Laser Cladding Refurbishment of Catapult Trough Covers

Abstract

ABSTRACTA laser cladding process has been developed and is now in production for the cladding of new aircraft carrier catapult components. The Service Life Extension Program (SLEP) Office of Naval Sea Systems Command (NavSea) suggested that this process be utilized for the refurbishment of catapult tracks. Early experiments were conducted by the Naval Surface Warfare Center in conjunction with the IIT Research Institute. The program was then transitioned to the Applied Research Laboratory, Pennsylvania State University (ARL Penn State) under the sponsorship of the Naval Air Systems Command (NavAir)/Navy MANTECH program, thus providing an effective solution to a NavSea/NavAir interface hardware problem.ARL Penn State was responsible for the production and evaluation of six laser clad aircraft carrier catapult tracks as part of a program sponsored and funded by NavAir Code 5512.Six catapult tracks that had been taken out of service because of excessive wear were laser clad at the Westinghouse Electric Research and Development Center (Now “Science and Technology Center”) for ARL Penn State. The composition of the clads was Inconel 625, Stellite 6/Stainless Steel 304, and Ferrelium 255. The tracks were machined and installed on the USS Constellation. Wear measurements were taken for the laser clad tracks and standard tracks ahead and behind the clad tracks.After 7,161 launches, the tracks were removed and returned to ARL Penn State for evaluation. The evaluation indicated that impact damage was observed on one track. No additional defects related to operations were found. Wear data indicated that the wear rate for it was 25%‐50% less than non‐clad. The results indicated that rejectable tracks (and one piece trough covers) could be successfully laser clad for extended operating life at acceptable costs.With emphasis for the future on a more affordable Navy, the need for viable refurbishment processes will be necessary for extending life and performance for the 21st century. Laser cladding and laser processing offer a real potential for affordable extended life systems.