COMMERCIAL ENGINE STANDARD PRACTICES MANUAL

	COMMERCIAL ENGINE STANDARD PRACTICES MANUAL	Dated: 10/25/2024
	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 specimensand special tools or fixtures required in the performance of specifictasks 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 completecoverage, uniform structure, freedom from cracks, voids, spalling,chipping, flaking, or other indications of poor adhesion. The qualityof 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. Itno longer needs to be performed even when specified in the Engine/ShopManual.

(2)

Bend test. Refer to TASK70-71-08-700-014, Bend Test.

The technical requirement for this test has been deleted. Itno longer needs to be performed even when specified in the Engine/ShopManual.

(3)

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

The tensile bond test is performed using pull test buttons oradapters in a tensile testing machine to check adherence of the thermalspray coating. A minimum of three tests shall be performed for eachpart. The material used for test specimens/adapters shall be eithersame 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 StrengthLap-Shear Testing of Thermal Spray Coatings.

The lap shear bond test is performed using a three-piece setof test panels in a tensile testing machine to check the adherenceof the thermal spray coating. The material used for test specimensshall be either same as parts they represent or as stated in Table2 below. Two pieces of each three-piece set are sprayed for a lengthof 0.50 inch (12.7 mm) along with the production part, and a minimumof three sets must be sprayed in conjunction with each part.

(5)

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

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

(6)

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

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

(7)

Rockwell hardness test.

This test is usually performed on a small coupon which shallbe 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, RockwellHardness Testing.

(8)

Vickers (microhardness) test.

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

Frequency of Testing.

(1)

After the initial coating qualification, part qualitytesting 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, ThermalSpraying Nickel-Aluminum (Powder)],

(c)

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

(d)

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

(e)

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

(2)

As spraying continues, passing data should be gatheredand analyzed by an acceptable statistical process control (SPC) system.The frequency of testing may then be reduced (or the time intervalsbetween quality control testing increased) based on the statisticalanalysis if consistent results are obtained. The frequency intervalsshould all be based on requirements documented in the repair shop'sinternal 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, Testingand 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)

2700 (18.6)

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)

NOTE:

(HES) For the repairs that require GE SPM 70-49-45 Electric-Arc Wire Spraying Alloy 718 (Wire), item "5.D Tensile" from "Subtask 70-49-45-340-444" which is 4,000 psi (27.6 MPa) minimum currently, must be followed. Refer to Case #02108156.

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 400 (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 hardnessof 83 (ASTM E18)

NOTE:

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

NOTE:

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

NOTE:

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

NOTE:

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

NOTE:

6. Rockwell hardness test with Rockwell 15-N superficialhardness of 82 (ASTM E18)

NOTE:

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

NOTE:

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

NOTE:

9. Rockwell hardness test with Rockwell 15-N superficialhardness of 89 (ASTM E18) and a Vickers 300 gram load hardness of675 (ASTM E384)

NOTE:

10. Rockwell hardness test with Rockwell 15-N superficialhardness of 70 (ASTM E18) and a Vickers 300 gram load hardness of675 (ASTM E384)

NOTE:

11. Rockwell hardness test with Rockwell 15-N superficialhardness of 83 (ASTM E18) and a Vickers 300 gram load hardness of500 (ASTM E384)

NOTE:

12. Rockwell hardness test with Rockwell 15-N superficialhardness of 75 (ASTM E18) and a Vickers 300 gram load hardness of400 (ASTM E384)

NOTE:

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

NOTE:

14. Rockwell hardness test with Rockwell 15-Y hardnessof 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