Transcript Review of tech orders and selection of candidate

Hard Chrome Alternatives
for Hydraulic Components
• Program established to assist United States
Air Force Airborne Accessories Directorate
Avionics and Accessories Division
(OCALC/LII) in development and
implementation of replacement repair and
overhaul procedures for hydraulic actuators
across multiple weapon systems.
A
Hard Chrome Alternatives
for Hydraulic Components
• Phase 1 - TO and Drawing Review,
Database Development, Test Requirement
Development
– 124 Air Force Technical Orders Reviewed
• 100% complete
– 697 Engineering Drawings Reviewed
• 57.7% complete
– 276 Chrome plated parts and 203 potentially
chrome plated parts have been identified.
A
Hard Chrome Alternatives
for Hydraulic Components
• Phase 2 - Material, Rig, and Flight Testing
– Flight Control Actuators
• 87 distinct part numbers
• Estimate 6 will require delta-qualification
• 6 candidate items selected
A
Hard Chrome Alternatives
for Hydraulic Components
• Phase 2 - Material, Rig, and Flight Testing
– Utility Actuators
• 73 distinct part numbers
• Estimate 15 will require delta-qualification
• 1 candidate items selected
– Snubbers
• 12 distinct part numbers
• Estimate 3 will require delta-qualification
A
Hard Chrome Alternatives
for Hydraulic Components
• Phase 2 - Material, Rig, and Flight Testing
– C-130 Rudder Booster Assembly
• All chrome plated components are within one SRU
(rudder booster actuator)
• Rudder booster actuator was qualified, and rudder
booster assembly was not.
• Delta-qualification will be performed only on the
rudder booster actuator.
A
Hard Chrome Alternatives
for Hydraulic Components
• Phase 2 - Material, Rig, and Flight Testing
– C-130 Rudder Booster Assembly
• Rudder booster actuator manufactured by Kaiser
Fluid Technologies.
• Qualified by Lockheed Martin.
• Delta-Qualification will be performed by Kaiser
Fluid Technologies.
• Expected to take 12 months.
A
Hard Chrome Alternatives
for Hydraulic Components
A
Hard Chrome Alternatives
for Hydraulic Components
• Phase 2 - Material, Rig, and Flight Testing
– C-130 Rudder Booster Assembly
• Delta Qualification will consist of the following
tests:
–
–
–
–
–
–
Operation and Leakage
Low Temperature Operation
Rapid Warm Up
High Temperature Operation
Endurance
Salt Fog (ASTM B117-95)
A
Hard Chrome Alternatives
for Hydraulic Components
• Phase 2 - Material, Rig, and Flight Testing
– C-130 Rudder Booster Assembly
• Delta Qualification will omit following tests from
qualification:
–
–
–
–
–
Proof Pressure and Leakage
Vibration
Slam Test
Piston Rod Column
Burst
A
Hard Chrome Alternatives
for Hydraulic Components
• Phase 2 - Material, Rig, and Flight Testing
– C-130 Rudder Booster Assembly
–
–
–
–
Sand and Dust
Salt Spray (Federal Test Standard 151)
Impact Shock
Fungus Resistance
A
Hard Chrome Alternatives
for Hydraulic Components
• Phase 2 - Material, Rig, and Flight Testing
– C-130 Rudder Booster Assembly
• 4 chrome plated surfaces.
– Piston rod
» 3 sections, with piston heads separating them
– Piston head (2 piston heads on the unit)
» Not part of the piston rod
– Trunnion OD
» Mates with an aluminum-bronze bushing
– Trunnion ID
» Not wearing part
A
Hard Chrome Alternatives
for Hydraulic Components
A
Hard Chrome Alternatives
for Hydraulic Components
• Phase 2 - Material, Rig, and Flight Testing,
rod coating surface finish and seal selection
– Existing seals are elastomeric T-seals contacting
chrome plated rod
– Various testing to date shows:
• Elastomeric seals do not wear as well against ground HVOF
coated surfaces as they do against chrome.
• Elastomeric seals do not wear as well as teflon capped seals
against HFOV coated surfaces.
• Additional Greene Tweed testing indicates that superfinishing
of the coated rod surfaces reduces elastomeric seal life during
endurance tests.
A
Hard Chrome Alternatives
for Hydraulic Components
• Phase 2 - Material, Rig, and Flight Testing,
rod coating surface finish and seal selection
– Options under consideration:
• Use existing seals and as-ground coating surface, 4-8 Ra.
• Use existing seals and strictly control surface finish to Greene
Tweed or Shamban recommendations (Ra, Rz, Rpk, Rsk, Tp).
• Use teflon capped seals and as-ground coating surface, 4-8 Ra.
• Use existing seals on one end, teflon capped seals on other end,
as-ground coating surface, 4-8 Ra.
• Use existing seals on one end, teflon capped seals on other end,
and strictly control surface finish to Greene Tweed or Shamban
recommendations (Ra, Rz, Rpk, Rsk, Tp).
A
Hard Chrome Alternatives
for Hydraulic Components
• Phase 2 - Material, Rig, and Flight Testing
– C-130 Rudder Booster Assembly
• Best technical coatings
– Piston rod: 82W-10Co-4Cr-3.5C
» AMS 2447-9
– Piston head: Tribaloy 400
» AMS 2447-2
– Trunnion OD: 82W-10Co-4Cr-3.5C
» AMS 2447-9
– Trunnion ID: 82W-10Co-4Cr-3.5C
» AMS 2447-9
A
Hard Chrome Alternatives
for Hydraulic Components
• Phase 2 - Material, Rig, and Flight Testing
– C-130 Rudder Booster Assembly
• Best coatings with no chrome
– Piston rod: 88W-6Co-5.1C
» AMS 2447-7
– Piston head: Cu-37Ni-5In
» BAC 5851, Type XIV
– Trunnion OD: Cu-37Ni-5In
» BAC 5851, Type XIV
– Trunnion ID: Cu-37Ni-5In
» BAC 5851, Type XIV
A
Hard Chrome Alternatives
for Hydraulic Components
• Phase 3 - Data Evaluation
– Results of Testing will be evaluated and a
solution finalized.
A
Hard Chrome Alternatives
for Hydraulic Components
• Phase 4 - Implementation
– The solution developed in Evaluation will be
implemented.
A
Hard Chrome Alternatives
for Hydraulic Components
F-5
Drawings
45
Repair Figures 41
Repair Procedures 36
IPB
18
Part Number Change 18
TO Val/Ver Change 18
Number Of LRUs 18
A-10 C/KC-135 F-15
15
80
96
13
65
0
14
65
88
5
29
35
5
29
35
5
29
35
5
29
35
B-1
173
53
68
30
30
30
30
C-130
72
85
72
26
26
26
26
B-52
68
23
45
18
18
18
18
E-3
83
127
61
22
22
22
22
A
C-141
102
70
90
20
20
20
20
Total
734
477
539
203
203
203
203