Integrated In-process Strategy for Material and Process Specification Optimization

ABSTRACT: The thermal spray process has many inherent complexities within each sub-process including feedstock manufacturing, component surface preparation and masking, torch parameter selection, robot trajectory and laboratory coating evaluation. Each sub-process is governed by rigid specifications that provide thermal spray applicators with procedural and process guidelines throughout the application. Current aerospace thermal spray specifications are not adequate to capture many nuances in feedstock procurement and process management. This allows non-optimal, yet conforming materials and processes to be used during overhaul and repair yielding unsatisfactory outcomes in some instances especially in cost and productivity. ReliaCoat Technologies, a small business specializing in advanced thermal spray concepts, will perform a detailed analysis of present coating specifications to determine the most critical areas of the process which are prone to variability in spite of operating within specifications. ReliaCoat"s strategy aims to improve these specifications from within: i.e. operate the materials and processes within the scope of the specifications but introduce robustness through in-process gates and appropriate knowledge management tools to shrink variability and tighten distribution. This will allow cognizant engineers to benefit from the outcome without moving away from decades of experience base, while process engineers will be able to use tools to improve productivity. BENEFIT: The benefits anticipated by investigating and implementing modified coating specifications include the following; reduction of laboratory test frequency, reduction of time required for qualification by minimizing process variability, increasing throughput of parts coated and minimizing the amount of rework, together providing higher productivity and enabling high velocity maintenance scenarios. The in-process gates will provide a deeper insight into thermal spray processing, enhancing the operator"s understanding of process variables. ReliaCoat is aiming to provide integrated process management solutions to the thermal spray industry via expert knowledge in materials science and process engineering into ruggedized yet readily adaptable industrial tools with user friendly software.