Table of Contents 2001 Aerospace/Airline Plating & Metal Finishing Forum March 27 - 29 • Portland, Oregon KEYNOTE ADDRESS—Paper not available Alan G. Miller, Senior Manager—Technology, Boeing Manufacturing Research & Development, The Boeing Company, Seattle, WA Isotropic Finishing of Helicopter & Turboprop Gearbox Components...............................................................................................4 William P. Nebiolo, REM Chemicals, Inc., Southington, CT Jet Engine Overhaul Environmental Management System 14001 .....................................................................................................12 Larry McCarthy, Lufthansa Airmotive Ireland, Dublin, Ireland Deep Cryogenic Treatment of Materials for Aerospace Applications ................................................................................................18 Joseph Shenosky, A. Alan Swiglo & Ali Manesh, IIT Research Institute, Chicago, IL The Propulsion Environmental Working Group (PEWG) Influences Environmental Operations & Compliance Strategies at Industrial Sources & Federal Facilities.................................................................................................24 Frank T. Ivancic, Chairman, ASC/LPJ, Wright-Patterson Air Force Base, OH; Robert E. Bondaruk, Charles H. Alford & Penny P. Kretchmer, PEWG Management Office, Anteon Corporation, Dayton, OH Paper not available Hydrogen Embrittlement in Coating Technology—Measurement & Testing...................................................................................25 Dr. W. Paatsch & V. -D. Hodoroaba, Bundesanstalt für Materialforschung und Prüfung (BAM), Berlin, Germany Status Report on Non-line-of-sight (NLOS) Hard Chromium Alternatives......................................................................................30 T. Naguy, Air Force Research Laboratory, MLQL, Wright-Patterson AFB, OH; M. Klingenberg, M. Neidbalson, M. Pavlik & D. Schario, Concurrent Technologies Corporation (CTC), Johnstown, PA Paper not available Acid Cleaning of Airplane Fuselage Prior to Painting ........................................................................................................................31 Thomas Stewart, Boeing Commercial, Seattle, WA Formulation & Evaluation of Chemistries for Cleaning Applications...............................................................................................36 Rick Reynolds, DuPont Chemical Solutions Enterprise, Wilmington, DE Aircraft Engine Parts Washwater Recycling System—An EPA ETV-MF P2 Technologies Center Test Report ..........................46 Donn Brown, Concurrent Technologies Corp., Largo, FL & Dr. A. Gus Eskamani, CAMP, Inc., Cleveland, OH Paper not available Status of DoD Program on Replacement of Hard Chrome Plating with Thermal Spray Coatings on Aircraft Components..............................................................................................................................47 Bruce D. Sartwell, Naval Research Laboratory, Washington, DC Paper not available Manufacturing of Carbide Materials for HVOF .................................................................................................................................48 Dipl. Ing. Falko Fischer, WOKA Schweisstechnik GmbH, Barchfeld, Germany & Larry Robbins, WOKA North America, Atlanta, GA Optimization of Precision Grinding Process .......................................................................................................................................54 Michael Nanlawala & Dr. Ali Manesh, P.E., ITT Research, Chicago, IL & Pankaj Patel, The Purdy Corporation, Manchester, CT Paper not available Materials of Concern for Gas Turbine Propulsion Systems................................................................................................................55 Glenn Welcher, Pratt & Whitney, East Hartford, CT Improvements in Blasting Process Media.............................................................................................................................................64 Raymond Williams, U.S. Technology Corp., Canton, OH Anodizing of Castings.............................................................................................................................................................................71 Dr. Jean Rasmussen, Jahl-Technology, Inc., Maribel, WI In-tank Removal of Hard Chromium Plating Contaminants.............................................................................................................79 Dr. David R. Stewart, P.E., Dr. Paul Thoen & Tom Grove, BASX Systems, LLC, Fort Collins, CO Improved Threaded Fastener Coatings for Turbine Engines .............................................................................................................84 Dr. Paul Sutor, Surfaces Research, Lenexa, KS Paper not available Technology Use at Tinker AFB ..............................................................................................................................................................85 Geri Hart & Linda Basinger, Tinker Air Force Base (AFB), Oklahoma City, OK Productivity Improvements with a New Vapor Degreasing Cleaning Process at Williams International......................................89 Roger Evans, Williams International; & John Hoffman & B. Carroll Smiley, Petroferm, Inc., Fernandina Beach, FL Paper not available Insights Regarding the Adhesion Mechanism for Supplementary Organic Coatings on Porous Anodic Films ............................90 Dr. Jude M. Runge & Aaron Pomis, C.J. Saporito Plating Company, Cicero, IL in cooperation with Bodycote Nussbaum Oberflachen- technik GmbH & Co. KG, Kaufbeuren, Germany Recycling Wax: What are the Benefits? ................................................................................................................................................96 Carol Eden, United Airlines (UAL), San Francisco, CA Paper not available A Step-by-step Approach for Specifying & Designing an Engine Overhaul Cleaning System........................................................97 Greg Heilman, Magnus Equipment, Willoughby, OH Coatings Applied by High Enthalpy Plasma Spraying with Axial Feed ..........................................................................................109 Dr. L.B. Delcea, Duran Technologies Inc., Port Coquitlam, British Columbia, Canada & L.C. George, Progressive Technologies Inc., Grand Rapids, MI Important New Tools for Plating & Anodizing Engineering.............................................................................................................114 Roger Mouton & Mark Thede, Stewart Technologies, Inc., Tempe, AZ Electrodialysis of Chromic Acid Anodizing Solutions for Bath Maintenance— An EPA ETV-MF P2 Technologies Center Test Report ....................................................................................................................121 Chris Start, Michigan Manufacturing Technology Center, Plymouth, MI & James Totter, Concurrent Technologies Corporation (CTC), Largo, FL Using Aqueous Chemistry to Clean Aircraft Engine Tubing ...........................................................................................................126 Parky May, Bergdahl Associates, Inc., Reno, NV 21st Century Process Surface Finishing Control at Pratt & Whitney .............................................................................................132 Peter Gallerani, CH2M Hill Engineered Systems, Danville, VT; Brent Pettegrow, Pratt & Whitney, North Berwick, ME; William Shively, CH2M Hill Paper not available Corrosion Protection of Al Alloys by Magnetron Sputtering & Ion Implantation.........................................................................133 J. Kohlscheen, H.-R. Stock & P. Mayr, IWT, Institute of Materials Science, Bremen, Germany KEYNOTE ADDRESS Paper not available About the Keynote Speaker Alan G. Miller, Senior Manager—Technology, Boeing Manufacturing Research & Development, The Boeing Company, Seattle, WA In his current assignment as senior manager—Technology, Alan Miller is responsible for the Manufacturing Pro- totyping Laboratories and for leadership, planning, research and development, and implementation to production for all manufacturing systems and processes used in Boeing Commerical Airplane Group products. In his 23 years with The Boeing Company, Alan has experienced many facets of management. He has served as chief engineer, Boeing Materials Technology; unit chief, Chemicals, Materials & Processes (Compos- ite & Bonding); 747 and 767 design support manager; manager, Metallurgy Group; chairman, Corporate Stan- dards Committee; corporate engineering representative to IAM/Boeing Health & Safety Institute; chairman, AIA TARC-211 Committee on Cabin Fire Safety; Boeing Structures/Materials Interdivision Coordination Group; SAE Technical Standards Board; chairman, SAE Commercial Jet Transport Standardization Committee; chair- man, SAMPE Commercial Transport Committee; member, National Materials Advisory Board of the National Research Council; and Boeing Product Standards Management Council. 3 Isotropic Finishing of Helicopter and Turboprop Gearbox Components William P. Nebiolo, REM Chemicals, Inc., Southington, CT 06489 The traditional finishing techniques for engineered gearbox surfaces include but are not limited to hob shaving, gear grinding and honing. Regardless of the technique employed, a unidirectional polishing pattern is achieved as the final component surface finish. This pattern consists of parallel rows of asperities peaks that