Transcript HVOF COATINGS AT SIKORSKY AIRCRAFT

CHROMIUM PLATING
REPLACEMENT AT
SIKORSKY AIRCRAFT
ROBERT GUILLEMETTE
JOHN BARTALOTTA
MATERIALS AND PROCESSES
ENGINEERING
APRIL 26, 2001
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OUTLINE
• I. Current chrome plating applications
• II. Past & current efforts with thermal spray
coatings
• III. Methodology for qualification of
thermal spray coated components
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US ARMY
US AIR FORCE
US NAVY
US MARINES
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Current Applications for
Chromium Plate
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Airframe
Drive System
Rotors
Flight Controls
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H-60 Airframe Chromium Plate Replacement
AXLE
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H-60 Drive System Chromium Plate Replacement
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H-60 Main Gearbox Chromium Plate Replacement
SEAL SLEEVE, MAIN ROTOR SHAFT
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H-60 Intermediate Gearbox Chromium Plate
Replacement
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H-60 Tail Gear Box Chromium Plate Replacement
OUTPUT GEAR
TORQUE WASHER
INBOARD RETENTION
PLATE SLEEVE
INPUT
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H-60 Main Rotor Head Chromium Plate Replacement
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Flight Controls Chromium Plate Replacement: nonhydraulic and hydraulic components
Primary Servos
Boost Servos
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Base Metals Plated With
Chromium
• Steels
– 4340 (150-280 ksi)
– 300M (280 ksi)
• Stainless Steels
• Titanium
– None
• Carburized Steels
– None
– 17-4
– 15-5
– PH13-8Mo
• Aluminum
– 7075-T73
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PRIMARY ALTERNATIVES
DETONATION GUN
SUPER DETONATION GUN
PLASMA
HVOF
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Detonation Gun
• Over 35 years experience with detonation
gun thermal spray coating
• Excellent track record
• Specified for difficult, critical applications
• Chromium replacement primarily done for
improved performance, now environmental
driven
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Current Super DGun Technology
• Several applications on S-92 and RAH-66
Comanche
• Implemented reduced weight designs by
taking advantage of improved fatigue
strength of DGun over chromium
electroplate
• Comparison testing shows Super DGun has
superior fatigue properties to HVOF
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HVOF Coating Evaluated at
Sikorsky Aircraft
• Diamond Jet
– Aluminum Silicon
– tungsten carbide
• JP5000 Tungsten Carbide
• Jet Kote tungsten carbide
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Base metals coated with thermal
spray coatings
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Thermal Spray Tungsten Carbide Results in Substantial
(6x) Life Improvement for H-60 Main Rotor Shaft
Detonation Gun
Tungsten Carbide
reduces fretting
fatigue at bearing
journals
(implemented 1987)
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HVOF Aluminum Silicon for Rework of Magnesium
Transmission Housings (implemented 1992)
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SH-60 DAMPER
•IMPROVEMENTS
– ZERO LEAKAGE FROM THE STATIC SEAL AREA HAS BEEN ACHIEVED
SINCE THE INCORPORATION OF THE TUNGSTEN CARBIDE COATING.
– THE TRIBALOY AND TUNGSTEN CARBIDE COATINGS ARE SHOWING
A GREAT IMPROVEMENT OVER THE CHROME AT 750 HOURS.
•ISSUES
– DAMPER BENCH TEST STOPPED AT ~750 HOURS DUE TO LEAKAGE
FROM DYNAMIC END OF DAMPER AND FAILURE OF THE NONMETALLIC BUSHING.
– AWAITING STRONGER NON-METALLIC BUSHING FROM SUPPLIER.
THE BUSHINGS ARE EXPECTED TO BE DELIVERED LATE MARCH 2001.
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Tail Landing Gear Piston
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SH-60B Tail Landing Gear Piston, Cleveland Pneumatic PN
2012C4, Base Metal: 300M Steel, Coated with SDG2057
tungsten carbide chromium
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Qualification Test matrix for
Navy H-60 Tail Gear Piston
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•
•
•
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•
•
Coating adhesion
Tensile
Fatigue (HCF)
Fatigue (LCF)
Cyclic stress/strain
Metallurgical
Wear test (bench
scale)
• Drop test (full scale)
• Corrosion
– open section
– crevice testing
• First article destructive
evaluation/validation
• NAVAIR review
• Lead-the-fleet testing
UH-60 Tail Landing Gear Fork
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UH-60 TAIL LANDING GEAR
Fork
Qualification Test Matrix for UH60 tail landing gear fork
• Adhesion (coupon)
• Metallurgical (coupon
& full scale)
– hardness
– porosity/uniformity
– heat/mechanical effect
on substrate
• Fatigue (coupon)
• Fatigue after exposure
to salt fog (coupon)
• Wear test (data from
Garlock)
• Corrosion testing (full
scale)
• Army AMCOM
review
• Lead-the-fleet testing
Guidelines for qualification of
components with chrome plate
replacement
• Parts have frozen process planning. Change
of supplier may require full scale testing
• Difficulty exist with across-the-board
substitution by similarity qualification
• Lead-the-fleet (actual service operations)
often needed as part of qualification
• Flight Safety parts to be addressed by Flight
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Safety Change Board
CONCLUSION
• Chromium replacement for multi-service
helicopters is a continuing effort at Sikorsky
Aircraft
• Criteria for qualification is a major
challenge
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