Fourteen Years Of Experience With Uhpw Stripping 2

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Use of Ultra High Pressure Waterjet stripping for removing thermal spray coatings from aircraft engine parts

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Fourteen Years Of Experience With Uhpw Stripping 2

  1. 1. Fourteen years of experience with UHPW stripping <ul><li>by </li></ul><ul><li>Andrew Tieu (VLN) </li></ul><ul><li>on behalf of Marcel van Wonderen </li></ul><ul><li>KLM Royal Dutch Airlines </li></ul><ul><li>engineering & maintenance </li></ul><ul><li>Schiphol Airport </li></ul><ul><li>The Netherlands </li></ul><ul><li>http://www.klm.com/engineeringmaintenance/site/en/index.html </li></ul>
  2. 2. <ul><ul><li>Contents: </li></ul></ul><ul><ul><li>History of UHPW project at KLM </li></ul></ul><ul><ul><li>System of 1994 </li></ul></ul><ul><ul><li>Which thermal spray coatings ? </li></ul></ul><ul><ul><li>Stripping Results </li></ul></ul><ul><ul><li>Data </li></ul></ul><ul><ul><li>Conclusion </li></ul></ul><ul><ul><li>Developments </li></ul></ul><ul><ul><li>Other waterjet developments </li></ul></ul><ul><ul><li>Awards </li></ul></ul>Fourteen years of experience with UHPW stripping
  3. 3. Fourteen years of experience with UHPW stripping <ul><li>History of UHPW project at KLM </li></ul><ul><li>Start investigation ‘91 </li></ul><ul><li>Coating and part related tests ‘91/’92 </li></ul><ul><li>Justification/Specification ‘92/’93 </li></ul><ul><li>Choice of supplier ‘93 </li></ul><ul><li>Jan ‘94, system built up and start </li></ul><ul><li>Full process approval of GE in March ‘94 </li></ul><ul><li>2004: 2 nd UHPW system in production </li></ul>
  4. 4. <ul><li>System of 1994: </li></ul>Fourteen years of experience with UHPW stripping <ul><li>Cabin with 4 axes Gantry robot and indexing turntable </li></ul><ul><li>CNC and Operator module controlled by PC with ‘PRIMS’ </li></ul><ul><li>20X ‘FLOW’ Intensifier (100 HP, max. 6.5 l/min., 350 MPa) </li></ul><ul><li>Closed Loop filtration with UV-radiation + particle-counter </li></ul><ul><li>6, 4 and 3 jet rotating nozzles </li></ul><ul><li>Straight and 90° non-rotating ‘FANJET’ </li></ul>
  5. 5. Fourteen years of experience with UHPW stripping
  6. 6. Fourteen years of experience with UHPW stripping
  7. 7. Fourteen years of experience with UHPW stripping
  8. 8. Fourteen years of experience with UHPW stripping
  9. 9. Fourteen years of experience with UHPW stripping
  10. 10. Fourteen years of experience with UHPW stripping
  11. 11. <ul><li>Which thermal spray coatings ? </li></ul><ul><li>(plasma, flame, electric wire): </li></ul>Fourteen years of experience with UHPW stripping <ul><li>Metallic: </li></ul><ul><ul><li>Al, NiAl, NiCrAl, Inc718, CuNi, CrNiCo, NiAlMo, etc. </li></ul></ul><ul><li>Ceramics: </li></ul><ul><ul><li>Al 2 O 3 , ZrO 2 /Y 2 O 3 , TiO 2 </li></ul></ul><ul><li>Carbides: </li></ul><ul><ul><li>WC, CrC </li></ul></ul><ul><li>Combinations: </li></ul><ul><ul><li>Ni/graphite, Polyester/Al </li></ul></ul>
  12. 12. Fourteen years of experience with UHPW stripping <ul><li>Velocity profile: </li></ul><ul><li>red: 800 m/sec </li></ul><ul><li>yellow: 500 m/sec </li></ul><ul><li>green: 350 m/sec </li></ul><ul><li>light blue: 200 m/sec </li></ul>
  13. 13. Fourteen years of experience with UHPW stripping
  14. 14. <ul><li>STRIPPING RESULTS (TAT) </li></ul>Fourteen years of experience with UHPW stripping Booster shrouds 1 week ½ day HPC-disk 2 weeks ½ day Spool 1 week ½ day HPC-stator case 1 week ½ day CRF 1 week 1 day Thermal Shield 3 days ½ day LPT casing 1 week 1 day Combustor liner 3 days 1 day PARTS: ‘old methods’ UHPW
  15. 15. <ul><li>DATA 1: Parts </li></ul>Fourteen years of experience with UHPW stripping <ul><li>Approx. 84.200 parts stripped since Jan. 1994 </li></ul><ul><li>225 different kind of parts </li></ul><ul><li>3 operational faults: </li></ul><ul><ul><li>wrong nozzle </li></ul></ul><ul><ul><li>wrong program </li></ul></ul><ul><ul><li>no rotating table start up in program </li></ul></ul>
  16. 16. Fourteen years of experience with UHPW stripping DATA 2: Maintenance <ul><li>High pressure seal change approx. every 1.3 months </li></ul><ul><li>Orifice life of approx. 150 - 300 hours (water quality) </li></ul><ul><li>High pressure cylinders (once in 9 years) </li></ul><ul><li>Initial Filtration problems (due to Polyester / Al ) with </li></ul><ul><ul><li>Filtration bags </li></ul></ul><ul><ul><li>Cartridge filters </li></ul></ul><ul><ul><li>Solved with extra: </li></ul></ul><ul><ul><li>Centrifuge (+ flogging liquid) </li></ul></ul>
  17. 17. Fourteen years of experience with UHPW stripping DATA 3: Production <ul><li>Average process times decreased 100 times </li></ul><ul><li>Average turnaround times decreased 5 times </li></ul>
  18. 18. <ul><li>DATA 4: ENVIRONMENT AND </li></ul><ul><li>OCCUPATIONAL HEALTH </li></ul>Fourteen years of experience with UHPW stripping <ul><li>No injuries or illnesses related to UHPW </li></ul><ul><li>Sound level < 75 dBa </li></ul><ul><li>Continuously recycling of water </li></ul><ul><li>Approx. 4300 liters less use of nitric acid per year </li></ul><ul><li>Approx. 520 kg less Nickel in sludge-waste per year </li></ul><ul><li>Approx. 1400 kg less Nitrates into sewer per year </li></ul><ul><li>Approx. 70 kg less use of Sodium Hydroxide per year </li></ul>
  19. 19. <ul><li>CONCLUSION: </li></ul>Fourteen years of experience with UHPW stripping The UHPW-stripping process is a superior alternative for traditional stripping: <ul><li>Very short stripping times </li></ul><ul><li>Only one strip station therefore reduction of turn around times </li></ul><ul><li>Virtually none or no attack of the base-material </li></ul><ul><li>Little waste </li></ul><ul><li>Only water as the active medium (recycled) </li></ul><ul><li>Compact system and no special building requirements </li></ul><ul><li>Hardly or no dangers for the environment and occupational health </li></ul>
  20. 20. Fourteen years of experience with UHPW stripping Developments at KLM: <ul><li>Using the UHPW system for cleaning parts, as </li></ul><ul><li>alternative for Chemical cleaning </li></ul><ul><li>Investigating possibilities of stripping HVOF coatings </li></ul><ul><li>Investigating possibilities of stripping EB-PVD coatings </li></ul><ul><li>2 nd UHPW-system </li></ul>
  21. 21. Fourteen years of experience with UHPW stripping <ul><li>“ Jet Edge” intensifier (150 HP, 11.4 liter/min., 350 MPa) </li></ul><ul><li>New features: </li></ul><ul><ul><li>Thermostatically controlled cooling system </li></ul></ul><ul><ul><li>Automatic high pressure bleed down valve </li></ul></ul><ul><ul><li>Integrated power distribution and power correction capacitors </li></ul></ul><ul><ul><li>PLC based control system with built-in network interface. </li></ul></ul>System of 2004: <ul><li>Robotic UHPW system (also for 3200 mm shafts) </li></ul>
  22. 22. Fourteen years of experience with UHPW stripping
  23. 23. Awards: <ul><li>1994 “LIFE”-award from the European Commission, Directorate </li></ul><ul><li>General XI of Environment, Nuclear Safety and Civil Protection for </li></ul><ul><li>Clean Strip Technology nr. 93/NL/A121/NL/3505 </li></ul><ul><li>1996 Dutch Industrial Environmental Award for Clean Technology </li></ul><ul><li>2005 Best research paper award on </li></ul><ul><li>abrasive waterjet stripping </li></ul>Fourteen years of experience with UHPW stripping

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