R-245-0419_A.doc

REVISION No. A .

CHANGE No. .

SPECIFICATION OR

STATEMENT OF WORK

COVER SHEET

TITLE

CONTROLLABLE PITCH PROPELLER HUB REPAIR SPECIFICATION

THERMAL SPRAY RESTORATION OF BLADE PORT AREA

FOR 210B WMEC

SPECIFICATION NUMBER

R-245-0419

ORGINATED BY

K.DANAHY

DATE

07/30/01

ORGINATOR'S COMMAND

USCG ELC

DEPARTMENT/DIVISION

PROPULSION MACHINERY (026)

INTERNAL REVIEWER

S. Hardsock

DATE 06/04

SOWRB APPROVAL

DATE

CONTROLLABLE PITCH PROPELLER HUB REPAIR SPECIFICATION

THERMAL SPRAY RESTORATION OF BLADE PORT AREA

FOR 210B WMEC

1.0

SCOPE

1.1 This specification document sets forth the requirements for the under-cut machining, thermal spray application, final machining, testing, inspection, and packing of controllable pitch propeller hub bodies used on 210 B Class Medium endurance cutters.

1.2 GOVERNMENT FURNISHED PROPERTY (GFP) – To be released by the Contractor after determination is made to repair.

1.2.1 Hub Body, NSN 2010-01-045-2783, P/N D066SM0201B.

2.0 APPLICABLE DOCUMENTS

2.1 DOCUMENT AVAILABILITY - To obtain the referenced documents see section 6.1.

2.2 GOVERNMENT DOCUMENTS - The following specifications and standards form a part of this specification to the extent specified herein. Unless otherwise specified, the documents listed here by number and date shall be those in the current Department of Defense Index of Specifications and Standards (DODISS) and supplements thereto.

2.2.1 MILITARY STANDARDS

a. MIL-STD-1687A, THERMAL SPRAY PROCESSES FOR NAVAL SHIP MACHINERY APPLICATIONS

2.3 OTHER GOVERNMENT DOCUMENTS - The following documents form a part of this specification to the extent specified herein. The documents listed shall be by title and effective date, unless otherwise documented.

2.3.1 COAST GUARD SPECIFICATIONS / DRAWINGS

a. DRAWING 620 WPC-4400-53, HUB ASSEMBLY– For illustration only.

2.4 COMMERCIAL DOCUMENTS - The following documents form a part of this specification to the extent specified herein. The documents shall be the version listed by number and date from the referenced industry organization. Commercial documents may also be listed in the Department of Defense Index of Specifications and Standards (DODISS).

2.4.1 Society of Automotive Engineers (SAE)

a. SAE-J-448A DATED 1994 Surface Texture Standard.

2.5 SPECIFICATION ORDER OF PRECEDENCE - In the event of a conflict between the text of this specification and the references cited herein, this specification shall take precedence.

3.0

REQUIREMENTS

3.1 GENERAL - The contractor shall provide all labor and materials required to repair, test, inspect, and package the propeller hub as outlined on the applicable drawings and herein.

3.1.1 The blade ports have been worn by interaction with the seal and machined to its maximum diameter allowed by the OEM. It is desired to restore the worn blade port to the original size with a material that has the same or better wear properties than the base material. This is considered to be a critical surface because failure of the o-ring seal, which interacts with the surface, would result in the need to dry-dock a cutter.

3.1.2 Machining is required to clean up the blade port seal areas and to finish the newly sprayed surface.

3.1.3 The hub port has a slight conical lead-in, which allows installation of the blade seal base ring without the o-ring contacting the hub body until the point where there would be 360-degree contact. However, the lead-in is insufficient to accommodate the O-ring of the second oversize blade seal base ring, therefore, additional machining is required to provide an enlarged lead-in.

3.1.4 The propeller hub was manufactured from nickel manganese bronze (Same as American Bureau of Shipping ABS Type 3).

3.1.5 Prior to the actual hub casting repairs, a test specimen shall be sprayed using the same process and materials as the hub repair and by the same operator in accordance with MIL-STD-1687a sections 4.5.3 – 4.6.5.2. The results of the test specimen shall be submitted to the Contracting Officer for approval.

3.1.6 The hub blade port areas in way of the blade seal base ring outside diameter shall be restored to original size using thermal metal spray. The coating thickness shall not exceed 0.075 inch. The spray material shall be similar to the base material and have hardness greater than 210 BHN.

3.1.7 The applied thermal spray shall meet requirements of MIL-STD-1687A for the following properties: visual, porosity level, oxide level, bends examination, and bond strength. The bond strength shall be greater than 4000 psi and density greater than 85 percent.

3.1.8 The Contractor shall machine the blade port lead-in area so that the outer most portions is increased by 0.050-inch diameter and then faired down to the line where the blade seal port area begins.

3.1.9 The blade port seal area to be thermal sprayed shall be machined to remove damage as an initial step for surface preparation.

3.1.10 The surfaces of the hub to be coated shall be thoroughly cleaned in accordance with MIL-STD-1687A and this specification. The cleaning process shall include the use of degreasers, solvents and heat. The hub shall be baked at a temperature between 350 to 400 deg F for a minimum of four hours to remove residual oils.

3.1.11 Grit blast shall be performed using virgin aluminum oxide to achieve SSPC#5 finish and 3-4 mil profile.

3.1.12 After metal buildup of the blade port surface the port shall be finish machined and have a phenolic sealant applied.

3.2 DIMENSIONS - All dimensions and dimensional tolerances shall be as follows:

3.2.1 Blade Port Sizes.

a. Original dimension 15.812 +0.002/-0.000.

3.2.2 Blade Port Circularity shall be within 0.0005 inch.

3.2.3 Blade port surface finish shall be 16 micro inch Ra, or better, polished finish.

3.3 SURFACE FINISH STANDARDS - All surface finishes shall be in accordance with SAE-J-448A.

3.4 PASS/FAIL CRITERIA FOR SEAL BORES – Any pitting that remains after final machining shall not extend beyond 0.125 inch from threaded shoulder. No pitting shall be allowed for the remainder of the seal areas.

3.5 QUALIFICATION and CERTIFICATION OF THERMAL SPRAY PROCEDURES & PERSONNEL - thermal spray procedures and operators, shall be qualified in accordance MIL-STD-1687A section 4.3 through 4.5.1.

3.5.1 Thermal spray procedure and operator qualifications shall be submitted to the Contracting Officer for approval.

3.5.2 The qualification report shall include as a minimum the following factors:

a. Preparation procedures including method of cleaning, grit blast type and size, and surface finish.

b. Chemical analysis of thermal spray material.

c. Thermal spray process.

d. Finishing method and sealer type.

e. Test results for visual inspection, microscopic examination, bend test, bond test and hardness.

f. Inspection method of completed repair.

3.6 REPORTS - All reports prepared for submission shall contain at a minimum the data listed herein.

a. Prime Contractor - Company Name, Address, Telephone Number, & Point of contact (POC).

b. Testing Contractor (if different from above).

c. Contract number.

d. All test and inspection information required herein for each Contract Line Item Number (CLIN).

3.7 TESTS & INSPECTIONS - All applicable Test and inspection acceptance criteria shall be in accordance with the below listed specifications.

a. MIL-STD-1687A

b. MIL-DTL-2945E

3.7.1 Pre Repair Inspection.

a. Each hub shall be inspected upon delivery at the Contractor’s facility. Any defects shall be noted in the pre repair inspection report.

3.7.2 Post Repair Tests & Inspections.

a. Each hub blade port shall be visually and dimensionally inspected for conformance to the drawing and this specification in the presence of a Coast Guard Quality Assurance (QA) inspector.

b. The Final diameters and surface finish of each blade port seal area shall be taken and recorded using calibrated measuring instruments (see section 4.4). The dimensional measurement positions shall be taken at 0, 45, 90 and 135 degree intervals using the narrowest diameter of the hub casting as the reference starting point. The recorded readings shall be taken to the thousandth of an inch, i.e. 00.000”. A report of the recorded measurements and surface finish shall be provided to the Contracting Officer.

3.8 NOTIFICATIONS & INSPECTIONS - The contractor shall be responsible for notifying the Contracting Officer at least seven (7) calendar days prior to being ready for any Quality Assurance Inspections.

4.0 QUALITY ASSURANCE

4.1 RESPONSIBILITY FOR INSPECTION - The Contractor shall be responsible for the performance of all inspection requirements specified herein. The Contractor shall provide space, personnel and test equipment for the conducting of all inspection requirements. All inspection and testing shall be performed at the Contractor's plant or at other facilities acceptable to the Coast Guard. The Coast Guard reserves the right to verify or have performed any of the inspections set forth in this specification where such inspections are deemed necessary to assure that supplies and services conform to the prescribed requirements.

4.2 RESPONSIBILITY FOR COMPLIANCE - All items shall meet the provisions of Sections 3 & 5. The inspections set forth in this specification shall become part of the contractor's overall inspection system or quality program. The absence of any inspection requirements in the specification shall not relieve the contractor of the responsibility of assuring that all products or supplies submitted to the government for acceptance comply with all requirements of the contract. Sampling for quality conformance does not authorize submission of known defective material (either indicated or actual) nor does it commit the government to acceptance of defective material.

4.3 RECORDS - The Contractor shall maintain records of all inspections and tests. The records at a minimum shall indicate the nature and number of observations made, the number and type of deficiencies found and the corrective action taken.

4.4 CALIBRATION SYSTEM - The Contractor as well as any subcontractors shall be required to maintain a test equipment calibration program in compliance with ANSI/NCSL Z540-1. The program shall be documented and traceable to the National Institute of Standards (NIST).

4.4.1 The calibration system records shall be maintained for inspection for the duration of any contract referencing this specification.

4.5 TESTS/INSPECTIONS - The inspections and tests required herein are the minimum required and are not intended to supplant any controls, examinations, inspections or tests normally employed by the Contractor. The following are required and may be monitored by a Government Quality Assurance Representative.

4.5.1 Blade port size dimensional inspection as per section 3.2.1.

4.5.2 Blade port circularity inspection as per section 3.2.2.

4.5.3 Blade port surface finish inspection as per section 3.2.3.

4.5.4 Test specimens required in 3.1.5 shall be subjected to tests to demonstrate the quality of the thermal spray repair. Tests shall include visual inspection, microscopic examination (porosity level and oxide level); bend test, bond test and hardness.

4.6 NONCOMPLIANCE - Shall mean any single failure of any individual part, measurement, or test during final inspection/testing.

a. The contractor shall report the failure and the recommended corrective action to the Contracting Officer.

b. The Inspection/Testing shall be discontinued until all corrective action has been taken.

c. After all corrective action has been taken; the Inspection and Test shall be repeated.

d. Acceptance shall be withheld until re-inspection has shown that the corrective action was successful and the item satisfactorily passes all inspections and tests.

e. All corrective actions shall be documented as part of the contractor's inspection system, and submitted for approval.

f. Each corrective action report shall include, but not be limited to, the cause of each defect, corrective action suggested, and steps taken to prevent a recurrence of each defect.

4.7 TEST AND INSPECTION REPORT - One copy of any required Inspection, Test or Tolerance check shall be sent to the Contracting Officer for approval.

a. A copy of any inspection or test report shall also be turned over to the Coast Guard Q.A. Representative upon his arrival at the Contractor's plant, and a copy of all tests performed while he is there.

4.8 PACKING INSPECTION - The Contracting Officer shall be notified prior to the packing of the repaired units in accordance with section 3.8.

5.0 PACKAGING AND PACKING

5.1 Plywood disks shall be fabricated and secured to the outside of all four ports of each hub body to protect the seal areas during shipment and handling. The disks shall be a minimum of ½ inch in thickness.

5.2 Each hub body shall be packed using the crate that it was received in. Preservation is not required.

6.0

NOTES

Hub drawing and figure 6-1 of tech pub 701 (for illustration of blade seal base ring position in hub) are attached at the end of this document.

6.1

GOVERNMENT & COMMERCIAL DOCUMENT SOURCES

6.1.1 GOVERNMENT DOCUMENTS

a.

Specifications and Standards (DODISS Documents)

Standardization Document Order Desk

7004, Section D

Building #4, Section D

Philadelphia, PA. 19111-5094

Voice: 215-697-1187 b.

DOD & Navy Publications & Forms (Other Than DODISS)

Naval Publication and Forms Center

5801 Tabor Ave.

Philadelphia, PA. 19120

Voice: 215-697-2000

6.1.2

COMMERCIAL DOCUMENTS

a.

Society of Automotive Engineers (SAE)

400 Common Wealth Drive

Warrendale, PA. 15096

Voice: 412-776-4841

FAX: 412-776-5760

b.

American National Standards Institute (ANSI)

1430 Broadway

New York, NY 10018

Voice: 212-642-4900 c.

American Society for Testing & Materials (ASTM)

1916 Race Street

Philadelphia, PA. 19103-1187

Voice: 215-299-5585

FAX: 215-977-9679

6.1.3

OTHER GOVERNMENT DOCUMENTS

A.

USCG Engineering Logistics Center

Mail Stop #026 BLDG 31 2nd Floor

2401 Hawkins Point Rd.

Baltimore, MD. 21226-5000

ATTN: Kelly Wyatt

Voice: 410-762-6472

FOR ILLUSTRATION ONLY

FOR ILLUSTRATION ONLY

In section 1.1, add the word “bodies” after “propeller hub” in the fourth line.

Change section 1.2 to read:

GOVERNMENT FURNISHED PROPERTY (GFP) – To be released by the Contractor after determination is made to repair.

Add paragraph 3.4 to read:

3.4 PASS/FAIL CRITERIA FOR SEAL BORES – Any pitting that remains after final machining shall not extend beyond 0.125 inch from threaded shoulder. No pitting shall be allowed for the remainder of the seal areas.

Re-number remainder of section 3.

In section 3.7.2.b, change the dimensional measurement positions to 0, 45, 90, and 135.

In section 4.8, change 3.7 at the end of the paragraph to 3.8.

Change section 5.0 and add sections 5.1 and 5.2 as follows:

5.0 PACKAGING AND PACKING

5.1 Plywood disks shall be fabricated and secured to the outside of all four ports of each hub body to protect the seal areas during shipment and handling. The disks shall be a minimum of ½ inch in thickness.

5.2 Each hub body shall be packed using the crate that it was received in. Preservation is not required.

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