Transfair Presentation 1 (pdf file 1MB)

The IMF
welcomes you to
Transfair
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IF YOU DISCOVER A FIRE:OPERATE THE NEAREST FIRE ALARM POINT.
ON HEARING THE FIRE ALARM:ALL PERSONNEL SHOULD EVACUATE THE BUILDING BY
THE NEAREST AVAILABLE FIRE EXIT AND ASSEMBLE AT
THE NEAREST ASSEMBLY POINT A, B OR C. (SEE MAP)
DO NOT STOP TO COLLECT PERSONAL BELONGINGS
DO NOT RE-ENTER THE BUILDING UNLESS
SPECIFICALLY INSTRUCTED TO DO SO BY THE
HERITAGE MOTOR CENTRE CONTROL/ DUTY OFFICER
FIRE ROUTINE
Welcome Address
Paul Lansdell FIMF; President – IMF
Keynote Speech
David Neal FIMF; Global Process
Owner, Painting - Rolls-Royce plc
REACh chrome free primer project
(HITEA)- update report
Brian Norton; Indestructible Paint
Ltd
New Developments in ElectroPolishing of stainless and aerospace
alloys using Ionic Liquids
Karl Ryder MIMF; Leicester
University
Electrochemical pulse technologies
for aeronautic applications
Wolfgang Hansal FIMF; Happy
Plating
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REACH is beginning to bite,
Substitution pressure mount
You are in the right place to
discuss all of this
 Surface
preparation
 Painting
 Plating including Pulse Plating
 Hard Coatings
 Corrosion protection
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Interdisciplinary action is VITAL
The range of processes requiring
improvement grows as the demands of
modern use continues to grow.
95% of manufacturing industry
finishing
depends on US
for
We are taking time out to broaden our
view of our industry - GOOD
 The attendance is heartening - GOOD
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We need to do is get that message across to
the world outside our industry
- - DIFFICULT !!!!
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Review the stands and manufacturers
Tell them what you want – they won’t know
unless you do
Make new contacts
Question the speakers
Oh ! By the way – Enjoy Yourselves
Rolls-Royce
Painting a Picture
David Neal BSc (Hons) Rsci MRSC FIMF
© 2013 Rolls-Royce plc
The information in this document is the property of Rolls-Royce plc and may not be copied or communicated to a third party, or used for any
purpose other than that for which it is supplied without the express written consent of Rolls-Royce plc.
This information is given in good faith based upon the latest information available to Rolls-Royce plc, no warranty or representation is given
concerning such information, which must not be taken as establishing any contractual or other commitment binding upon Rolls-Royce plc or
any of its subsidiary or associated companies.
Global Process Owner – Painting
Technology
• What does it mean to be a Global Process
Owner?
 Functionally responsible for Painting Technology
for Rolls-Royce across all business sectors.
 Defining strategy for use of Paints within RollsRoyce.
 Act as focal point for Rolls-Royce Global paint
community.
Rolls-Royce proprietary information
Rolls-Royce – Global Paint Community
Aerospace (Civil/Defence)
Energy
Nuclear (Civil/Submarines)
Marine
Rolls-Royce proprietary information
Strategy Summary
Rolls-Royce proprietary information
Paint Community - Past
Energy
Expert 1
Civil Nuclear
Expert 1
Large Civil
Engine
Aerospace
OEM
Expert 1
Expert 2
Submarine
Expert 1
Defence
Aerospace
Expert 1
Small/Medium
Engine Civil
Aerospace
OEM
Expert 1
Expert 2
Rolls-Royce proprietary information
Marine
Expert 1
Expert 2
• Limited
communication
between
business
sectors
Paint Community - Present
Civil Nuclear
Expert 1
Large Civil
Engine
Aerospace
OEM
Expert 1
Energy
Expert 1
Expert 2
GPO Paint
Defence
Aerospace
Expert 1
Submarine
Expert 1
Small/Medium
Engine Civil
Aerospace
OEM
Expert 1
Expert 2
Rolls-Royce proprietary information
Marine
Expert 1
Expert 2
Paint Community - Future
Small/Medium
Engine Civil
Aerospace
OEM
Civil Nuclear
Energy
Marine
GPO Paint
Large Civil
Engine
Aerospace
OEM
Defence
Aerospace
Submarine
Rolls-Royce proprietary information
Why do we paint?
Early examples of paint
specifications:
Merlin Drawing instructs
“Paint – Black”
Cosmetic only.
Merlin with “black paint” in Spitfire – Photograph courtesy of Rolls-Royce Heritage Trust.
Rolls-Royce proprietary information
Why do we paint now?
• CORROSION PROTECTION
• EROSION PROTECTION
• LUBRICATION
• FIRE RETARDATION
• COSMETIC / DECORATIVE
• MARKING / IDENTIFICATION
• TEMPERATURE PROFILES
Rolls-Royce proprietary information
What do we paint?
Sacrificial Coating applied to Shaft
DFL applied to LP Fan Disc
Epoxy and Polyurethane applied Nose Cone
Rolls-Royce proprietary information
What do we paint?
Azimuth Thruster (Sub – surface)
Rolls-Royce proprietary information
Azimuth Thruster (Thruster room side)
What do we paint?
Contaz Thruster (Inboard – Top View)
ContazThruster (Inboard – BottomView)
ContazThruster (Sub-surface)
Rolls-Royce proprietary information
Challenges in Paint
• European REACh regulations currently a major issue:
• Finding alternatives to Hexavalent Chrome (Cr 6+) an on going challenge.
• Number of projects running to find alternatives to Cr 6+ containing
systems.
• N-Methyl-2-pyrrolidone (NMP) used in paint strippers and resins may prove
to be an issue.
Rolls-Royce proprietary information
Future of Paint within Rolls-Royce
Future State 1.
6+ Products
Non Cr
found/developed
that have a
performance ≥
than current Cr 6+
paint products.
Rolls-Royce proprietary information
Future State 2.
Non Cr 6+ Products
found/developed that
have a performance ≤
than current Cr 6+ paint
products resulting in
increased inspection
operations and increased
burden on MRO network.
Questions?
Rolls-Royce proprietary information
Functional Coatings for Industry
11th June 2013
TSB Funded R&D Programme
REACh Compliant Hexavalent
Chrome Replacement for Corrosion
Protection
Brian Norton
Call for the Project
• The UK surface treatment industry is worth
£10.8bn p.a.*. Of this, the aerospace sector
accounts for £982m p.a. which supports
products worth £6bn p.a.**
• Metal corrosion and wear problems
currently cost industry $1.5-2 trillion
globally every year (3% of GDP)
Source: * Whittle Market Data 2010, ** UK DTI/BIS Report 2011
Call for the Project
• Compounds containing Hexavalent Chromium (Cr6+) proven to
provide most robust solution.
• Important to aerospace industry because aircraft design life is 30+
years and they operate in aggressive environments.
• Industry is highly regulated, changes to a certified product must be
proven to have no safety implications.
Call for the Project
REACh Legislation
Registration, Evaluation, Authorisation and
Registration of
Chemicals
• Came into force 1st June 2007
• Expected to ban the use of Cr6+ containing materials by 2016 /17
Some of the aerospace processes
affected by REACH and Chrome
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Chromic Acid Anodising (CAA )
Alocrom
Magnesium Chromating
Dow 17 anodising
Chrome “seals” for anodising
1 part air dry chromate
primers eg TTP1757
• Wash primers such asBSX32
• Chromate 2 part epoxy
primers such as BSX33; Mil-P23377
• Chromate containing sealants
such as JC5A ; Mastinox ;
• High temp chromate baking
primers ; eg MSRR 9226
• PR type sealing compounds ;
as Chrome catalyst
• High heat chromate materials
eg engine pylons
• IPCOTE type sacrificial turbine
blade coatings
• IPAL type diffusion coatings
• Hard Chrome Plate ; Others
Chromates in Annex XiV
Chrome VI 6 ( Chromic Acid ) ( hexavalent )
Legal effort to try and get Cr VI 6 Authorised in
consortium known as CTAC ( Chrome Trioxide
Authorisation Committee )
154 members
Chrome “salts” in CCST or not
• Now only maybe 30 members
• 17 chrome “salts “ originally
• CCST being discussed to Authorise only 8 of
these
• Of these 8 ; now only 4 may go forward
• Closing date late May 2013
Chrome “salts “
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Being supported possibly
Strontium Chromate
Ammonium dichromate
Dichromium tris
(chromate)
Potassium dichromate
Sodium Dichromate
Zinc TetroxyChromate
Potassium Zinc Chromate
• Another 9 salts already
“abandoned” including
for example
• Zinc Chromate
Strontium Chromate
• Only being supported for Flying Vehicles
• Discussion ; is a hand held missile a Flying
Vehicle ?
• Not for coil coating etc
Scope of the Project
Generate valid, industry-wide accepted test
methodologies and application of these for the
development of REACh compliant replacements.
Suitable for rapid deployment before 2016.
The Consortium
The Coating Materials Provider
• Formulate and provide consortium with formulations to be
investigated.
• Empirical knowledge on existing and proposed alternatives to be
captured through data capture exercise for future use.
The Consortium
The Paint Applicators
• Application and quality control testing of the formulations and new
processes.
• Ensure new formulations suitable for processing.
• Share understanding of experience.
The Consortium
The OEMs
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End user requirements.
Background for new processes.
Route to market.
Fund testing development.
The Consortium
A Specialist Materials Information Group
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Capture data.
Develop data management structures.
Run knowledge management system.
Provide a route to wider dissemination through their database.
The Consortium
The Academic Consortium
• Recognised UK expertise.
• Provide underpinning science that will lead the development
of new corrosion/protection models.
Intended Outputs of the Project
1.
New test methodologies for surface protective coatings which allow
more rapid testing when compared with current salt spray methods.
2.
Identification and demonstration of new Cr6+ free surface protection
systems.
3.
Improved science-based understanding of the coatings, surfaces and
how these can be optimised by closer integration between the industry
and the academic partners.
4.
Development of new test methodologies which allow quantitative
assessment of material degradation modes with the aim to establish
fast, inexpensive and robust tests for selecting the most promising
chromium-free alternatives.
5.
Seek to get outputs adopted in standards.
Thank You
Any questions?
New Developments in the Electropolishing of
Stainless Steel and Aerospace Alloys Using
Ionic Liquids
Prof. Karl S. Ryder
Scionix Laboratory,
Department of Chemistry,
University of Leicester,
Leicester, LE1 7RH,
UK
k.s.ryder@le.ac.uk
Contents
• What is an ionic liquid
• Eutectic-based ionic liquids and how to make them
• Electropolishing
• Single-crystal investment castings
– Etch rate
– Micro-scale phase selectivity
• HIP casting
• Stainless steel rapid prototyping
• Closing remarks
Ionic liquids: definition
Ionic material that melts below 100 ºC
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Unusual solvent properties
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Very low / negligible vapour pressure - do not evaporate
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Most liquids thermally stable >200 ºC
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Immiscible with many organic solvents
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Some have wide potential windows
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Large and unsymmetrical ions -> low lattice energy and
hence low melting point
Eutectic-based ionic liquids
Organic cations with halide anions and various complexing
agents to make an anionic complex
R1R2R3R4N+ [X-. z Y]
complexing
agent
cation
Type I
Type II
Type III
Y = MClx, M = Zn, Sn, Fe
Y = MClx.yH2O
Y = RZ, Z = CONH2, COOH, OH
CH3
HO
+
N
-
Cl
CH3
CH3
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Lower cost
Easier to make
Less water sensitive
High metal solubility
Less registration requirements
anion
Electropolishing
Electrochemical dissolution:
 ChCl / EG liquid
 High current efficiency
 Low toxicity
 No strong acids
 Comparable finish
Ionic Liquids Demonstrator facility (ILD)
Pilot plant
 Functional process line
 Pre treatment
 Process, 50 L IL
 Rinse
Works very well for 300
series stainless steels and
high value performance
alloys, Ni / Co, Ti etc.
Aerospace castings
Aerospace castings
Rolls-Royce Trent XWB
Aerospace castings, scale and RX
Grain structure induced by mechanical
stress prior to heat treatment
Electropolishing; surface characterisation
Electrolytic polishing in IL removes
virtually all residual shell.
Electropolish
First results suggest alloy composition
is not effected by etch
Surface roughness greatly reduced
Sample 1 (pale)
Ni(3p)
Electropolishing; surface characterisation
Etch rate characterisation
Mounted sections are made the
base of an electrochemical cell.
Each section piece is then a
separate electrode.
The edge from a masked region
can then be profiled.
Etch rate characterisation
Etch depth easily quantified under
these conditions over distances of
around 100 μm from the mask
interface.
Etch rate characterisation
Etch depth easily quantified
using focus variation optical
profilommetry
Etch rate characterisation
Etch rate characterisation
Phase selectivity
3V
𝛄' selective
Ni based superalloys are micro
phase-segregated materials.
A γ' phase of blocks separated by
a lattice of refractory rich γ phase.
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Phase selectivity
Electropolishing in ionic liquids etches the γ' phase faster than the γ
lattice.
This is also true of the aqueous phosphoric acid electrolytes.
Chemical etches, FeCl3 and nitric / sulphuric acids, etch in the opposite
sense.
Phase selectivity
6V
𝛄 selective
3V
𝛄' selective
Phase selectivity
6V
𝛄 selective
CMSX10 at 4V, heat treated
3V
𝛄' selective
Phase selectivity
6V
𝛄 selective
CMSX10 at 4V, heat treated
3V
𝛄' selective
CMSX4 at 4V, as cast
Alloy composition and metallurgy
Electropolishing as-cast turbine blades
Fully immersed , polished blade
60 mins, total process time.
Eapp < 6 V
Incipient melting
No evidence of incipient melting in
polished region where scale was
removed.
Partially polished Trent 500 IP
Batch trials
HIP Castings
HIP Castings
Powder granulation exposed by electropolish.
HIP Castings
Elemental content of Fe and Ni determined
by EDAX as a function of etch depth.
Stainless rapid prototyping
Laser ablated (top)
End electropolished (bottom)
Stainless rapid prototyping
Stainless rapid prototyping
Conclusions
Electropolishing of superalloy turbine blades in DES type
(choline chloride based) ionic liquids:
• Effective in removing Ni-based surface scale
• Effective in removing residual shell
• Homogeneous dissolution of metal
• Isotropic etching (semi-quantitative XPS)
• Reducing surface roughness
• High volume etching for HIP components
• Surface finish improvement for rapid prototypes (3D printing)
“Electrolytic Processing of Super-alloy
Aerospace Castings using Choline chloridebased Ionic Liquids", A.P. Abbott, N. Dsouza, P.
Withey and K.S. Ryder, Trans. IMF, 2012, 90(1),
Visualising grain structure possible prior to heat treatment using
electrolytic etch. This has the potential to save process time and
reduce production costs.
“Mechanism for Formation of Surface Scale
During Directional Solidification of N-Based
Superalloys”, H. Dong, N. D'Souza, G.
Brewster and K.S. Ryder, Metallurgical &
Materials Trans A, 2012, 43, 1288.
9.
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