Transcript Review of all fatigue, corrosion, and wear tests

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HCAT Propeller Chrome Plate
Replacement Program
Edward Faillace - Steve Pasakarnis - Aaron Nardi
Hamilton Sundstrand- Engineering
August 29, 2001
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Program Milestones
Fatigue Testing - completed April 2001
Wear - completed April 2001
Corrosion - completed January 2001
TCLP - completed January 2001
LPS Component Test
Chrome plated - completed August 2001
WC-17Co - coating in process
Full Scale Engine Test of P-3 Hub at HS Feb. 2002
Original
JTP
Added
Effort
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Proposed Follow-on Work
• Compression - Compression Fatigue
– Recent spalling concerns prompted effort
– Evaluate effect of compressive fatigue loading on HVOF coating
– Funded this year by Navy under Component Improvement Program (CIP)
• Four Point Bend Testing
– Evaluate test techniques for QC of coating application
– Requested funding for FY 2002
•
Residual Stress Evaluation
– Evaluate coating/substrate compressive residual stresses using MLRM,
XRD and Hole-drill techniques
– Correlate test specimen stresses to actual part stresses
– Requested funding for FY 2002
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Summary Of Fatigue Test Results
• WC-Co exhibit no strength degradation on AISI 4340
HRC 40-44
• WC-Co exhibit superior fatigue properties to both EHC
and T-800
• Shot peening had minimal effect on the fatigue strength
of WC-Co and T-800
• Unable to discern surface roughness effect due to final
specimen condition
• WC-Co is more notch sensitive than T-800
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Peened Fatigue Data
AISI 4340 HRC 40-44, R=0.1
250
200
Unpeened 4340 Steel
Peened WC - 17% Co .003" 4 Ra Finish
150
Stress (ksi)
Peened WC - 17% Co .010" 16 Ra Finish
Peened WC - 17% Co .010" 4 Ra Finish
Peened WC - 17% Co .015" 4 Ra Finish
Peened EHC .003" 16 Ra
Peened EHC .010" 16 Ra Finish
100
Peened EHC .015" 16 Ra Finish
Peened T-800 .003" 8 Ra Finish
Peened T-800 .010" 8 Ra Finish
Peened T-800 .010" 16 Ra Finish
Peened T-800 .015" 8 Ra Finish
50
0
104
105
106
Cycles
107
108
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Macro Cracking from Grinding Operation
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Unpeened and Notched Fatigue Data
AISI 4340 HRC 40-44, R=0.1
250
Bare 4340
Unpeened EHC, 0.003
Max Stress (ksi)
200
Unpeened EHC, 0.010
Unpeened EHC, 0.015
150
Unpeened WC, 0.003
Unpeened WC, 0.010
100
T-800, Kt=2.70
WC, Kt=2.70
50
0
10000
100000
1000000
Cycles
10000000
100000000
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AlSI4340 HRC 40-44, R=0.1, .010" WC-17Co
Green Points Were Not Peened
240
Maximum Stress (ksi)
230
220
210
200
190
180
170
160
150
140
1.0E+02
1.0E+03
1.0E+04
1.0E+05
Cycles
1.0E+06
1.0E+07
1.0E+08
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4340 HRC40-44, R=0.1,WC-17Co .003" 4Ra
Green Points Were Not Peened
220
Maximum Stress (ksi)
210
200
190
180
170
160
150
140
1.0E+02
1.0E+03
1.0E+04
1.0E+05
Cycles
1.0E+06
1.0E+07
1.0E+08
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AISI 4340, HRC 40-44, R=0.1, T-800 .015
Green Points Were Not Peened
210
Maximum Stress (ksi)
200
190
180
170
160
150
140
130
120
110
1.0E+02
1.0E+03
1.0E+04
1.0E+05
Cycles
1.0E+06
1.0E+07
1.0E+08
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AISI 4340 HRC 40-44, R=0.1,.015" Cr 16Ra
Green Points Were Not Peened
Maximum Stress (ksi)
250
200
150
100
50
0
1.0E+02
1.0E+03
1.0E+04
1.0E+05
Cycles
1.0E+06
1.0E+07
1.0E+08
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AISI 4340, HRC 40-44, R=0.1, T-800 .010
Green Points Were Not Peened
210
Maximum Stress (ksi)
200
190
180
170
160
150
140
130
120
110
1.0E+02
1.0E+03
1.0E+04
1.0E+05
Cycles
1.0E+06
1.0E+07
1.0E+08
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AlSI4340 HRC 40-44, R=0.1, .010" Cr
Green Points Were Not Peened
Maximum Stress (ksi)
250
200
150
100
50
0
1.0E+03
1.0E+04
1.0E+05
1.0E+06
Cycles
1.0E+07
1.0E+08
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AISI 4340, HRC 40-44, R=0.1,.003" T-800
Green Points Were Not Peened
220
Maximum Stress (ksi)
200
180
160
140
120
100
1.0E+02
1.0E+03
1.0E+04
1.0E+05
Cycles
1.0E+06
1.0E+07
1.0E+08
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HCAT Propeller ProjectWear Testing
Aaron Nardi
Hamilton Sundstrand- Materials Engineering
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Wear Testing
• Coating Types
•
•
•
•
•
WC-Co
WC-Co-Cr
Tribaloy T-800
Chrome Plate (AMS 2406)
Nickel Plate (AMS 2423)
• Counterfaces
•
•
•
•
4340 Steel
Beryllium Copper
Viton Seal Material
15% Glass filled PTFE
• Test Variables
•
•
•
•
•
Contamination
Oil Type (Mil-H-83282, Mil-H-87257)
Stroke Length
Load
Surface Finish
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Wear Test Fixture
Load Pin
3000 lb. capacity
Flat Counter-face
Specimens
Spring Washers
Pivots
Coated Panel Specimen
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Wear Testing Results
• Coatings against Steel Counterfaces
– Wear rates of steel specimens were comparable between EHC and
WC-Co, but generally lower for T-800
– EHC and T-800 performed much poorer than WC-Co with respect
to coating performance
– Oil type had negligible effect on wear of steel specimens or
coatings
– Lower coating surface finishes produced less steel specimen wear
– Oil contamination caused marco-spalling of EHC and T-800 in a
dithering mode, WC-Co exhibited only a small spot of steel
adhesion to the coating
– All friction coefficients ranged from 0.1 - 0.15
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Steel Wear Rate Comparison
Lubrication System Failure
2.0E-12
Chrome Plate
Tungsten Carbide
Tribaloy T-800
1.5E-12
Heavy pitting and
adhesion of panel
coating on steel
-1.0E-12
-1.5E-12
Test Condition
High/Long/O
Low/Long/C
Low/Dither/C
-50.0E-14
High/Long/SF
00.0E+0
High/Long
50.0E-14
Low/Dither
Wear Coefficient
1.0E-12
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Panel Wear from Steel Specimens
Chrome Plate
Tungsten Carbide
Tribaloy T-800
Heavy 4
Moderate 3
1
Test Condition
O
Hi
gh
/L
on
g/
/L
on
g/
C
Lo
w
Lo
w
/D
ith
er
/C
SF
Hi
gh
/L
on
g/
Hi
gh
/L
on
g
0
ith
er
No Wear
2
/D
Mild Wear
Lo
w
Adhesive /
Abrasive Wear
Pitting 5
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Dithering Tests With Steel Counterfaces
in Contaminated Mil-PRF-83282
Hard Chrome Plate
WC-17Co HVOF
T-800 HVOF
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Wear Testing Results (cont’d)
• Coatings against Beryllium Copper Counterfaces
– Copper specimens exhibited higher wear rates than steel due to
poor lubrication of copper by the TCP anti-wear additives in the
hydraulic oil
– WC-Co far outperformed both EHC and T-800 in Beryllium
Copper material wear and panel coating performance
– Surface finish did not play a significant role in the wear
performance of either coated panel or Beryllium Copper specimen
– Contamination resulted in minor overall changes in Beryllium
Copper specimen wear but resulted in a reduced performance of all
coatings
– Friction coefficients were generally higher than for the steel
specimens, ranging from 0.1 - 0.2
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Copper Specimen Wear Rate Comparison
40.0E-12
Chrome Plate
Tungsten Carbide
35.0E-12
Tribaloy T-800
Wear Coefficient
30.0E-12
25.0E-12
20.0E-12
15.0E-12
10.0E-12
5.0E-12
000.0E+0
r
the
i
D
w/
Lo
ng
Lo
/
w
Lo
w
Lo
F
g/S
n
/Lo
w
Lo
r/C
he
t
i
/D
Test Condition
/C
ng
o
L
h/
Hig
r/O
he
t
i
h/D
Hig
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Panel Wear from Copper Specimens
Pitting 5
Chrome Plate
Tungsten Carbide
Tribaloy T-800
Moderate 3
Mild Wear 2
No Wear 1
Test Condition
O
h/
Lo
ng
/
Hi
g
Lo
w/
Lo
ng
/C
er
/C
Lo
w/
Di
th
SF
h/
Lo
ng
/
Hi
g
h/
Lo
ng
Hi
g
er
0
Lo
w/
Di
th
Adhesive /
Abrasive Wear
Heavy 4
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Stroking Tests With Copper Counterfaces in
Clean Mil-PRF-83282
Hard Chrome Plate
WC-17Co HVOF
T-800 HVOF
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Wear Testing Results (cont’d)
• Coatings against Viton Counterfaces
– Viton wear rates were generally similar between coatings but will
be evaluated by wear step measurement .
– Mil-PRF-87257 hydraulic oil increased the wear and the friction
coefficient of the Viton specimens relative to the Mil-PRF-83282
baseline
– Contamination had no effect on the WC-Co and had a slight effect
on the EHC and T-800
– Dither tests exhibited higher friction coefficients than long stroking
tests
– Friction coefficients ranged from 0.1 - 0.3
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Viton Wear Rate Comparison
400.0E-12
Chrome Plate
Tungsten Carbide
Tribaloy T-800
300.0E-12
Wear Coefficient
200.0E-12
100.0E-12
000.0E+0
r
he
t
i
D
w/
Lo
-100.0E-12
g
on
L
/
h
Hig
F
g/S
n
/Lo
h
g
Hi
h/
g
i
H
C
er/
h
t
Di
Acetone Exposure, weights inaccurate
-200.0E-12
Test Condition
g/C
n
Lo
w/
o
L
/O
ng
o
h/L
g
i
H
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Panel Wear from Viton Specimens
Chrome Plate
Tungsten Carbide
Tribaloy T-800
Heavy 4
Moderate 3
1
Test Condition
O
Hi
gh
/L
on
g/
/L
on
g/
C
Lo
w
Lo
w
/D
ith
er
/C
SF
Hi
gh
/L
on
g/
Hi
gh
/L
on
g
0
ith
er
No Wear
2
/D
Mild Wear
Lo
w
Adhesive /
Abrasive Wear
Pitting 5
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Wear Testing Results (cont’d)
• Coatings against Glass Filled PTFE Counterfaces
– WC-Co-Cr out-performed EHN in both coating performance and
PTFE specimen wear
– Nickel exhibited moderate abrasion by the PTFE specimens in
both contaminated and non-contaminated oil
– PTFE specimens exhibited slightly more wear with contaminated
oil than with clean oil.
– Friction coefficients ranged from 0.04-0.05
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Dithering Tests With Glass Filled PTFE
Counterfaces in Clean Mil-PRF-83282
Hard Nickel Plate
WC-Co-Cr HVOF
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HCAT Propeller ProjectCorrosion Testing
Aaron Nardi
Hamilton Sundstrand- Materials Engineering
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Corrosion Testing
• Salt Fog Corrosion Testing Per ASTM B117
– Coating Types
•
•
•
•
Nickel Plate (AMS 2423)
WC-Co
WC-Co-Cr
Tribaloy T-800
– Test Variables
• As Plated vs. Machined
• Coating Thickness
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Results From Corrosion Testing
• Nickel Plating was the overall top performer
• WC-Co-Cr was marginally the best HVOF coating
• In General, the thick coatings performed better
than thin coatings
• Machined specimens generally performed worse
than panels in the as coated condition.
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As Coated Nickel Corrosion Panels
W-1, 8 days, 0.001 Thick
W-6, 8 days, 0.005 Thick
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As Coated Tribaloy T-800 Corrosion Panels
T-1, 5 days, 0.001 Thick
T-2, 5 days, 0.001 Thick
T-3, 5 days, 0.001 Thick
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As Coated WC-Co Corrosion Panels
W-1, 12 days, 0.001 Thick
W-2, 8 days, 0.001 Thick
W-6, 20 days, 0.005 Thick
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As Coated WC-Co-Cr Corrosion Panels
WCR-1, 20 days, 0.001 Thick
WCR-2, 8 days, 0.001 Thick
WCR-3, 8 days, 0.001 Thick
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HCAT Propeller ProjectToxicity Characteristic Leaching Procedure
Aaron Nardi
Hamilton Sundstrand- Materials Engineering
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Corrosion and TCLP Testing
• TCLP Testing
– Evaluate environmental impact of powder disposal
• Unsprayed powder
• Sprayed Powder
– Checks For Leaching of Heavy Metals Into Soil
• Chrome
• Nickel
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TCLP Testing Results
•
•
•
•
Spent Material Tested (WC-Co-Cr, T-400, T-800)
Virgin Powder Tested (WC-Co-Cr, T-400, T-800)
NOT HAZARDOUS WASTE
In Connecticut Would Be Considered NonHazardous Regulated Waste