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Welcome

January 2011 | | Company Confidential


Corporation Overview

January 2011 | | Company Confidential


The Carlyle Group

The Carlyle Group is one of the worlds


largest private equity firms with $91.5
billion in capital committed to 66 private
equity funds worldwide.

y has been the leading


Carlyle g investor in
the aerospace, defense and IT /
government services sectors .

Carlyles goal is to build the long-term


value of Sequa and its holding
companies through synergies, process
improvement and investment.

Backed by one of the largest private equity banks in the world

January 2011 | | Company Confidential Page 3


Sequa Corporation

~ $1.5B / 5,000 people world wide

January 2011 | | Company Confidential Page 4


Chromalloy History

Started as a Chromalloy American Corporation in the late 1950s

The first company to leverage protective coatings on Turbine Airfoils

Developed repair technologies as an extension to OEM designs

Acquired by Sequa Corporation in 1986

DER repairs started in the 1990s

Gas path replacement parts started in 2000

Acquired by The Carlyle Group in December 2007

2009 / 10 invested $27M


$ in Tampa casting facility

> 50 years of leadership in gas turbine repair technology

January 2011 | | Company Confidential Page 5


Organization

A F
A. F. Lauzon
Lauzon, Jr
Jr.
President

Dr. P. Howard
T. van der Linden Pete Watson Dr. M. Beffel D. Walsh
VP Technology &
VP Sales, Aero VP Sales, Energy VP Operations VP Bus. Develop.
Quality Assurance

A Farrant
A. S. Lowson
S
M. Held J. Bollman D. Albert
VP Marketing & VP Legal
VP Finance VP HR VP External Affairs
Corp. Comm General Counsel

Dedicated, focused and proven leadership

January 2011 | | Company Confidential Page 6


Coatings
Aluminides Overlays Thermal Barriers

Chromalloy yp
provides advanced The single
g largest
g provider
p of Chromalloyy has invested over
vapor aluminide coating services Low Pressure Plasma Spray $75M in Electron Beam Physical
to the all the major OEMs Overlay coatings for Turbine Vapor Deposition
Applications

The worlds largest provider of EBPVD coatings

January 2011 | | Company Confidential Page 7


Repairs

Blades Casting Cases

Advanced blade tip weld


repairs
i using
i Chromalloys
Ch ll
patented laser powder welding
techniques

Chromalloy s advanced Airfoil


Chromalloys LPT Case Flange Replacement
Replacement (AFR) repairs for Repairs
100% yield programs

Patented and proprietary processes define Chromalloys repair capabilities

January 2011 | | Company Confidential Page 8


Chromalloy Castings

$27M investment = world-class state-of-the-art casting facility

January 2011 | | Company Confidential Page 9


Locations

Phoenix, AZ
Calexico, CA
El Cajon, CA
Gardena, CA
San Diego, CA
San Francisco, CA
Windsor, CT
Oldsmar, FL
Stuart, FL
Tampa, FL
Newnan, GA
Burlington, MA
Carson City, NV
Middletown, NY Saint Ouen, France
Orangeb rg NY
Orangeburg, M b i India
Mumbai, I di
Midwest City, OK Cengkareng, Indonesia
Dallas, TX Qiryat-Gat, Israel
San Antonio, TX Kuala Lumpur, Malaysia
Vancouver, Canada Tilburg, Netherlands
Victoria, Australia Jeddah, Saudi Arabia
Perth, Australia Lamlukka, Thailand
Beijing, China Nottingham, UK
Dubai, UAE Glasgow, UK
Indicates Corporate Headquarters
Rochefort, France

4,000 people, 33 facilities in 14 countries around the world

January 2011 | | Company Confidential Page 10


Markets Served

Commercial Military Marine & IGT

We provide cost We provide repair services We provide cost attractive


attractive
tt ti hihigh
h quality
lit on TF39,
TF39 F108 andd other
th hi h quality
high lit maintenance
i t
maintenance solutions engines under contract solutions
All major airlines in the USAF and other air forces Aero-derivative engine end
world users, depots and HIT users,
Navy

Very secure position in commercial aviation


Growth opportunities in Military and Marine & IGT

January 2011 | | Company Confidential Page 11


Chromalloy Heavy IGT

Chromalloy Heavy IGT Presentation Outline

Overview & History


Description of Technical Capabilities
Investments made in IGT

January 2011 | | Company Confidential Page 12


History
CTT Chromalloy Turbine
Technology/ Middletown/
USA

TACR Turbine Airfoil Coating


and Repair/ Berlin/ Germany
CHIT Chromalloy Heavy
Industrial Turbine/ Dallas/ USA

January 2011 | | Company Confidential Page 13


History

TACR officially unwound as of 1 Dec 2010. Under the terms of the unwind, TACR-
Middletown became a wholly owned subsidiary of Chromalloy and TACR Berlin
reverted back to a wholly owned subsidiary of SIEMENS

Chromalloy Middletown has signed a 3 year LTA with Siemens for 25M in sales for
year 1; with 17M in sales for years 2 and 3

Chromalloy Middletown is now free to pursue 3rd party IGT Hot Gas Path repair and
coating sales outside of Siemens using Chromalloy intellectual property

January 2011 | | Company Confidential Page 14


History
Middletown repaired > 60,000 IGT hot gas-path blades and
vanes over the last decade as the supplier of choice for the
OEM

The estimated EOH of these 60,000 repaired airfoils


exceeds 4,500,000 hours

Middletown has coated >750,000 IGT hot g gas-path blades


and vanes over the last decade for the OEM

CMT can deliver your repaired F class blades and vanes in


10 weeks or less with non OEM pricing and best in class
quality and yields

January 2011 | | Company Confidential Page 15


January 21, 2011

January 2011 | | Company Confidential Page 16


Chromalloys IGT Area of Focus

Outlet

W501F & G
SWPC Design

V84/94.3AX
V84/94 3AX
PG Design

Hot Section:
Blade and Vane
p
Components
Inlet Compressor TACR business scope
January 2011 | | Company Confidential Page 17
TECHNICAL CAPABILITIES OF
Chromalloy
y IGT

January 2011 | | Company Confidential Page 18


Data Acquisition Hardware

X-Ray C.M.M.
(C.T.)
(C T )

V.M.M. ATOS

January 2011 | | Company Confidential Page 19


Data Acquisition Methods Define Part Geometry

X-Ray (CT Scans) ATOS


3D, Digital Data, Point Cloud to 3D, Digital Data, Point Cloud to
Model Model
t tto 0.001
Accurate
A 0 001 t tto 0.001
Accurate
A 0 001
Density 50,000 Pnts/in2 Density 50,000 Pnts/in2
January 2011 | | Company Confidential Page 20
Data Acquisition Methods Define Part Geometry

C M M Data
C.M.M V.M.M
V M M Data
3D, Digital Data 2D, Digital Data
Accuracy to 0.0001 Accuracy
y to 0.0001
Point Spacing 0.005 Point Spacing 0.001

January 2011 | | Company Confidential Page 21


Geometry Data is Acquired on Multiple OEM Parts

As Example:
Data From Eight OEM
Parts are Overlayed to
Create Nominal Data
Cloud

January 2011 | | Company Confidential Page 22


Nominal Model is Defined Within Cloud Scan

January 2011 | | Company Confidential Page 23


Nominal Internal Surface Sectional Cut

January 2011 | | Company Confidential Page 24


Data Processing Used To Create Nominal
Model
Spreadsheet Data + ProE Data = Final Nominal Model

+ =

External Model + Core Model = Complete Airfoil Definition

January 2011 | | Company Confidential Page 25


Data Processing Used To Create Part Drawing

Solid Model

January 2011 | | Company Confidential Page 26


Part Print,, Tooling,
g, and CNC Programs
g Written

Tool designs developed


directly from solid model

2D Part Drawing Reflects Nominal Solid


Model with Tolerances All Dimensions
Critical to Quality (CTQ) are Defined

Gage to inspect a machined surface


January 2011 | | Company Confidential Page 27
Casting Material Analysis Examines Complete Airfoil

Macroetch for Grain Size / Orientation


Crystal
y Orientation for Single
g Crystal
y Castings
g
Mechanical Tests on Specimens from Parts: Tensile and Stress
Rupture
Oxidation Tests
Microstructure, Porosity, Inclusions, etc.

G A
B C
E
H

F F
D D

B
A C
G
E
Example of a Casting Cut-Up Scheme to
Metallurgically Compare OEM and OERP Castings

January 2011 | | Company Confidential Page 28


Machining Technologies
Conventional Machining

January 2011 | | Company Confidential Page 29


Machine Shop Equipment

4 Huffman 255S CBN Grinder (5-Axis)


- GE-Fanuc Control
- Axis Travel: 800 x 600 x 400
- C-Axis (rotary): +360
- B-Axis (rotary): 90

1 Huffman 155S CBN Grinder (5-Axis)


GE Fanuc Control
Axis Travel: 400 x 400 x 400
C-Axis (rotary): +360
B-Axis (rotary): 105

1 Elb Cam Master Dual Wheel Grinder


GE Fanuc Control
Pallet Table

3 Makino Horizontal Milling Center (4-Axis)


GE Fanuc Control
Axis Tavel 900 x 800 x 1020mm
Pallet: 630 x 630mm
50 Spindle Taper
Tool Changer for 40 Tools

January 2011 | | Company Confidential Page 30


Machine Shop Equipment (cont.)

6 Blohm Creep Feed Grinder (3-Axis) 4Profimat MT and 1 Profimat MC


- GE Fanuc Control
- Siemens Control
2 Hass VF4 and VF5 Milling Machines (3 & 4 Axis)
GE Fanuc Control
Axis Travel 1270 x 508 x 635mm
Tool changer for 20 Tools
40 Spindle Taper
2 Sodick EDM AQ55 (3 Axis)
GE Fanuc Control
Axis Travel: 550 x 400 x 350mm
Axis Travel 1270 x 508 x 635mm
Work Tank Dimension: 960 x 730 x 500
2 Sodick EDM AQ75 ((3 Axis))
GE Fanuc Control
Axis Travel: 700 x 500 x 350mm
Work Tank Dimensions: 1100 x 950 x 550mm
3 Brown & Sharp
p CMM
PC DMIS
1 Nikon Vision System
January 2011 | | Company Confidential Page 31
Non Conventional Technologies

January 2011 | | Company Confidential Page 32


OEM Laser Drilling and Laser Shaping

2 Laser drillers and


2 Laser shapers

1 DL130 for drilling


thi d stage
third t
components

Fully OEM qualified


on drilling cylindrical
and shaped holes
th
through h th
the TBC
(post-coat)

January 2011 | | Company Confidential Page 33


Laser Drilling / Shaping

2 Laserdyne 790 Beam Director Machines


With P50 Convergent
g Laser
6 Axis Driller/Shaper
2 Laser Machines
With 5 Axis P50 Convergent Energy
Laser
ase
9 Laser Machines
5 Axis
Convergent Energy Laser Systems
Aero application
pp
FADAL Vision System
Hole location inspect

Laser Machining Cooling Holes in Gas Turbine


Components Patent# 6,420,677
January 2011 | | Company Confidential Page 34
Laser Welding and Cutting

4 CO2 5-axis laser welding and cutting systems


Precise laser cutting to separate vane doublets
Removal of vane covers
Pattern cutting of braze sheets or masking tape cut outs
Welding of vane or duct segment covers
Welding of duct segment covers
Welding of blade metering/cover plates
2 CO2 5-axis CNC Laser Powder Welding systems
Knife edge seal refurbishment
Blade tip refurbishment
Vane side rail buildup
Laser Powder weld development of more base-metal
p
compatible nickel weld versus the current cobalt weld for better
durability

Welding Single Crystal Articles


Patent# 6,872,912
, ,

January 2011 | | Company Confidential Page 35


Coatings

Metallic Bond Coatings:


LPPS: Low Pressure Plasma
Spray
HVOF: High Velocity Oxy Fuel

LPPS Coater

Ceramic Thermal Barrier Coatings: Chemical


APS: Air Plasma Spray Vapor
EB PVD TBC
EB-PVD D
Deposition
iti
Coating
January 2011 | | Company Confidential Page 36
Low Pressure Plasma Spray Bond Coatings

LPPS Coating Process


MCrAlY
MCrAlY Bond Coat

Bond Coating Purpose:


Oxidation and Corrosion Protection
Allows for Application of TBC
Ceramic

January 2011 | | Company Confidential Page 37


High Velocity Oxy Fuel Bond Coating

HVOF: High
g Velocity
y
Oxygen Fuel Spraying

Bond Coating
g is applied
pp in an open
p booth with no p
pre heating
g required
q

January 2011 | | Company Confidential Page 38


Air Plasma Spray TBC Ceramic
Air Booth, Room Temperature
Application of a Zirconia Based
Ceramic Coatings & Low K
Coatings

Ceramic Thermal Barrier


Coatings

January 2011 | | Company Confidential Page 39


TBC Coating systems

APS EB-PVD

MCrAlY
MC AlY bbondd coatt
(Overlay / Stand Alone)

Ni/Co- (Super) alloy

January 2011 | | Company Confidential Page 40


Industrial Component Repair

January 2011 | | Company Confidential


Typical 501F Heavy Repair

Tip condition at the incoming

Common platform cracking at incoming

January 2011 | | Company Confidential Page 42


Typical 501F Heavy Repair
Blades
Bl d h have bbeen ti
tip welded
ld d
in the hot box with IN738

Blades are flat


ground in
preparation for
laser powder
welding of
squealer tip

Excess weld
from the tip
repair is
remove by
blendingg

January 2011 | | Company Confidential Page 43


Typical 501F Heavy Repair
The welding
process is
performed in
LPW hot
hot
using
IN738LC
Powder or IN
625

then the blades


are CBN
ground, CNC
milled to re-
re
contour

January 2011 | | Company Confidential Page 44


CBN grinding post weld repair
CBN Grinder (post-weld)
Component Tooling Program
V84.3A2 Tla1
V84.3A2 Tla2
V84.3A2 Tla3
V94.3A2 Tla3
V84.3A2 Tle1 N/A N/A
V84.3A2 Tle2 N/A N/A
V84.3A2 Tle3 N/A N/A
F Tla1
F Tla2
F Tla3
F Tla4
G Ta1
G Tla2
G Tla3
Tl 3
G Tla4

Capacity multiplier
as a single operator
can run grinders and
EDM simultaneously

January 2011 | | Company Confidential Page 45


CNC Milling
CNC Mill (Tip Contour)
Component Tooling Program
V84.3A2 Tla1
V84.3A2 Tla2
V84.3A2 Tla3
V94.3A2 Tla3
V84.3A2 Tle1 N/A N/A
V84.3A2 Tle2 N/A N/A
V84.3A2 Tle3 N/A N/A
F Tla1
F Tla2
F Tla3 N/A N/A
F Tla4 N/A N/A
G Ta1
G Tla2
G Tla3 N/A N/A
G Tla4 N/A N/A

Complete Tip Removal


Tip Cap Weld Removal
Tip Cap Weld Contour
Squealer Contour
Benefits
Finish Tip Height Q lit Improvement
Quality I t
Concave and Convex Sidefaces Capacity multiplier
January 2011 | | Company Confidential Page 46
Typical 501F Heavy Repair

Bond coat applied by Low Pressure Plasma Spray


The next process is (LPPS) or High Velocity Oxy-Fuel (HVOF)
to restore the
cooling holes by
EDM or laser

The ceramic coating is applied by Air Plasma Spray (APS)


January 2011 | | Company Confidential Page 47
Typical V84/94.3AX Heavy Repair

Blended tip
Prepared for laser powder welding
(LPW)

LPW nozzle and argon box

January 2011 | | Company Confidential Page 48


CO2 Laser Cladding and Fusion Weld
A Huffman CO2 Laser is used for both
Cladding Build up of Squealer Tips
And Fusion Welding of Orifice Plates

Tip
p Rebuilt

Welded
Orifice Plate

January 2011 | | Company Confidential Page 49


Tip Restoration -Automated

Machined (ground) Tip Re-established Laser Welded Tip


Prepped for Weld

LPW
Re-contoured
Re contoured Tip By CNC mill 625 cold 738 hot
Component Tooling Program Program
V84.3A2 Tla1 N/A
V84.3A2 Tla2
V84.3A2 Tla3 N/A
V94.3A2 Tla3
V84.3A2 Tle1 N/A N/A N/A
V84.3A2 Tle2 N/A N/A N/A
V84.3A2 Tle3 N/A N/A N/A
F Tla1
F Tla2
F Tla3 N/A
F Tla4 N/A
G Ta1
T 1 N/A
G Tla2 N/A
G Tla3 N/A N/A N/A
G Tla4 N/A N/A N/A

January 2011 | | Company Confidential Page 50


Repair Technologies
Diffusion Brazing
g

January 2011 | | Company Confidential Page 51


Diffusion Brazing Overview
C
Crack
kRRepair
i and
dCCooling
li H
Hole
l Fill off Ni and
d Co
C Alloys
All

For crack repair and


cooling hole fill of
small aerospace
components to large
industrial components
Inexpensive process
using braze pastes
and pre sinters and
vacuum furnaces
Over 30 years
Pre Braze Braze Post
production experience
Paste Blend

January 2011 | | Company Confidential Page 52


HF cleaning

Hi-Tek HF cleaning unit in Middletown installed and in use for


FIC & NGB on V84/94.3AX
V84/94 3AX Tle2s
Tle2 s ( Rene80 alloy)
Can also perform HBA and NGB/OB on MarM509 V84/94.3AX
Tle1s
Clean EB-PVD Tooling

January 2011 | | Company Confidential Page 53


Braze repairs

Braze furnace

Braze

Brazed 501F R1 Blade Base


Alloy

January 2011 | | Company Confidential Page 54


TV1 REPAIR Incoming
co g Condition
Co d t o

Example of a Engine Run Vane

January 2011 | | Company Confidential Page 55


TV1 REPAIR Cover / Baffle Removal

January 2011 | | Company Confidential Page 56


TV1 REPAIR POST STRIP

January 2011 | | Company Confidential Page 57


TV1 REPAIR PRE BRAZE

January 2011 | | Company Confidential Page 58


TV1 REPAIR BRAZE Applied (AERO)

White Stop-Off.

Braze

January 2011 | | Company Confidential Page 59


MARM509 60 HZ Brazed Airfoils

50X non-etched 100X non-etched

January 2011 | | Company Confidential Page 60


TV1 REPAIR P
Postt Bl
Blend
d (AERO)

January 2011 | | Company Confidential Page 61


TV1 REPAIR Post
ost MCrAlY
C Coat

LPPS Bond coat applied, diffused and surface peened and ready for laser drill.

January 2011 | | Company Confidential Page 62


TV1 REPAIR POST EDM

Part has been laser drilled, EDM shaped


p and de-burred.

January 2011 | | Company Confidential Page 63


TV1 REPAIR Post
P t EB-PVD
EB PVD Ceramic
C i

AERO REPAIR FINAL ASSEMBLY

January 2011 | | Company Confidential Page 64


Rene80 60 HZ Brazed Airfoils

200X Etched

January 2011 | | Company Confidential Page 65


Automation Laser Re-op (Repair)

To re-establish cooling holes post repair


and for removal of coating

Airfoils which require this technology


V84.3A2 Row 1 and 2 Blades & Vanes
V94 3A2 Row 1 and 2 Blades & Vanes
V94.3A2
501FD3 Row 1 Blade
501G Tla1 and 2 Blades
Required for VGP cooling hole re-
opening

Manual Re
Re-op
op of cooling holes Laser Re
Re-op
op of cooling holes
V84.3A2 Row 2 vane 160 holes 160 holes
Re-op time 2.5 hours Re-op time 1 hour 15 minutes
60 Reamers (50% Rework) No Rework

January 2011 | | Company Confidential Page 66


Quality and Evaluation

NDE and Inspections:


FPI
X-Rayy
Eddy Current
Ultrasonic Testing
Air Flow
Profilometer

Optical Scope

Metallurgical Lab
Optical
Optical Microscope
SEM Scanning Electron Microscope
Coating Structure and Thickness
Welding Evaluations
Material
Material Characterization

January 2011 | | Company Confidential Page 67


Other Supporting equipment

Currently In-House
Vacuum Furnaces for Heat Treatments
Airflow Bench
CMM Measurement System
Moment Weighting System
Acid Stripping Line
Grit Blasting
Peen and Tumble Polisher
Autoclave

Recent Developments
Robotic surface finishing
Robotic polymer masking
Root Peening
Lean Repair cell complete

January 2011 | | Company Confidential Page 68


Ch
Chromalloy
ll Investments
I in
i IGT

January 2011 | | Company Confidential Page 69


Technology investments in IGT

CAPITAL INVESTMENT ~ $ 15 Million in CMT


Machining
g Investment ~ $ 15 Million in IGT Total
Casting Investment ~ $ 27 Million in IGT Total
January 2011 | | Company Confidential Page 70
Value Proposition

Chromalloy is a global technology company.

We partner with customers to deliver innovative

solutions that reduce the operating expense, and

extend the life, of gas turbine engines.

January 2011 | | Company Confidential Page 71


ONE STOP SHOP
FROM CASTING TO FINISHED PART
Chromalloy Has The Necessary Technologies

CASTING MACHINED FINISHED

January 2011 | | Company Confidential Page 72


In Summary

Chromalloy is not only a one stop shop for all original


manufacturing needs but a one stop shop for the
lifetime of the engine components.
Extensive knowledge in all areas of gas turbine
manufacture and repair results in better parts, better
service, and more opportunity for our customers.
We dont make turbine engines. We make them last.

January 2011 | | Company Confidential Page 73


Questions and Discussion

January 2011 | | Company Confidential Page 74