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    Component Protection Problems We Solve

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    Component failure is usually due to a sequence or combination of events which can initiate from the design and choice of materials through to manufacturing processing and assembly including the application of heat, welding and grinding, as well as machining and distortion of the part due to bending, rolling or forging.

    In services conditions can also contribute to the failure of a part such as variation in temperature and environmental conditions, uneven, high or low cyclic loads or stress profile, compression, torsion and bending as well as foreign object damage.  Matching the maintenance needs of the component to its operating conditions and environment is also important to reduce the effects of ageing and wear.

    Curtiss-Wright Surface Technologies support every stage of the manufacturing process from design and new manufacture through to in service maintenance, metal repair and overhaul of components – our metal repair and component protection services increase the strength  and performance of parts and reducing costs and downtime.

    What Causes Component Failure?

    The table below gives a brief overview of typical components that we process, what failures they are susceptible to and the component protection available to prevent failure.

    Note: Failure Modes and Solutions may be relevant for some or all of the components.

    Aero-Engine

    Blade roots
    Air foils
    Tie wire holes
    Propeller blades
    Turbine discs and blisks and drums
    Rotating rings
    Engine mounting brackets
    PTO Gears

    Failure modes

    Fretting
    Galling
    Fatigue
    Contact fatigue
    Corrosion
    Stress corrosion cracking
    Micro cracking
    Foreign object damage
    Erosion
    Water droplet erosion

    Solutions

    Controlled shot peening
    Laser shock peening
    C.A.S.E. isotropic superfinishing
    Thermal spray coatings
    Liquid coatings

    Aero Landing Gear

    Failure modes

    Foreign object damage
    Temperature variation
    Fatigue
    Tensile stresses from hard chroming process
    Stress corrosion cracking
    Fretting
    Galling

    Solutions

    Controlled shot peening
    HVOF WC coating

    Airframe

    Wing skins
    Fasteners
    Fuselage
    Stringers
    Spars
    Bulkheads
    Bolts

    Failure modes

    Fatigue
    Flexural bending fatigue
    Stress corrosion cracking
    Lighting strike

    Solutions

    Controlled shot peening
    Shot peen forming
    Laser peening
    Laser peen forming

    Connecting Rods

    Bore fillets
    Feed rollers
    Bearing races
    Screw and oil holes
    Contact faces
    Radii’s

    Failure modes

    Residual compressive stress
    Fatigue

    Solutions

    Controlled shot peening

    Crankshafts, Camshafts, Axles

    Crank pin bearing fillet
    Keyways
    Splines
    Shear sections
    Torsion bars
    CV joint windows
    Gears
    Drive shafts

    Failure modes
     

    Fatigue cracking
    Contact fatigue
    Pitting

    Solutions
     

    Controlled shot peening
    Laser Peening
    C.A.S.E. isotropic superfinishing

    Exhaust Stacks and Manifold Adapters

    Flanges
    Holders
    Weldings

    Failure modes
     

    Heat variation

    Solutions
     

    Controlled shot peening
    Laser Peening

    Gas and Steam Turbines

    Blade roots
    Air foils
    Diaphragm couplings
    Rotors
    Fir tree grooves
    Locking nuts

    Failure modes

    Fretting
    Cavitation erosion
    Water droplet erosion
    Fatigue
    Stress corrosion cracking

    Solutions

    Controlled shot peening
    Laser shock peening
    Thermal spray – HVOF, Plasma and Flame spray

    Gears and Gear Systems

    Fillet at root
    Flanks

    Failure modes

    Macro and micro pitting
    Fretting
    Fatigue

    Solutions

    Controlled shot peening
    C.A.S.E. isotropic superfinishing

    Medical Implants

    Hip joints
    Medical screws
    Bars

    Failure modes

    Fatigue
    Stress corrosion cracking
    Fretting
    Environmental attack

    Solutions

    Parylene coating
    Controlled shot peening
    Laser peening

    Pipes and Tubes

    Internal bores and surfaces
    Oil well drill pipes
    Cooling tubes – water walls and heat exchangers
    Transmission shaft oil holes
    Steam generator roll transition zone
    Plastic pallet transportation

    Failure modes

    Corrosion
    Stress corrosion cracking
    High temperature corrosion
    Fatigue
    Fretting
    Galling
    Angel hair effect

    Solutions

    Controlled shot peening
    Liquid coatings
    Thermal spray coatings
    Thermal barrier coatings

    Springs

    Compression/tension coil springs
    Valve springs
    Torsion springs
    Disc springs
    Leaf springs

    Failure modes

    Fatigue
    Fretting
    Corrosion

    Solutions

    Controlled shot peening
    Liquid coatings

    Steam and Gas Turbines

    Blade roots
    Air foils
    Diaphragm couplings
    Rotors
    Fir tree grooves
    Locking nuts

    Failure modes

    Fretting
    Cavitation erosion
    Water droplet erosion
    Fatigue
    Stress corrosion cracking

    Solutions

    Controlled shot peening
    Laser shock peening
    Thermal spray – HVOF, Plasma and flame spray

    Valves for Compressors and Pumps

    Flapper valves
    Seals

    Failure modes
     

    Fatigue

    Solutions
     

    Controlled shot peening
    C.A.S.E. isotropic superfinishing

    Welded Components and Fabrications

    Fillet weld toe profile
    HAZ (Heat affected zone)

    Failure modes
     

    Fatigue
    Stress corrosion cracking

    Solutions
     

    Controlled shot peening
    Laser peening

    Subsea Components and Structures

    Christmas tree structures
    Welds – heat affected zones
    Seals
    Connectors
    Valves
    Fasteners, threads and shafts

    Failure modes
     

    Environmental corrosion
    Stress corrosion cracking
    Pressure and hydrogen cracking
    Galling
    Fretting

    Solutions
     

    Controlled shot peening
    Liquid coatings
    Thermal Spray coatings
    Cathodic protection
    Zinc phosphate coatings