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Shot Peening / Blast Cleaning Workshop 2008
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FUNDAMENTAL CLASSES |
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Class Number |
Class Name Instructor |
Description |
|
| 100 L1 |
Peening Overview Dr. John Cammett |
Are you fairly new to the world of shot peening? This introductory class
explains the history and basic theory of peening as well as examines common reasons to peen. This class contains material covered in the FAA certification exams Level 1. |
|
| 110 L1 |
Coverage I Dr. John Cammett |
Coverage, too much or too little can be detrimental. Learn how to
measure and control coverage by evaluating samples of % covered. This class contains material covered in the FAA certification exams Level 1. |
|
| 120 L1 |
Intensity I Jack Champaigne |
This class will introduce the concept of peening intensity and
how it is measured using Almen strips, holders and gages. Almen’s patent, granted in 1944, and
the SAE guidelines are reviewed. The saturation curve and the 10% rule is explained and guidelines
for new set-ups and verification trials for peening intensity are discussed. This session is
recommended for operators, quality personnel and designers and anyone registered for level
one examination. This class contains material covered in the FAA certification exams Level 1. |
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| 130 L1 |
Media Dr. John Cammett |
This class examines the acceptable forms of media used in
peening as well as proper media selection and maintanence. This class contains material covered in the FAA certification exams Level 1. |
|
| 140 | Applications for Shot Peening, Blast
Cleaning and Deburring Herb Tobben |
Automated air-blast systems can be tailored to just about any blasting, peening, and deburring application. This session covers criteria for selecting suction or pressure systems and the effects of media, pressure, and part handling, and more. Learn how many Fortune 500 companies and others are reducing costs through automation. | |
| 200 L2 |
Peening Science Dr. John Cammett |
This advanced class dives into the science of peening. This
session is recommended for production engineers, supervisors and quality personnel. This class contains material covered in the FAA certification exams Level 2. |
|
| 210 L2 |
Coverage II Dr. John Cammett |
Coverage, too much or too little can be detrimental. Learn how to
measure and control coverage by evaluating samples of % covered. This class contains material covered in the FAA certification exams Level 2. |
|
| 220 L2 |
Intensity II Jack Champaigne |
So, you think you're good at generating saturation curves. It's
time to see how good you are. This presentation reviews the basic concepts of level one saturation
curves and then offers three practice saturation curves that students will develop. How to choose
the correct Almen strip exposure time for the saturation curve is discussed. The “Curve Solver”
routine is described as an automatic method to plot saturation curve and determine “intensity”.
(Curve Solver can be downloaded for free from shotpeener.com website.) This session is recommended
for supervisors and quality personnel and anyone registered for level two examination. This class contains material covered in the FAA certification exams Level 2. |
|
| 240 L2 |
Peening Applications Jim Harrison |
Has your exposure to shot peening been limited? Well, this process
is not a one trick pony. This class shows many different applications of shot peening from
stripping to strengthening to forming. This class contains material covered in the FAA certification exams Level 2. |
|
| 320 L3 |
Intensity III Jack Champaigne |
This presentation explores intensity specifications, error conditions
and remedies and cites examples of problems caused by mixed shot sizes, machine parameter changes
which may not be detected by single point intensity verifjications. Quality issues relating to Almen
strips, holders and gages are discussed. This session is recommended for supervisors, quality
personnel and human resource trainers and anyone registered for level three examination. This class contains material covered in the FAA certification exams Level 3. |
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| Classes marked L1, L2, L3 are recommended as preparation for level 1, 2, & 3 FAA certified exams. | |||
| All Instructor Profiles | |||
BLAST CLEANING |
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Class Number |
Class Name Instructor |
Description |
|
| BC100 | The Essentials of Blast Cleaning, Part 1 Joe McGreal |
This is the first part of two sessions that will help you understand how shot is manufactured, how to select the proper abrasive size, hardness and methods to extend steel shot life. It is recommended to attend both Part 1 and Part 2 to get the full benefit of this course. | |
| BC101 | The Essentials of Blast Cleaning, Part 2 Joe McGreal |
This is the second part of two sessions that will help you understand techniques to lower blast cleaning time, reduce machine maintenance and cleaning costs, and various cleaning methods to prevent damage. It is recommended to attend both Part 1 and Part 2 to get the full benefit of this course. | |
| BC102 | Abrasive Handling and Control Dwight Lutsko |
Discussion of the 5 basic components of all Blast Cleaning (Shot Peening) Machines, Separators as a component, Mechanical Separators and Spirolators and most important - Impact Ratio of your abrasive mix | |
| All Instructor Profiles | |||
AIR MACHINES |
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Class Number |
Class Name Instructor |
Description |
|
| AM100 | Air Blast Machine Types and Applications Bill Barker |
Learn about air type machine selection and the description of different types of air blast machines and their applications. | |
| AM101 | General Air Blast Equipment Maintenance Will Green |
Learn an overview of the operating and controlling devices common on all air blast and peening machines. Learn the basic diagnostic techniques for trouble shooting air blast machines. Learn how to set-up a preventative maintenance program on air blast machines. AM 100 is suggested as a prerequisite. | |
| AM102 | Advanced Air Blast Equipment Maintenance Will Green |
Students should have attended AM 101 at this workshop or a recent one. This course will detail methods, procedures and set-ups for the critical process controlling component of modern, automated and robotic peening and blasting, air delivery machines. This course will discuss automated PM programs. Students are encouraged to bring problem descriptions with them to this course. | |
| AM103 | Air Machine Nozzle Design and Application Herb Tobben |
In this session, learn how to achieve highest performance from an air-blast system, both suction and pressure, through proper nozzle selection. Nozzle material, shape, and angle of impingement impact efficiency and productivity. Get tech tips from an industry expert, the man in the white coat. | |
| AM104 | Intelligent Nozzle Motion
Dan Dickey |
This class presents how proper shot delivery can be obtained through intelligent mechanical nozzle movement and motion interaction. | |
| AM105 | Magnavalve Applications for Air Blast Machines
Mark Ingram |
MagnaValves offer many advantages over mechanical valves in air blast applications, such as low maintenance and compatibility with computer control. Learn how to specify, install and maintain this new type of valve. | |
| All Instructor Profiles | |||
WHEEL MACHINES |
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Class Number |
Class Name Instructor |
Description |
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| WM100 | Centrifugal Blast Wheels Dwight Lutsko |
Historical developments to today's Impeller/Control Cage wheels, wear items, controlling blast patterns, load and motor amps. Innovations and The Future? | |
| WM101 | Wheel Machine Maintenece Part 1 Pete Bortnichak |
Two part series of the description of wheel machines and proper maintenance procedures. | |
| WM102 | Wheel Machine Maintenece Part 2 Pete Bortnichak |
Two part series of the description of wheel machines and proper maintenance procedures. | |
| WM103 | See numerous applications of wheel re-build projects to upgrade older equipment. | ||
| WM104 | Magnavalve Applications for Wheel Blast Machines Mark Ingram |
MagnaValves are a popular replacement for abrasive "slide gates" or "dipper valves" because they offer low maintenance and improved process control. Now you can reduce your media flow rate thereby conserving media and reducing damage to the throwing wheel and the cabinet. Learn how to specify, install and maintain this new type of valve. | |
| All Instructor Profiles | |||
MEDIA |
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Class Number |
Class Name Instructor |
Description |
|
| ME100 | Media Properties and Specifications Bob Gillespie |
This class discusses important media properties, how they are measured and their effect on the shot peening process. It also reviews the significant differences between new and used shot specifications. | |
| ME101 | Cut Wire Shot Bob Gillespie |
The advantages and benefits of using cut wire shot are discussed. | |
| ME102 | Glass Beads Chris Davies |
Manufacturing, quality control and applications in glass bead peening. | |
| ME103 | Abrasive Media Selection Joe McGreal |
Abrasive media selection for blast cleaning will detail the specific application for both metallic and non metallic abrasives. Abrasive performance for each type and specific applications for each will be discussed. | |
| ME104 | Ceramic Beads for Surface Treatment and Shot Peening Jeff Girman |
Learn about shot peening applications . Topics will cover rudiment aspects of ceramic beads and their chemical properties, and various surface applications, all with emphasis on shot peening. | |
| ME105 | Sieving - Theory, Practice and the Reality Terry Reckart |
The Theory, The Practice, The Reality - During the course of this seminar discussion we will talk about how the sieve is designed to work in theory and what that means to you when you perform your everyday sieve analyses. We will discuss current sieving practices good and bad and end up looking into the reality of sieving and how you can achieve the highest degree of accuracy and repeatability from your sieving equipment. | |
| ME106 | Optical Media Analysis Terry Reckart |
Automation of the Sieving Process - During the course of this seminar discussion we will talk about how modern technology allows us to automate the media sizing requirement. We will look into methods that require a minimum amount of user interface, too systems that are totally automated and require no human intervention to get highly accurate and repeatable results. You will see equipment in operation that can and will reduce your media analysis time significantly. We will also discuss how this technology can be integrated into your specifications that now require a shaking device and sieves to do the media analysis. | |
| ME107 | Media Size and Quality Inspection Dave Barkley Bryan Chevrie |
Every specification for peening media requires inspection for proper shape. Practice inspecting media for proper shape (also called "fracture count") using microscopes and samples of good and bad media. Learn how to select the correct sieves and operate the Ro-Tap system for size inspection of media size. An instructor will operate a machine in the classroom using various samples of media. | |
| All Instructor Profiles | |||
EQUIPMENT and MASKING |
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Class Number |
Class Name Instructor |
Description |
|
| EQ100 | New Tools for Coverage and Peening Control Sylvain Forgues |
In this presentation, new tools for controlling peening will be presented and discussed. This will include portable visual inspection cameras for inspecting coverage in difficult to reach areas as well as special control units for flapper peening. The working of these new tools will be explained and examples of their use will be given in the context of NADCAP requirements. | |
| EQ101 | Peening Equipment Basics, Features and Advances Kumar Balan |
Blast machines originally intended for cleaning applications have been magically transformed by many users for peening applications too! Part of this presentation will discuss why this may not always be possible, the different process variables and their impact on the final peening results. Common variables in wheel peening and air peening will be presented, with details on their significance. Commonly used specifications and design of equipment for conformance will be discussed. Some of the latest developments in peening machine technology will be introduced to provide a flavor of the future in this industry. | |
| EQ102 | Dust Collection Dwight Lutsko |
What is Dust? It's size and the Physics of Air, Types of Dust Collection units, Fires and Explosions, Maintenance Tips and NFPA requirements. | |
| EQ103 | Explosive Dust Case Ferguson |
This class offers a discussion on dust collectors and your process. Learn what you will need to protect yourself and your company from the possibility of explosive dust. | |
| MK100 | Masking Techniques and Adventures Bryan Chevrie |
In this section we will go over when and how to pick different types of masking (tape, urethanes and or metal). Topics covered include: Questions to ask yourself when selecting masking for your project, holding fixtures and how they interact with the your parts and mask, how to incorporate Almen test strip holders into your masking, masking for grit blast and vapor blast, masking used on robotic line, and taking Carpal Tunnel Syndrome out of your masking. | |
| All Instructor Profiles | |||
PARAMETERS and MEASUREMENT |
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Class Number |
Class Name Instructor |
Description |
|
| PM100 | Nadcap Audit Preparation Dr. John Cammett |
Have you ever wondered or worried about what will happen during an audit of your shot peen process? This class will guide you through the before, during and after of the typical Audit. You will be able to prepare your team for the day before the Audit, the inspection of equipment, paperwork, media, and proficiency of the operators in the shot peen process. We will cover from the beginning to the end and include plans for a possible follow-up Audit if needed. | |
| PM102 | Shot Peen Technique Card - Putting it all Together
Michael Sorenson |
This class focuses on the various methods for documenting the shotpeen process for parts, with emphasis on technique (or setup) cards, and includes discussion on part preparation and post-peening requirements. | |
| PM103 | Lean Manufacturing in the Shot Peen Process at Boeing
Michael Sorenson |
This class focuses on how Lean Manufacturing can be applied to the shotpeening process. This class will include a brief introduction on some basic Lean Manufacturing concepts, then include multiple examples of how they have been applied successfully (and unsuccessfully) at Boeing shotpeening facilities. | |
| PM104 | Almen Gage Calibration Holly Williams |
How to calibrate an Almen gage using a portable kit. You can now perform your own Almen gage calibrations. The kit includes NIST traceable step blocks to calibrate the digital indicator and a 9-hole template that confirms the ball and indicator tip placement. Save time and money with by Calibrating your gage yourself. | |
| PM105 | Almen Gage R&R "Repeatability and Reproducibility"
Jeff Derda |
Wouldn't it be a shame to be doing a great job (peening) but not to get credit for it? That could happen if you don't have a good Almen gage and know how to use and maintain it. Practice with old and new gages to show Repeatability and Reproducibility. | |
| PM106 | Thriving with Nadcap
Don Buehler |
A basic look at Nadcap, how to prepare and the key to success. | |
| PM107 | Export Control
Don Buehler |
Knowledge and action - the keys to compliance. Why do we have export control, What are the regulations, What do you have to be concerned about, and steps to compliance. | |
| All Instructor Profiles | |||
SPECIALTY PEENING |
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Class Number |
Class Name Instructor |
Description |
|
| SP230 FL |
Flapper Peening Theory and Applications Pete Bailey Dave Barkley |
Flapper Peening aids in spot repair (re-peening) and small part peening
without requiring a blast cabinet or having to send a part back out to a job shop. This class offers
the history and current practices of Flapper Peening. Procedure, intensity, coverage, standards and
equipment are all covered in this presentation. A supplemental hands-on class is also offered
(see schedule) for those willing to take an extended look into this emerging peening technology. A FAA certification exam is offered for this class but candidates must also attend and pass the "Flapper Peening Practical" course. |
|
| SP231 FL |
Flapper Peening Lab and Practical Pete Bailey Dave Barkley |
This is a supplemental class to the "Flapper Peening Theory and
Applications" course. This class is hands-on and students can test their technique by generating
a saturation curve via Flapper Peening. Since testing can be time consuming, students taking the
Flapper Peening exam have preferential treatment with the equipment. Flapper Peening
demonstrations will also be available during Trade Show breaks on Wednesday. A FAA certification exam is offered for this class but candidates must also attend and pass the "Flapper Peening Theory and Applications" course. |
|
| SP101 | Ultrasonically Activated Spot Peening: Principles
and Applications
Brigitte Labelle |
In this class, the principles of Ultrasonically Activated Shot Peening will be reviewed along with several production and repair applications illustrating how the technique can lower costs and shorten cycle times. Special applications such as disk slots and irregular holes will be discussed and compressive residual stress distributions, surface finish and fatigue lives will be compared with conventional peening. | |
| SP102 | Laser Peening Jim Harrison |
Laser peening can impart a compressive stress about twice as deep as conventional shot peening. This is very important in rotating jet engine parts for FOD control. Learn about the space age technology used for critical peening applications. | |
| SP104 | Ultrasonic Impact Technology
Dan Spinner |
Ultrasonic Impact Technology (also known as UIT) can impart compressive stresses to depths (+0.120”) greater than twice the maximum of shot peening (~0.060”) and stress relieve up to 0.60” deep. By selection of the proper indenters, treatment can be highly focused in small areas such as the HAZ of welds, or across complete component surfaces such as brake rotors, crank shafts and cam shafts, giving fatigue life strength up to 5 times that of conventional shot peening. The technology has also given superior performance in SCC in stainless steels and exfoliation of aluminum aerospace components. | |
| Classes marked FL are recommended as exam preparation for flapper peening. Any persons interested in flapper certification must attend "Flapper Peening Practice / Practical" and demonstrate proficiency to the instructor prior to sitting for the examination. | |||
| All Instructor Profiles | |||
ADVANCED CLASSES |
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Class Number |
Class Name Instructor |
Description |
|
| AT100 | Residual Stress Measurement Michael Brauss |
X-ray diffraction (XRD) is the standard tool for measuring residual stress in shot peened components. This session will explain how XRD is used to quantitatively measure residual stress, the types of equipment that are available, the basic techniques and the type of information that can be obtained to optimize the shot peening process and ensure that peening has been correctly applied. | |
| AT101 | Shot Peening Problem Resolution at Boeing
Michael Sorenson |
This class focuses on observations and strategies related to common shotpeen producibility problems. A shotpeening shop may have their process very much in control, but problems can develop with the shotpeened parts for a variety of reasons (part configuration, machine capabilities, etc). Primary emphasis will on the common sources and strategies for dealing with part distortion issues related to shotpeening. The topics of producibility issues with edges and holes, as they relate to shotpeen, are also discussed. | |
| AT102 | Peening Techniques for Challenging Applications Jim Whalen |
Learn about tools and techniques to solve difficult peening configurations with emphasis on robotic parts handling. | |
| AT103 | Corrective Peening of Fighter Aircraft Components
Sylvain Forgues |
This class will present a study on rework alternatives following the poor peening of critical fighter components. The effect of coverage, Almen intensity and surface finish on fatigue life will be discussed. Rework alternatives will then be presented including direct re-peening, polishing + re-peening as well as multiple re-peening. | |
| AT104 | Shot Peen Forming of Wing Skins Jim Harrison |
Wing skins can be formed to have a curved surface. Like with an Almen strip, Peen forming involves blasting a stream of shot at the metal surface with each piece of shot acting as a tiny peening hammer but unlike most other forming methods, all surface stresses generated by peen forming are compressive - counter-balancing the tensile forces acting on the lower surface of the wing while the plane is in flight. | |
| All Instructor Profiles | |||
