Development of Novel Cooling and Temperature Monitoring for High Velocity Oxygen Fuel (HVOF) Coating Applications

Award Information
Agency: Department of Defense
Branch: Air Force
Contract: FA8501-13-C-0033
Agency Tracking Number: F073-121-0230a
Amount: $1,180,329.00
Phase: Phase II
Program: SBIR
Awards Year: 2013
Solicitation Year: 2007
Solicitation Topic Code: AF073-121
Solicitation Number: 2007.2
Small Business Information
(ES3) Engineering & Software System Solu
550 West C Street, Suite 1630, San Diego, CA, -
DUNS: 127283500
HUBZone Owned: N
Woman Owned: Y
Socially and Economically Disadvantaged: N
Principal Investigator
 Jay Randolph
 Director, SE Operations
 (478) 957-1278
 jay.randolph@es3inc.com
Business Contact
 Doug Wiser
Title: COO
Phone: (801) 298-2769
Email: doug.wiser@es3inc.com
Research Institution
N/A
Abstract
ABSTRACT: Temperature control has been a major concern during High Velocity Oxygen Fuel (HVOF) processing since its introduction to the aerospace industry. Typically, substrate temperature must not exceed 300oF to prevent heat damage/ tempering of steel alloys, and even lower temperature requirements for aluminum and titanium alloys. Shop air cooling, most common temperature control, has proven to be inadequate for controlling substrate temperatures during many HVOF applications. As a result, longer off-part dwell times are required to allow for component cooling that results in significant cost due to powder and gas consumptions. Traditionally temperature measuring control has been a continuous single infrared point location on the component being sprayed. Consequently, temperature variations across the component causes inaccuracies. Phase I and II of this effort matured the ES3 novel cooling and temperature monitoring system on 6Al-4V Ti substrate to a TRL 7 by evaluating the system"s affect on fatigue and coating integrity characteristics; including Demostration/Validation testing on a C-5 slat track proving its overall effectiveness for future implementation. Phase II.5 will focus on additional qualification testing on 4340 steel and Inc718 substrates, and develop a technical data package for engineering evaluation for implementation, maturing the overall process to a TRL 8. BENEFIT: ES3 anticipates the results of Phase II.5 work will qualify and validate the usage of the ES3 novel cooling and temperature monitoring system for typical alloys utilized on aircraft components qualified for HVOF coating application. ES3 anticipates the following benefits from Phase II testing: A novel cooling process for HVOF coating applications Specifications for a Multi-location Temperature Monitoring System Eliminate extended off-part dwell time for cooling Reduce process time Reduce powder and fuel costs Environmentally friendly process

* information listed above is at the time of submission.

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