COMMERCIAL ENGINE STANDARD PRACTICES MANUAL

	COMMERCIAL ENGINE STANDARD PRACTICES MANUAL	Dated: 11/10/2020
	SPM 70-70-00 TESTING AND QUALITY ANALYSIS

TASK 70-70-00-700-001

1 .

General.

This procedure consists of a series of operations. Test specimens and special tools or fixtures required in the performance of specific tasks are described in the procedures that make use of them.

2 .

Thermal Spray Coating Quality Tests.

Subtask 70-70-00-700-011

Types of Tests.

All thermal spray deposits shall be visually checked for complete coverage, uniform structure, freedom from cracks, voids, spalling, chipping, flaking, or other indications of poor adhesion. The quality of the thermal spray deposit shall be tested, as shown in Table 1, by the following methods:

(1)

Wire brush test.

The technical requirement for this test has been deleted. It no longer needs to be performed even when specified in the Engine/Shop Manual.

(2)

Bend test. Refer to TASK 70-71-08-700-014, Bend Test.

The technical requirement for this test has been deleted. It no longer needs to be performed even when specified in the Engine/Shop Manual.

(3)

Tensile bond test. Refer to TASK 70-71-01-700-002, Bond Strength Tensile Testing of Thermal Spray Coatings.

The tensile bond test is performed using pull test buttons or adapters in a tensile testing machine to check adherence of the thermal spray coating. A minimum of three tests shall be performed for each part. The material used for test specimens/adapters shall be either same as parts they represent or as stated in Table 2 below.

(4)

Lap shear bond test. Refer to TASK 70-71-02-700-003, Bond Strength Lap-Shear Testing of Thermal Spray Coatings.

The lap shear bond test is performed using a three-piece set of test panels in a tensile testing machine to check the adherence of the thermal spray coating. The material used for test specimens shall be either same as parts they represent or as stated in Table 2 below. Two pieces of each three-piece set are sprayed for a length of 0.50 inch (12.7 mm) along with the production part, and a minimum of three sets must be sprayed in conjunction with each part.

(5)

Scratch hardness test. Refer to TASK 70-71-03-700-004, Scratch-Hardness Testing of Thermal Spray Coatings.

The scratch hardness test is performed using a test panel sprayed in conjunction with the production part. Refer to TASK 70-71-03-700-004, Scratch-Hardness Testing of Thermal Spray Coatings to see test material requirement.

(6)

Metallographic examination. Refer to TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings.

A test panel which shall be either same as parts they represent or as stated in Table 2 below or scrap part, sprayed in conjunction with the production part, is sectioned, polished, and examined microscopically.

(7)

Rockwell hardness test.

This test is usually performed on a small coupon which shall be either same as parts they represent or as stated in Table 2 below, sprayed with the part and sometimes on the same coupon used for metallography. The hardness of the coating is determined in accordance with TASK 70-34-03-220-009, Rockwell Hardness Testing.

(8)

Vickers (microhardness) test.

This test is performed on a mounted cross-section of coupon which shall be either same as parts they represent or as stated in Table 2 and the same sample prepared for the metallographic evaluation can be used. The hardness of the coating is determined in accordance with TASK 70-34-02-220-008, Vickers Hardness Testing.

Frequency of Testing.

(1)

After the initial coating qualification, part quality testing should begin with evaluation of all test coupons (at 100% frequency) as required by:

(a)

The specific Engine/Shop Manual Repair,

(b)

The specific thermal spray procedure [for example, TASK 70-49-10-340-011, Thermal Spraying Nickel-Aluminum (Powder)],

(c)

The general thermal spray requirements in TASK 70-49-00-340-001, Thermal Spraying,

(d)

The specific testing procedures (for example, TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings), and

(e)

The general testing requirements in TASK 70-70-00-700-001, Testing and Quality Analysis.

(2)

As spraying continues, passing data should be gathered and analyzed by an acceptable statistical process control (SPC) system. The frequency of testing may then be reduced (or the time intervals between quality control testing increased) based on the statistical analysis if consistent results are obtained. The frequency intervals should all be based on requirements documented in the repair shop's internal Quality Assurance System.

3 .

Metal-To-Metal, Film Adhesive Bonding Quality Tests.

Subtask 70-70-00-700-012

NOTE:

Test procedure adhesive evaluations can now be found in TASK 70-70-01-700-001, Testing and Quality Analysis of Metal-to-Metal Bonding.

Test Requirements for Thermal Spray Coating - Table 1

Coatings

Coating Procedure

Tensile Bond per 70-71-01 psi (MPa)

Metallo-graphic Exam per 70-71-04

Hard-ness

Aluminum, Pure

70-49-01 (powder)

(also see 70-49-23 and 70-49-40)

1200 (8.3)

Alumina

70-49-02 (powder)

1000 (6.9)

Chromium Carbide

70-49-03 (powder)

3000 (20.7)

Note 1

Copper-Nickel

70-49-04 (powder)

2900 (20.0)

Copper-Nickel-Indium

70-49-05 (powder)

(also see 70-49-49)

2000 (13.8)

Magnesium

70-49-06 (powder)

Molybdenum

70-49-07 (powder)

(also see 70-49-08 and 70-49-51)

2500 (17.2)

Molybdenum

70-49-08 (wire)

(also see 70-49-07 and 70-49-51)

2500 (17.2)

Nickel-Aluminide

70-49-09 (powder)

2500 (17.2)

Nickel-Aluminum

70-49-10 (powder)

(also see 70-49-11 and 70-49-38)

4000/5000 (27.6/34.5)

Nickel-Aluminum

70-49-11 (wire)

(also see 70-49-10 and 70-49-38)

4000/5000 (27.6/34.5)

Nickel-Chromium

70-49-12 (powder)

Nickel-Chromium

70-49-13 (wire)

Nickel-Graphite (75:25)

70-49-14 (powder)

750 (5.2)

Note 2

Nickel-Graphite (85:15)

70-49-15 (powder)

1200-3000 (8.3-20.7)

Note 3

Nickel-Silicon-Boron

70-49-16 (powder)

5500 (37.9)

Silver Alloy (Cu-Zn-Ag)

70-49-17 (wire)

(also see 70-49-44)

3000 (20.7)

50% Tungsten Carbide

70-49-18 (powder)

5500 (37.9)

Note 1

Tungsten Carbide-Cobalt

70-49-19 (powder)

(also see 70-49-28)

5500 (37.9)

Note 1

Chromium Carbide No. 1 Composite

70-49-20 (powder)

Nickel-Chromium/Aluminum Composite

70-49-21 (powder)

(also see 70-49-39)

4000-5000 (27.6-34.5)

Alumina/Nickel-Aluminum (55:45)

70-49-22 (powder)

2000 (13.8)

Aluminum, Pure

70-49-23 (wire)

(also see 70-49-01 and 70-49-40)

1200 (8.3)

75% Tungsten Carbide

70-49-24 (powder)

Note 1

Aluminum-Bronze

70-49-25 (powder)

(also see 70-49-26 and 70-49-52)

2000 (13.8)

Aluminum-Bronze

70-49-26 (wire)

(also see 70-49-25 and 70-49-52)

2000 (13.8)

Tribaloy 400 (CoMoCrSi)

70-49-27 (powder)

3100 (21.4)

Note 4

Tungsten Carbide-Cobalt

70-49-28 (powder)

(also see 70-49-19)

5500 (37.9)

Note 1

Chromium Carbide-Nickel Chromium

70-49-29A (powder)

5000 (34.5)

Note 1

70-49-29B (powder)

5000 (34.5)

Note 5

Tribaloy 800 (CoMoCrSi)

70-49-30

(powder)

4000 (27.6)

Note 6

Nickel Aluminum-Molybdenum Composite

70-49-31 (powder)

2500 (17.2)

Inconel 718

70-49-32 (powder)

(also see 70-49-45)

7000 (48.3)

Alumina, fine

70-49-33 (powder)

4000 (27.6)

Aluminum-Silicon-Polyester

70-49-34 (powder)

800 (5.5)

Note 7

NiCrAlY

70-49-35 (powder)

4000 (27.6)

TBC

70-49-35 (powder)

Inconel 718 (HVOF)

70-49-36 (powder)

9000 (62.1)

Note 13

Tungsten Carbide-Cobalt (HVOF)

70-49-37 (powder)

10,000 (68.9)

Note 8

Nickel Aluminum, Electric Arc

70-49-38 (wire)

(also see 70-49-10 and 70-49-11)

4000/5000 (27.6/34.5)

Nickel Chrome Aluminum, Electric Arc

70-49-39 (wire)

(also see 70-49-21)

4000/(27.6/34.5)

Pure Aluminum, Electric Arc

70-49-40 (wire)

(also see 70-49-01 and 70-49-23)

1200 (8.3)

Tribaloy 800 (CoMoCrSi Powder) HVOF

70-49-43 (powder)

8500 (58.6)

Note 9

Copper Zinc Silver, Electric Arc

70-49-44 (wire)

(also see 70-49-17)

3000 (20.7)

Inco 718 Wire, Electric Arc

70-49-45 (wire)

(also see 70-49-32)

7000 (48.3)

Nickel Chrome Silicon Iron, HVOF

70-49-46 (powder)

10,000 (68.9)

Note 10

Aluminum Silicon Poly (Cold Process)

70-49-47 (powder)

800 (5.5)

Note 14

Tribaloy 800 (CoMoCrSi Powder) HVOF

70-49-48 (powder)

8500 (58.6)

Note 11

Cu-Ni-In Electric Arc

70-49-49 (wire)

(also see 70-49-05)

2000 (13.8)

Ren. 80 (HVOF)

70-49-50 (powder)

9000 (62.1)

Note 12

Molybdenum Electric Arc

70-49-51 (wire)

(also see 70-49-07 and 70-49-08)

2500 (17.2)

Al-Bronze Electric Arc

70-49-52 (wire)

(also see 70-49-25 and 70-49-26)

2000 (13.8)

Alumina/Ni-Al (powder)

70-49-53

None

1. Rockwell hardness test with Rockwell 15-N superficial hardness of 83 (ASTM E18)

NOTE:

2. Rockwell hardness test with Rockwell 15-Y hardness of 30-50 (ASME E18)

NOTE:

3. Rockwell hardness test with Rockwell 15-Y hardness of 50-70 (ASME E18)

NOTE:

4. Rockwell hardness test with Rockwell 15-N superficial hardness of 80 (ASTM E18)

NOTE:

5. Rockwell hardness test with Rockwell 15-N superficial hardness of 75 (ASTM E18)

NOTE:

6. Rockwell hardness test with Rockwell 15-N superficial hardness of 82 (ASTM 18)

NOTE:

7. Rockwell hardness test with Rockwell 15-Y hardness of 65-80 (ASTM E18)

NOTE:

8. Rockwell hardness test with Rockwell 15-N superficial hardness of 89 (ASTM E18) and a Vickers 300 gram load of 950-1200 (ASTM E384)

NOTE:

9. Rockwell hardness test with Rockwell 15-N superficial hardness of 89 (ASTM E18) and a Vickers 300 gram load hardness of 675 (ASTM E384)

NOTE:

10. Rockwell hardness test with Rockwell 15-N superficial hardness of 70 (ASTM E18) and a Vickers 300 gram load hardness of 675 (ASTM E384)

NOTE:

11. Rockwell hardness test with Rockwell 15-N superficial hardness of 83 (ASTM E18) and a Vickers 300 gram load hardness of 500 (ASTM E384)

NOTE:

12. Rockwell hardness test with Rockwell 15-N superficial hardness of 75 (ASTM E18) and a Vickers 300 gram load hardness of 400 (ASTM E384)

NOTE:

13. Rockwell hardness test with Rockwell 15-N superficial hardness of 79 (ASTM E18)

NOTE:

14. Rockwell hardness test with Rockwell 15-Y hardness of 55-80 (ASTM E18)

Test Specimen Material - Table 2

Part Material

Test Specimen Material

Specification Reference

Iron-base Alloys

410SS, 321

AMS 5504, AMS5613, AMS5510, AMS5645

Nickel-base and Cobalt-base Alloys

IN718, Hastelloy X

AMS 5596, AMS5662, AMS5663, AMS5536, AMS5754

Titanium-base Alloys

Ti-6Al-4V

AMS4911, AMS4928

Aluminum-base Alloys

6061-T6 Al

AMS4027, AMS4117, AMS4127, AMS4150, AMS4312

GE Designated: - CONFIDENTIAL Subject to the restrictions on the media