabrication of today's platforms require manufacturers with expertise, experience, and skill. Fabricators and designers must incorporate specialized features in many areas never before seen or even considered. Safety, configurability, mobility, material selection, worker access, and utilities are all requirements that need to be considered.

Aerospace Work Platforms — More than Meets the Eye

TBMG-345456/1/2019

For maintenance personnel in the aerospace industry to do their jobs effectively, they need to be able to get physically close to the equipment they are working on. This statement sounds obvious, but in order to meet this requirement, it is very important to utilize quality work platforms. Although most people are familiar with the basic uses of work platforms, there is not always much thought given to everything that goes into their design and fabrication.

Additive manufacturing of titanium alloys by cold spraying onto Al7075

F-0075-2019-14629

5/13/2019

The aluminum alloy Al7075 is commonly used in aircraft industry due to its high mechanical resistance to weight ratio. Nevertheless when the structure is being serviced upon the severe environmental conditions or loads degradation mechanisms could often been found in the material. To improve its behavior the cold spray process with various titanium powders (e.g. CP Ti, Ti-64) deposited onto Al7075 was investigated. The spraying of angular titanium powder was performed in the presence of nitrogen and helium supplied at process parameters (temperature, pressure), which were the maximum values attainable by the CS system used. The deposits were sprayed while maintaining a standoff distance in the range from 20 to 100 mm increased by 10 mm. The experimental data indicated that the deposition efficiency had increased significantly with increasing standoff distance. The coating porosity first decreased to minimum 0.6% and then increased significantly to 9.8%. The mechanical properties of the coatings reached the highest values when the porosity was minimum. No new phases were reported in the cold sprayed titanium coatings when compared with the starting feedstock. The same process parameters were transferred to Ti- 6Al-4V coral like powder deposition process. The shear strength between Ti coating material and Al7075 substrate was measured. Additionally the tensile strength of the deposit only, previously disintegrated from the substrate, was checked out. The data obtained indicate that the consolidation of Ti powder with Al7075 substrate made by cold spray could be served for both: materials integration and building a component by materials disintegration, where Al substrate is removed on spraying and machining; and simply used as a technological support for additive manufacturing of a self-standing real life component.

Sienicki, Jaroslaw, Żórawski, Wojciech

Enabling Technology for Sustainment of Navy Aircraft Structures

F-0075-2019-14601

5/13/2019

The Structures Division at the Naval Air Systems Command (NAVAIR) continues to support capital investment in enabling technologies for sustainment of our aircraft which will lower total life cycle costs, ensure safety, and increase operational readiness. This paper presents a general overview of the major improvements which have been made in the area of Structural Health and Usage Management (SHUM), including: usage severity monitoring via regime recognition (RR), gross weight and center of gravity (GW/CG) estimation, local/global damage detection, environmental effects monitoring, damage alleviation, prognostication, and individual asset/component tracking (IAT). Advances in structural analyses have been made in the accuracy of predicted rotorcraft loads using coupled rotor and fuselage interactions. Innovative approaches to fatigue testing at both the component and full scale airframe levels will allow for more accurate introduction of vibratory loading content from operation, reveal failure modes, and improve fatigue life predictions. Additive manufacturing (AM) of fly-away aircraft parts and the standardization of cold spray repair applications present unique qualification challenges and benefits to the warfighter.

Semidey, Roberto, Glucksman-Glaser, Mark, Phan, Nam

Army Aviation Additive Repair/Manufacture (AR/M) Qualification

F-0075-2019-14624

5/13/2019

The U.S. Army overhauls aircraft weapon system (AH-64, CH-47, UH-60) and associated components. Significant damage, corrosion, and wear are a main cause of component discrepancies. Typical issues with current fusion weld/thermal spray repair is high distortion and a large heat affected zone (HAZ) to an operational aviation component. These repairs often require large and complex fixtures and processes to stabilize the component during the repair process. The additive repair / manufacture (AR/M) has shown to give a very small HAZ and footprint not requiring the use of complex fixtures. This paper outlines the approach taken to develop and qualify AR/M necessary for airworthiness qualification. Two areas that are researched are laser additive manufacturing (LAM) powder fed systems (or directed energy deposition (DED)) and cold spray additive manufacturing. Establishment of mechanical and metallurgical properties of AR/M are presented. Significant return on investment is being shown using these AR/M repair processes.

Cass, Wesley

LED Lighting Improves Efficiency and Imaging

TBMG-343975/1/2019

Rocket engine testing requires a lot of light since all tests are filmed with high-speed cameras to monitor performance; however, those cameras have to adjust to the bright plume from a firing engine, which would black out the rest of the image. Traditionally, that light has been provided by metal halide bulbs.

Functional PVD Coatings Improve Medical Device Performance and Life

TBMG-344345/1/2019

As the medical device industry continues to grow rapidly, manufacturers must contend with a variety of challenges if they wish to differentiate products in a highly competitive market. With this in mind, greater emphasis is being placed on the functional coatings that are applied to stainless steel, titanium, and other substrates of critical medical devices from implants to scalpels, needle drivers, bone saws, and reamers.

Experimental Study on Impingement of Fuel Droplet on Substrates

2019-01-0300

4/2/2019

Within a gasoline direct injection (GDI) engine, the impingement of fuel droplet on substrates induces various problems such as particular matter emission, oil dilution and abnormal combustion. Therefore, in order to solve these problems, it is urgent to have a clear understanding of the impingement behavior of fuel droplet impacting on substrates. Most previous studies have focused on the impingement of either water droplet on dry solid surface or the impinging droplet on the liquid film of the same type of liquid, while little research has been conducted on the impingement of fuel droplet on relevant substrates existing in GDI engines. The impingement of fuel droplet with higher Weber number on dry surface, fuel film and oil film with different thickness and viscosity were investigated experimentally. Results show that fuel droplet impacting on dry wall is easy to be deposited to form a fuel film. The fuel film attached to the wall is the main reason for the splash. The thickness of fuel film adhered to the dry wall affects the splash degree of secondary droplets. As the fuel droplet impacts on pure oil film of different thickness and viscosity, there is no secondary droplets spattering into the air. After collision, the fuel droplet together with the jet deposits into the oil film causes the oil dilution.

Peng, Zhenshan, Pei, Yiqiang, Qin, Jing, Lu, Lili, Zhu, Qingyang

Fabric Alternative to Batteries for Wearable Devices

TBMG-341484/1/2019

Wearable biosensors for health monitoring lack a lightweight, long-lasting power supply. A new method was developed for making a charge-storing system that is easily integrated into clothing for embroidering a charge-storing pattern onto any garment.

New 3D Printing Process for Bone Implants

TBMG-342634/1/2019

Researchers have developed a technique with which bone implants that are precisely fitting, stable, and variable in dimensions can be 3D printed from a special plastic. In the printing process, individual layers are treated with a cold plasma in order to improve the bonding of bone-forming cells.

Enhancing Electrode Properties with Laser Restructuring

TBMG-342654/1/2019

The materials that go into medical devices — particularly implantable electrical devices — have to strike a unique balance of properties. Once you consider biocompatibility and all the required physical and mechanical properties, there are very few metals that will make the grade. In fact, for electrode materials, you won't get much further than platinum and gold. And while innovative new alloys do occasionally emerge, there are usually limited opportunities to solve engineering problems by turning to entirely new materials.

Scalable Manufacturing Process for Creating Spools of Graphene

TBMG-336952/1/2019

For many researchers, graphene is ideal for use in filtration membranes. A single sheet of graphene resembles atomically thin chicken wire, and is composed of carbon atoms joined in a pattern that makes the material extremely tough and impervious to even the smallest atom: helium.

Does Your Coating System Require Climate Control? What to Look For and What to Expect

TBMG-3342212/1/2018

There is one aspect of the paint and coatings finishing business virtually guaranteed to give the budget director heart failure: climate control. There's no way around it – climate control systems are expensive.

Optimizing Plasma Treatments to RESOLVE Challenging Adhesion Issues

TBMG-3342312/1/2018

The process of determining the ideal plasma treatment that will resolve a challenging bonding or adhesion issue is an exact science, often the domain of chemists and physicists.

Enhanced Contacts for Inverted Metamorphic Multi-Junction Solar Cells Using Carbon Nanotube Metal Matrix Composites

TBMG-3336812/1/2018

In order to address issues related to mechanical and vibrational stresses that are commonly experienced in mounting, launch, and deployment of spacecraft, metal matrix composite (MMC) electrodes were fabricated with carbon nanotubes (CNTs) as reinforcement. The research plans were centered on first developing and selecting appropriate processes for fabricating CNT-MMCs based on characterization of their material properties, followed by optimizing MMC designs based on electrical testing under stress. Efforts in the program were also directed toward implementing the CNT-MMCs into solar cell device processing in a process compatible with standard clean room procedures.

Two-Dimensional Semiconductor Materials Created Using Artificial “Superlattices”

TBMG-3324111/1/2018

One current method to build a semiconductor superlattice — materials comprised of alternating layers of ultra-thin, two-dimensional sheets only one or a few atoms thick — is to manually stack ultrathin layers one on top of the other, but this is labor-intensive. In addition, since the flake-like sheets are fragile, it takes a long time to build because many sheets will break during the placement process. The other method is to grow one new layer on top of the other, using a process called chemical vapor deposition. But since that means different conditions such as heat, pressure, or chemical environments are needed to grow each layer, the process could result in altering or breaking the layer underneath. This method is also labor-intensive with low yield rates.

2018 Create the Future Design Contest: Robotics/Automation/Manufacturing Category Winner

TBMG-3331611/1/2018

Increase Dental Implant Longevity with Bio-functional TiN and DLC Coatings

TBMG-3306410/1/2018

Artificial dental implants are the most reliable restoration option available for mature tooth loss. Despite their long potential lifespan, poor integration into the jaw and a slow healing process often create implant failure. Ensuring longevity requires adequate protection of the abutment-implant interface, protection achieved with surface functionalization by biocompatible coatings or advanced surface plasma treatments. The research summarized in this article examines the effect of using titanium nitride (TiN) and diamond-like carbon (DLC) thin-film coatings for implants.

Electric double layer capacitors prepared with polyvinyl alcohol and multi-walled carbon nanotubes

2018-36-03139/3/2018

Portable electronics, wearables, electric vehicles and solar cells are sectors in increasingly development which include innovation and miniaturization of the devices. In this scenario, the development of smaller and lightweight energy storage devices, which store more energy, is required. Besides, it is desirable for these devices to be environmentally friendly to minimize pollution. In an attempt to meet these requirements, this work purposes the development and the characterization of nanofibers-based electrode composed of Polyvinyl alcohol (PVA) and multi-walled carbon nanotubes (MWCNT) for electric double layer capacitors (ELCDs) devices with aqueous electrolyte. This composite has been prepared by electrospinning technique and consolidate an electrical conductive and high-surface material electrode. After that, the PVA/MWCNT electrode was assembled in coin cell device with Sodium Sulfate (Na2SO4) electrolyte for electrochemical characterization. The characterization results showed that EDLCs devices present specific capacitance of ∼4.8 Fg-1, energy density of ∼0.1 Wh kg-1, power density of ∼600W kg-, fast charge transfer at electrode/electrolyte interface and high lifetime All these results encourage further development on PVA/MWCNT materials as electrode for EDLCs and Li-Air batteries devices. This new generation of devices are opening niches of applications on multi billionaire markets from communication to transport.

Real, Carla Giselle Martins, Vicentini, Rafael, Nunes, Willian Gonçalves, Boas, Otávio Vilas, Costa, Lenon Henrique, Soares, Davi Marcelo, Zanin, Hudson

Q&A: Dr. André D. Taylor, Chemical & Biomolecular Engineering Dept., New York University Tandon School of Engineering, New York, NY

TBMG-328569/1/2018

An international team of university researchers, led by Dr. Taylor, reports solving a major fabrication challenge for perovskite cells — the intriguing potential challengers to silicon-based solar cells. These crystalline structures show great promise because they can absorb almost all wavelengths of light. Perovskite solar cells are already commercialized on a small scale, but recent vast improvements in their power conversion efficiency are driving interest in using them as low-cost alternatives for solar panels.

Specifying Coatings for Military and Aerospace Applications

TBMG-328769/1/2018

Optics are employed in virtually every area of military operations, from vision systems and target designators used by troops on the ground, through guidance systems utilized in both manned and unmanned aircraft, to reconnaissance and surveillance packages carried by satellites in Earth orbit. These optics are often subjected to large variations in ambient temperature and humidity, as well as contact with abrasive or corrosive materials (such as sand or salt spray). Thin film coatings, which are almost universally required on military optics, must be able to physically withstand these stressors, as well as deliver their design performance in an environment where “failure is not an option.” But, increasingly, achieving these ends must also be balanced with cost.

Coatings Make Natural Fabrics Waterproof

TBMG-328459/1/2018

Fabrics that resist water are essential for everything from rainwear to military tents, but conventional water-repellent coatings have been shown to persist in the environment and accumulate in our bodies, and so are likely to be phased out for safety reasons. That leaves a big gap to be filled if safe substitutes can be found. The goal is for the materials to be repellent — for the drops to bounce back.

White Paper to Support Supersession of MIL-S-8879C With AS8879C

AIR5926 (Current)

8/23/2018

This paper was prepared to support supersession of MIL-S-8879C with Screw Thread Conformity Task Force selected industry standard AS8879C, published by the Society of Automotive Engineers (SAE). Other documentation changes will be covered by separate papers. Separate papers are anticipated for thread gaging issues, and thread gage calibration procedures. The STC-TF decided that the thread design standard needed to be completed before thread gage definition could be addressed. Thread gage definition has to be known before calibration procedures can be addressed.

E-25 General Standards for Aerospace and Propulsion Systems