Transcript HCAT Propeller Hub Chrome Plate Replacement Program

HCAT Propeller Hub Chrome Plate
Replacement Program
Aaron Nardi - Steve Pasakarnis
Hamilton Sundstrand- Materials Engineering
Coatings Characterization Testing
Contacts
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Fatigue - Steve Pasakarnis
Wear - Aaron Nardi
Corrosion - Blair Smith, Aaron Nardi
TCLP - Folashade Anderson
Low Pitch Stop Lever Sleeve, Sub-Component
Test - Ed Faillace, Folashade Anderson
Fatigue
• Covered in fatigue
presentation on
Wednesday morning by
John Sauer
Wear Testing
• Coating Types
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WC-Co
WC-Co-Cr
Tribaloy T-800
Chrome Plate (AMS 2406)
Nickel Plate (AMS 2423)
• Conterfaces
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4340 Steel
Beryllium Copper
Viton Seal Material
15% Glass filled PTFE
• Test Variables
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Contamination Iron oxide, silica sand, Arizona Road Test
Oil Type (Mil-H-83282, Mil-H-87257) Drip on each specimen
Stroke Length- Full Stroke and Dithering
Load
Surface Finish
Wear Test Fixture
Load Pin
3000 lb. capacity
Flat Counter-face
Specimens
Spring Washers
Pivots
Coated Panel Specimen
Wear Testing Results
• Quantitative Results
– Weight loss and wear depth ( profilometer )results being measured
– Data not yet reduced
• Qualitative Results
– Chrome plate exhibited the most extensive pitting when dithering
against steel with contaminated Mil-H-83282
– Chrome plate exhibited the most extensive adhesive plowing
against the Be-Cu samples
• phosphate lubricants in Mil-H-83282 will only lubricate iron based
alloys
– Neither HVOF WC-Co or T-800, exhibited pitting or adhesive
plowing to the extent of the Chrome Plate in any samples tested,
with WC performing the best overall
Dithering Tests With Steel Counterfaces
in Contaminated Mil-H-83282
Hard Chrome Plate
WC-17Co HVOF
T-800 HVOF
Stroking Tests With BeCu Counterfaces
in Clean Mil-H-83282
Hard Chrome Plate
WC-17Co HVOF
T-800 HVOF
Corrosion Testing
• ASTM B-117 Testing
• Checked panels on a daily basis
• .001, .005, .010” coating thickness on
coupons
• Testing ground vs. as sprayed surface
• Removal from tank criteria was:
– 3 or more spots
– Spot bigger than 1/4”
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.e to
substantial corrosion
• Photos are worst case-coated panels showed
– Co and CoCr showed varying results from panel to
panel
– T800 results were very consistent across all panels
• Trends were similar across the thickness ranges
As Coated Nickel Corrosion Panels
W-1, 8 days, 0.001 Thick
W-6, 8 days, 0.005 Thick
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
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
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
TCLP Testing Results
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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
Rig/Component Testing
• Rig test of low pitch stop lever sleeve
component
– Part experiences 10 cycles per flight and
testing will accumulate sufficient cycles
to correspond to 7500 hrs of flight
(i.e. overhaul interval)
– Loading will simulate actual flight
conditions using hydraulic fluid at 150
degrees and pressure of 310 psi
Program Milestones
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Wear Testing - April 2001
Fatigue Testing - April 2001
Corrosion Testing - Complete
TCLP Testing - Complete
Component Testing – Testing to begin April 2001
• Flight Test - Start September 2001
– Navy to Define Test Location