ARL Laser Processing Open House
Transcription
ARL Laser Processing Open House
Newsletter 2 0 1 1 No. 3 iMAST Institute for Manufacturing and Sustainment Technologies IN THIS ISSUE Feature Article Focus on Manufacturing Systems Preservation of 688 Class Normal Fuel Oil Tanks Program Update Calendar of Events ADMINISTRATOR’S CORNER I’m stepping in for Tim Bair this iteration as he enjoys some well-earned vacation time, in addition to business travel commitments that are keeping him on the road. The past couple of months have been both busy and eventful for iMAST, as you’ll see in the “Institute Notes” section of this newsletter. We Gregory J. Johnson have just completed a comprehensive program review as part of a visit by the Joint Defense Manufacturing Technology Panel (JDMTP). We are now turning our focus towards our primary event which is the annual Defense Manufacturing Conference (DMC), which will be held in Anaheim, California (28 November through 1 December). If you have not had a previous opportunity to attend this event, I think you will find it worth visiting, especially if you are located on the west coast. For more information visit <http://dmc2011.com/>. ARL Laser Processing Open House The Applied Research Laboratory’s Laser Processing Division, a premier U.S. Navy sponsored leading-edge applied laser research laboratory, will host an Open House 12 October 2011 in State College, PA on Penn State’s University Park campus. This event will provide an opportunity to showcase the newly renovated laser processing facility, in addition to providing a forum on recent advances in laser processing technologies. The event will include optional tutorial sessions on laser material processing, presentations highlighting the development and application of advanced laser processing technology, as well as tours and demonstrations, which will include laser deposition for additive manufacturing and portable repair, hybrid laser arc welding, and micro-processing. Ms. Agnes Klucha, an engineer at Pratt & Whitney’s Engineering Integrated Solutions Group, will be a keynote speaker addressing Additive Manufacturing. The Open House will be followed by a meeting of the Mid-Atlantic Chapter of the Laser Institute of America (LIA). LIA is an international professional society chartered to foster laser safety and applications world-wide. Industry leaders present fundamental perspectives on ultra-short laser processing, advances in beam delivery optics, as well as laser technologies in the photovoltaic industry. For more information on the Open House please visit <http://www.arl.psu.edu/ laserprocessing.htm> or contact Dr. Rich Martukanitz at (814) 863-7282, or by e-mail at <rxm44@arl.psu.edu>. If laser technologies are important to you, then you will not want to miss these two events! Continued on Page 2 A U.S. Navy Manufacturing Technology Center of Excellence Dist rib ution Statem en t A : App rove d f o r p u bl i c re l e a se ; d i s t r i b ut i o n un li m i t ed . 2 0 1 1 No. 3 i MA S T Ne ws let t er 1 ADMINISTRATOR’S CORNER Applied Research Laboratory Institute for Manufacturing and Sustainment Technologies DIRECTOR, iMAST & NAVY/MARINE CORPS REPAIR TECHNOLOGIES Timothy D. Bair (814) 863-3880 tdb14@arl.psu.edu MATERIALS PROCESSING TECHNOLOGIES Timothy J. Eden, Ph.D. (814) 865-5880 tje1@arl.psu.edu LASER PROCESSING TECHNOLOGIES Richard P. Martukanitz, Ph.D. (814) 863-7282 rxm44@arl.psu.edu COMPOSITES MATERIALS TECHNOLOGIES Kevin L. Koudela, Ph.D. (814) 863-4351 klk121@arl.psu.edu MANUFACTURING SYSTEMS TECHNOLOGIES Mark T. Traband, Ph.D. (814) 865-3608 mtt1@arl.psu.edu SYSTEMS OPERATIONS AND AUTOMATION/ COMPLEX SYSTEMS MONITORING Eddie C. Crow (814) 863-9887 ecc1@arl.psu.edu DRIVETRAIN TECHNOLOGIES Suren Rao, Ph.D. (814) 865-3537 sbr1@arl.psu.edu iMAST ADMINISTRATION and EDITOR Gregory J. Johnson (814) 865-8207 gjj1@arl.psu.edu RESEARCH COORDINATOR Brenda E. Kephart (814) 865-3264 bew3@arl.psu.edu As was mentioned in the last newsletter, we are gravitating towards the electronic medium. Although we will maintain hard copies for those who prefer it (for various understandable reasons), we encourage you to enter the cyberspace arena. Doing so will cut expenses and provide a more efficient and timely means of communicating our activities to you. If you interested in supporting this transition, please send a note to Ms. Brenda Kephart <bew3@psu.edu> noting “Add me to Electronic iMAST Newsletter” or “Keep me on Hard Copy iMAST Newsletter” Please be sure your name and company are noted in order to help us update our master files. If we do not hear from you we will assume that those of you on the hard copy mailing list are no longer interested in receiving our newsletter. Accordingly, you will be deleted. Challenging fiscal times demand we exploit the electronic medium to the maximum extent possible. We will indeed continue to send you hard copy version of the newsletter, but you need to request it. Also be mindful that all of our current and previous newsletters, and annual reports, are posted on our web site <www. arl.psu.edu> (search “iMAST Newsletters”). To this end, we are doing our best to serve you while continuing to make sure iMAST remains an all-around cost-effective resource for the U.S. Navy and the DoD. In this issue our feature article addresses an (understandably) overlooked challenge facing the Navy. Maintenance and repair of shipboard tanks and voids presents huge costs to the Navy. Our feature article discusses the innovative efforts Mr. Charles Tricou is using to address the current challenges fuel tanks (in particular) present the Navy. Mr. Tricou is well known and respected throughout the naval service maintenance and repair community. Navy and Marine Corps operations and service (O&S) costs are significant. Viable repair solutions contribute to an on-going emphasis on Reduced Total Ownership Costs (RTOC). Every viable repair technology solution iMAST is able to contribute brings a high return on the investment (ROI) to the Navy-Marine Corps Team’s O&S bottom line. Please contact Mr. Tricou if you have any questions or issues related to his current activity or related subject matters. As I look at the calendar I am amazed at how fast time seems to be flying by. Don’t forget to consider our upcoming Laser Processing Open House event, noted on our cover page, as well as the DMC event in late November. Also, please don’t hesitate to contact Tim Bair if you have any questions or issues you’d like to discuss with him. You are also welcome to contact our principal project investigators (PIs) directly. Greg Johnson WORLD WIDE WEB www.arl.psu.edu/capabilities/mm_imast.html NAVY PROGRAM MANAGER Greg Woods (703) 696-4788 gregory.woods1@navy.mil ©2011. The iMAST quarterly newsletter is published by the Institute for Manufacturing and Sustainment Technologies of the Applied Research Laboratory at Penn State, University Park, Pa. iMAST is sponsored by the U.S. Navy Manufacturing Technology (ManTech) Program, Office of Naval Research, under Navy Contract N00024-02-D-6604. Any opinions, findings, conclusions, or recommendations expressed within are those of the authors and do not necessarily reflect the views of the U.S. Navy. Send mail list requests or address corrections to: iMAST Administrator, ARL Penn State, P.O. Box 30, State College, PA 16804-0030 or e-mail: bew3@arl.psu.edu. Parcel delivery address (UPS, FedEx, USPS): N. Atherton St. Rear; Research Building West, State College, PA 16804 PROFILE Charles Tricou is an Associate Research Engineer at ARL Penn State. Mr. Tricou manages projects involving paint application and removal for maintenance and repair of DoD assets, and new construction in shipbuilding. His current projects include development of high transfer efficiency painting processes, development of long-life nonskid flight deck coating systems, and UHP waterjet surface preparation and cleaning equipment. Mr. Tricou earned a B.S. in engineering science and mechanics, and an M.S. in theoretical and applied mechanics at the University of Illinois at UrbanaChampaign, where he studied material design and analysis, with a minor in computer applications. Mr. Tricou can be reached at (814) 863-4459, or by e-mail at <cst101@arl.psu.edu>. This publication can be made available in alternative media on request. Penn State is committed to affirmative action, equal opportunity and the diversity of its workforce. U.Ed. ARL 12-1 2 2011 No.3 i M A S T Ne w sl e t t e r MATERIALS PROCESSING TECHNOLOGIES MECHANICAL DRIVE TRANSMISSION TECHNOLOGIES LASER PROCESSING TECHNOLOGIES COMPLEX SYSTEMS MONITORING TECHNOLOGIES COMPOSITES MATERIALS TECHNOLOGIES NAVY/MARINE CORPS REPAIR TECHNOLOGIES MANUFACTURING SYSTEMS TECHNOLOGIES FEATURE ARTICLE Focus on Manufacturing Systems Preservation of 688 Class Normal Fuel Oil (NFO) Tanks by Charles Tricou Maintenance and repair of shipboard tanks is among the top 5 largest corrosion-related costs for Navy Ships. Based on FY 2007 data1,the maintenance cost of ballast tanks in Navy ships is $376M per year, of which $240M is attributed to repair of corrosion damage. This represents the third highest cost to the Navy by Expanded Ships Work Breakdown Structure (ESWBS), for both maintenance and repair of corrosion damage. Hydrocarbon contamination and/or the presence of soluble salts are the primary causes of premature coating failure in these tanks. Ultra-high pressure (UHP) water-jetting (water-jet blasting at 36,000 psi and above) has proven to be an effective method for removing old coatings and surface contamination. Any type of work in these confined spaces is difficult, but the use of UHP waterjet tools in such spaces is downright dangerous. To address the safety concerns associated with UHP cleaning in confined spaces, the UHP waterjet tools would need to be contained. The primary goal of this Navy ManTech program effort was to use closed-cycle ultrahigh pressure water jet cleaning to remove hydrocarbon contamination from 688 Class NFO tank surfaces, with the secondary goal of achieving a “Light Flash Rust” condition (or lower). The presence of stiffeners and other complicated geometries within the NFO tank provided a substantial challenge. Specialized tooling was needed to ensure complete coverage and efficient vacuum collection. With support from the ONR Technology Insertion Program for Savings (TIPS), iMAST-ARL has developed closed-cycle UHP waterjet cleaning tools for removing oil and grease within Normal Fuel Oil (NFO) tanks on 688 class submarines. NFO tanks contain the diesel fuel used to power backup systems on Los Angeles Class submarines. Diesel fuel is consumed as these backup systems are periodically tested, and the NFO tank is compensated with seawater to maintain the tank at a full level. Seawater lying in the bottom portion of unpainted NFO tanks results in extensive corrosion damage. To reduce the recurring cost of corrosionrelated repairs in NFO tanks, a method of cleaning the steel is necessary to enable these tanks to be painted. require extensive weld-repair, and abrasive blasting of weld-repairs is required to ensure proper adhesion of preservation coatings to the repaired areas. For this reason the requirement to achieve a “Light Flash Rust” condition was understood to be of lower importance than ensuring all hydrocarbon contamination was removed during cleaning. Mechanical methods of surface preparation such as abrasive blast cleaning do not remove oil and grease contamination and may even spread the contamination or embed it into the substrate. An important property of the UHP water jet blasting process is that it can emulsify and remove oil and grease from a surface as it is blasted. One drawback of open-cycle UHP blasting, however, is the formation of flash-rust. Flash rust is quantified using the SSPC‑VIS 4 / NACE VIS 7 Guide and Reference Photographs for Steel Surfaces Prepared by Waterjetting. APPROACH / TOOL INFORMATION The following closed-cycle UHP cleaning tools were designed and fabricated by ARL. All tools incorporate vacuum collection to minimize formation of flash rust. • Vertical T-bar stiffener cleaning tool • 90° corner cleaning tool • Tool for cleaning the pockets within the 688 NFO tank • Compact flat-surface cleaning tool designed for bulkhead cleaning • Compact flat-surface cleaning tool designed for cleaning decks or other horizontal surfaces • Multi-purpose hand-held gun with multiple end-effectors designed for In the case of unpainted NFO tanks, corrosion damage in the seawater-affected area can 2 0 1 1 No. 3 i MA S T Ne ws let t er 3 FEATURE ARTICLE Continued from Page 3 cleaning small areas and for detail work around stiffeners or other encumbrances. All tools incorporate an “electronic-over-air” safety system. Electronic proximity sensors ensure the tools are in close proximity to, and pointing directly at the steel, before the tools will operate. Several tools may be used simultaneously at different locations within the tank and the safety system allows insertion of multiple emergency-shutoff switches (E-stops) with E-stop indicator lights showing which shutoff has been triggered. These multiple E-stop switches provide the ability for hole-watch personnel, assistants or operators to shut down UHP waterjet flow if an unsafe situation arises. In the interest of brevity, only one of the tools will be described in detail. VERTICAL T-BAR STIFFENER CLEANING TOOL The vertical T-bar cleaning tool can be operated at 40,000 psi, and is capable of removing coatings, fuel-oil residue and corrosion products from all surfaces of the vertical T-bar. Placement and installation requires ~ 5-10 minutes per move. The vertical T-bar tool incorporates magnets to aid in installation and to maintain position during operation. Vacuum recovery occurs at the bottom of the containment shroud. Process water, corrosion products and paint are collected to a holding tank. Water is tested prior to disposal to ensure compliance with environmental regulations. An electronic proximity sensor is employed to ensure the waterjet does not function unless the containment is tight against the work surface. The vertical T-bar tool incorporates a deadman type switch and control box. The vertical T-bar tool will fit through a 15½” diameter access hole. The vertical T-bar tool (and all other tools) can be operated at a distance of approximately 300 feet from the pump. The vertical T-bar tool is shown in Figure 1. As part of this project, ARL Penn State was tasked with ensuring that UHP cleaning does, in fact, remove all NFO and milPRF-3150 lube oil from the steel. To this end, ARL Penn State developed improved visual inspection equipment. Currently, the 4 2011 No.3 i M A S T Ne w sl e t t e r Figure 1. Modular track based tee bar tool. (A) shown installed in training structure, (B) CAD image of structure in comparable orientation, (C) CAD image of work area of tool showing UHP work head installed to clean inside web of tee bar only non-destructive method of detecting hydrocarbon contamination on steel surfaces is visual inspection using black-lights. Black lights produce Ultra Violet (UV) light in the range of 365nm. Hydrocarbon compounds fluoresce under UV light. If the fluorescent response is both efficient, and if it occurs in the human visible wavelength range, then black-lights will improve the sensitivity of visual inspection methods. This enhanced visual inspection equipment was field-tested at the Portsmouth Naval Shipyard during the UHP water jet technology demonstration. The NFO tank was inspected following gas-free cleaning and prior to UHP waterjet blasting. When the tank was viewed through the enhanced eyewear using 465nm inspection light, a faint orange glow was present on all surfaces. Contrast was poor, but a definite fluorescent response was observed. Areas cleaned with water jet tools indicated no detectable fluorescence. Water-break and solvent extraction was used to verify contamination removal. Water-break testing of all surfaces prior to UHP cleaning exhibited strong water beading. Knowledge and understanding of the spectral properties of common hydrocarbon contaminants can inform knowledge-based design of inspection lights and eyewear. Using such enhanced inspection equipment, substantial improvements in the detection sensitivity and efficiency of visual inspection methods is possible. The enhanced inspection equipment discussed in this document has been shown to dramatically improve contrast between diesel fuel-oil contaminants and blasted steel surfaces. The order-ofmagnitude improvement in contrast results in dramatically improved detection efficiency, at greater standoff distances, than is possible using the best currently available inspection equipment and techniques. COST-BENEFIT ANALYSES A cost-benefit analysis was based primarily upon eliminating corrosion damage (and corresponding repair costs) and on extending the repair interval from 10 years to 15 years. A conservative, 15 year coating life was assumed for the purpose of this cost-benefit analysis. Actual coating life is expected to last 20–30 years. Cost avoidance expected from using UHP water jet cleaning technology for NFO tank repair has been calculated based upon data FEATURE ARTICLE ACKNOWLEDGEMENT The author wishes to express appreciation for support of this effort by NAVSEA 07T, ONR TIPS and the Institute for Manufacturing and Sustainment Technologies (iMAST), a U.S. Navy Center of Excellence sponsored under contract by the U.S. Navy Manufacturing Technology Program, Office of Naval Research. Any opinions, findings, conclusions and recommendations expressed in this material are those of the author and do not necessarily reflect the views of the United States Navy. REFERENCES 1 Logistics Management Institute MEC81T3 report “The Annual Cost of Corrosion for Navy Ships” dtd 2006–2007. Post-abrasive blast photo of tank. Top coat application. Application of primer and stripe coat. provided by shipyard and NAVSEA personnel. Robust and conservative assumptions have been made where required. • Based upon information gleaned during the 2010 shipboard demonstration at PNS, there are several areas in which the use of closed-cycle UHP cleaning and application of preservation coatings within NFO tanks can save money. These are: • Reduction of weld-repairs • Unpainted tanks @ 10 years • • • OEM-painted tanks @ 30 years Elimination of abrasive blast • Painted tanks (before substantial coating breakdown occurs) Surface preparation cost reduction (UHP vs. abrasive blasting) Elimination of 99 month inspections Based upon the limited data available, a conservative estimate of cost savings (per each 688 Class submarine) is $814K. 2 0 1 1 No. 3 i MA ST New s le t t e r 5 PROGRAM UPDATE Damage Accumulation of MRAP Under Impulse and Cyclic Loading Conditions iMAST is currently wrapping up a project in support of the Mine Resistant Ambush Protected (MRAP) combat vehicle program office. Damage accumulation due to impulse and cyclic loading has been identified as a source of desired information for providing a quantitative description of decreased structural integrity due to the potential for crack initiation and propagation. This will assure the capability of the MRAP platform to defeat stated threats. Benefits of this analysis will include the understanding of impacts of alterations to field repair procedures, determination of field reparability of critical components, and initial representation of mission readiness based on various damage accumulation scenarios. A sound assessment of structural integrity and survivability of MRAPs after field use, theater events, and forward repairs will benefit the vehicle by providing insight addressing the impact of alterations to field repair procedures, determination of field reparability of critical components, and initial 6 2011 No.3 i M A S T Ne w sl e t t e r representation of mission readiness based on various damage accumulation scenarios. Potential benefits include alterations to field repair procedures, determination of field reparability of critical components, initial representation of mission readiness based on various damage accumulation scenarios, and future depot sustainment strategies. For more information on this program effort, contact Dr. Rich Martukanitz at 814-863-7282, or by e-mail at: <rxm44@arl.psu.edu>. INSTITUTE NOTES JDMTP Subpanel Visit Members of the subpanel receive brief on Spark Plasma Sintering Process. Members of the Joint Defense Manufacturing Technology Panel (JDMTP) recently visited ARL Penn State to conduct its annual review of iMAST program efforts. The JDMTP, composed of Army, Navy, Air Force and DLA ManTech leaders, is chartered to identify and integrate requirements, conduct joint program planning, and develop joint strategies. The FY-2010 National Defense Authorization Act (NDAA) gives permanent authority for the JDMTP. The primary mechanism which supports the panel efforts are the JDMTP subpanels. All projects funded by DoD ManTech programs are coordinated through the JDMTP and its subpanels. Each of the four subpanels review the projects within their respective technology portfolios in order to identify opportunities for collaboration, and provides input to the panel on opportunities for future investment areas. All of the chairmen of each subpanel meet regularly to coordinate on projects which cross traditional subpanel boundaries and enhance subpanel processes to increase efficiency and effectiveness in achieving the ManTech mission. FAST Workshop Concludes Dr. Edward Liszka (Director, ARL Penn State) presents Mr. John Carney (Director, ONR Navy ManTech Program) with a memento commemorating his support of and participation in the FAST Workshop. Over 100 conference attendees turned out recently to attend iMAST’s Field-Assisted Sintering Technology workshop at Penn State University. Also known as Spark Plasma Sintering, the technology is an emerging manufacturing technology that produces cost-effective components with enhanced performance and durability characteristics. The workshop provided an opportunity to close the gap between applied research, end users and equipment manufacturers. Special guest speakers for the event included Mr. Robert Dowding (Director of Research Directions and SPS Activities, U.S. Army Research Laboratory), Dr. Michael Kassner (Director of Research, Office of Naval Research), and Mr. John Carney (Director of the U.S. Navy Manufacturing Technology Program, Office of Naval Research). For more information about the event, you are welcome to contact Dr. Jogender Singh at (814) 863-9898, or by e-mail at <jxs46@psu.edu>. NAVAIR Visits iMAST Dr. Suren Rao (right), Director of ARL’s Drivetrain Technology Center, explains iMAST Ausform Finishing program effort with Mr. Michael Houck (center), while Mr. Darrell Grant (left) looks on. Mr. Michael Houck and Mr. Darrell Grant visited iMAST recently as part of a capabilities review of iMAST assets that can support Naval Air activities. Mr. Houck is the division director of NAVAIR 4.4.2 (Mechanical Systems, Controls and Diagnostics). Mr. Grant is currently serving as a NAVAIR Fellow. Following a series of power train-related and healthcare monitoring presentations, the visitors were escorted on a tour of facilities by iMAST’s director of drivetrain technologies, Dr. Suren Rao. The tour included laser, drivetrain, and composite material enhancements to mechanical drive systems. Following the iMAST tour, Mr. Houck and Grant visited Penn State’s Vertical Lift Research Center of Excellent, within Penn State’s College of Engineering. For more information on iMAST’s powertrain-related activities, contact Dr. Suren Rao at (814) 865-3537, or by e-mail at <sbr1@psu.edu>. U.S. Army Chief Scientist Visits iMAST Pausing during facilities tours for a group photo are (l-r) Dr. Tom Donnellan (ARL Associate Director for Materials and Manufacturing), LTC Amanda Grieg, Dr. Fish, Dr Kevin Koudela (ARL Composites Director), Dr. Patricia Gruber (ARL Deputy Director) Dr. Scott Fish, Chief Scientist of the U.S. Army, recently visited iMAST facilities as part of a capabilities assessment overview associated with his role as Chief Scientist. As Chief Scientist of the Army, Dr. Fish identifies and analyzes technical issues and brings them to the attention of Army Leaders. He also interacts with operational commanders, combatant commands, acquisition, and science and technology communities to address cross-organizational technical issues and solutions. Dr. Fish, also interacts with other services and the Office of the Secretary of Defense through the Army’s Deputy Assistant Secretary for Research and Technology. This interaction includes addressing issues affecting the Army in-house technical enterprise. The Chief Scientist of the Army is also the principal science and technology representative of the Army to the civilian scientific and engineering community, and to the public at large. 2 0 1 1 No. 3 i MA S T Ne ws let t er 7 U.S. Postage PAID State College, PA Permit No. 1 Applied Research Laboratory P.O. Box 30 State College, PA 16804–0030 CHANGE SERVICE REQUESTED “Whether you think you can, or whether you think you can’t, you’re right!” —Henry Ford CALENDAR of EVENTS 2011 27–29 Sep Modern Day Marine Expo ** Quantico, VA 28–29 Sep Materials & Manufacturing Advisory Board Meeting (Aviation) State College, PA 10–12 Oct AUSA Expo Washington D.C. 11–14 Oct Logistics Officer Association Conference ** Ft. Worth, TX 24–27 Oct Expeditionary Warfare Conference Panama City, FL 2–4 Nov U.S. Coast Guard Innovation Expo Tampa, FL 14–17 Nov DoD Maintenance Conference ** Ft. Worth, TX 28 Nov–1 Dec DMC 2011 ** Anaheim, CA 2012 Jan TBA Surface Navy Association Symposium ** Crystal City, VA Apr TBA ShipTech 2012 15–18 Apr Navy League Sea-Air-Space Expo 19–20 Apr “Made in Pennsylvania” 1–3 May 68th American Helicopter Society Forum ** Ft. Worth, TX Jun TBA Johnstown Showcase for Commerce ** Johnstown, PA Jun TBA Letterkenny Showcase for Commerce 12–14 Jun MegaRust 2012 (U.S. Navy Corrosion Control Conference) 18–19 Sep Fleet Maintenance & Modernization Symposium 22–24 Oct ONR S&T Conference ** TBA ** National Harbor, MD ** Kittanning, PA ** Chambersburg, PA San Diego, CA ** Virginia Beach, VA ** Crystal City, VA ** Visit iMAST booth 8 2011 No.3 i M A S T Ne w sl e t t e r