SITIS Archives - Topic Details
Program:  SBIR
Topic Num:  AF071-104 (AirForce)
Title:  Quality Control for Advanced Residual Stress Inducing Surface Treatment Processes
Research & Technical Areas:  Materials/Processes

  Objective:  Develop and demonstrate quality control systems that facilitate incorporation of surface treatment-induced compressive residual stresses into aerospace design.
  Description:  Residual stress-inducing surface treatments, including conventional shot peening, laser shock processing, and low plasticity burnishing are widely used inside the turbine engine design community. However, in most circumstances, full design credit is not taken for these processes. This is due to 1) the general lack of comprehensive quality control techniques that would allow for real-time monitoring of all process parameters that are critical to quality, and 2) nondestructive techniques for the validation of processing effects, primarily in-depth residual compression. Technology-driven approaches for advances in cost-effective, real-time process monitoring and nondestructive process validation are sought. The proposed approaches must considerably advance the state of the art. Partnership with a surface treatment provider is strongly encouraged to maximize commercialization potential and facilitate suitable demonstrations of developed technologies.

  PHASE I: Demonstrate prototype quality control capabilities in a production environment. Demonstrate how the developed technologies facilitate design credit for the use of advanced surface treatments.
  
  PHASE II: Develop and construct a fully production-hardened quality control system based on development from the Phase I demonstration system. The system shall include all required data management tools to facilitate the data archival and management required as part of a comprehensive quality control program. Demonstrate the system in a production environment.

  DUAL USE COMMERCIALIZATION: Military application: Military turbine engine and airframes are expected to make increased use of advanced surface treatments shortly. Enhanced quality control measures will be required for design credit. Commercial application: Commercial turbine engines are expected to make increased use of advanced surface treatments in the future. Enhanced quality control measures will be required for design credit.

  References:  1. Trantow, R.L., and U.W. Suh, Patent No. 6,075,593, Method for monitoring and controlling laser shock peening using temporal light spectrum analysis, General Electric Company, Cincinnati, OH, 2000. 2. Sokol, D.W., C.T. Walters, et al., Quality control plasma monitor for laser shock processing, Patent No. 6,254,703, USA, LSP Technologies, Inc., Dublin, OH, 2001. 3. Sokol, D.W., C.T. Walters, et al. (2003). Patent No. 6,554,921, Quality control plasma monitor for laser shock processing. USA, LSP Technologies, Inc., Dublin, OH, 2003. 4. Shepard, M.J., "Laser Shock Processing Induced Residual Compression for Improved Damage Tolerant Design," University of Dayton, Ph.D dissertation 191, 2004.

Keywords:  laser shock processing, LSP, low plasticity burnishing, LPB, quality control, surface treatments

Questions and Answers:
Q: Could you please provide information about companies that provide surface treatment services for you?
A: Information about various surface treatment providers is readily available on the internet.

A partial list includes:
Laser Shock Processing
www.lspt.com/ - LSP Technologies

Laser Shock Processing and Conventional Shot Peening
www.metalimprovement.com/ - Metal Improvement Company

Low Plasticity Burnishing
www.lambdatechs.com/ - Lambda Technologies

Cold Hole Expansion
www.fatiguetech.com/ - Fatigue Technology Inc.

StressWave process
www.stress-wave.com/index.html - StressWave Inc.
Q: 1. I understand that OC/ALC applies shot peening to engine parts as a repair process. Is that correct?
2. Does OC/ALC have LSP available to them in-house for engine part repair?
3. Do they send parts to an outside shop or OEM for LSP?
A: 1. OC/ALC applies shot peening to engine parts on an as required basis. This may be as part of a repair process or may be called out as part of the refit process. Whether and how peening will be utilized is laid out in the pertinent technical orders.
2. OC/ALC does not currently have an in-house LSP capability.
3. Parts are sent to a vendor that is qualified as a production source for the particular job at hand. This may be an OEM or a separate vendor.
Q: Could you please provide information about companies that provide surface treatment services for you?
A: Information about various surface treatment providers is readily available on the internet.

A partial list includes:
Laser Shock Processing
www.lspt.com/ - LSP Technologies

Laser Shock Processing and Conventional Shot Peening
www.metalimprovement.com/ - Metal Improvement Company

Low Plasticity Burnishing
www.lambdatechs.com/ - Lambda Technologies

Cold Hole Expansion
www.fatiguetech.com/ - Fatigue Technology Inc.

StressWave process
www.stress-wave.com/index.html - StressWave Inc.
Q: 1. I understand that OC/ALC applies shot peening to engine parts as a repair process. Is that correct?
2. Does OC/ALC have LSP available to them in-house for engine part repair?
3. Do they send parts to an outside shop or OEM for LSP?
A: 1. OC/ALC applies shot peening to engine parts on an as required basis. This may be as part of a repair process or may be called out as part of the refit process. Whether and how peening will be utilized is laid out in the pertinent technical orders.
2. OC/ALC does not currently have an in-house LSP capability.
3. Parts are sent to a vendor that is qualified as a production source for the particular job at hand. This may be an OEM or a separate vendor.

Record: of