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HARD CHROME PLATING ALTERNATIVES
POLLUTION PREVENTION SUB-IPT
HARD CHROME PLATING ALTERNATIVES
Mary Gilman
Boeing C-17 Pollution Prevention Project Manager
Boeing Hard Chromium Natural Work Group Leader
HCAT MEETING
25-26 April 01
Long Beach, CA
HARD CHROME PLATING ALTERNATIVES
POLLUTION PREVENTION SUB-IPT
BOEING HARD CHROMIUM
NATURAL WORK GROUP
• Hold quarterly telecon and net meetings.
• Bring together chromium plating experts at various
locations.
• Identify environmentally compliant, safe alternatives.
• Disseminate information and data.
• Share and leverage results and lessons learned.
• Document cost savings across programs.
• Monitor in-house evaluation and implementation
programs.
HCAT MEETING
25-26 April 01
Long Beach, CA
HARD CHROME PLATING ALTERNATIVES
POLLUTION PREVENTION SUB-IPT
BOEING HARD CHROMIUM
NATURAL WORK GROUP (cont)
• Renton Evaluation Programs
– Thermal spray coatings on various substrates, high strength
steel for landing gear -- Gary Erickson
– Diamond-like-carbon coating -- Dennis Dull
– Wet chemical methods -- Mike Ware
• St. Louis Evaluation Program
– Corrosion resistance of thermal spray coatings -- Steve Gaydos
• Mesa Evaluation Program
– Sputtering down gun barrels -- Tony Piazza
• Long Beach Evaluation Programs
– Commercial working with FAA to use Seattle testing results and
documentation -- Tom Posten
– C-17 planning coupon fatigue testing, landing gear durability
testing and hydraulic actuator component testing -- Mary Gilman
HCAT MEETING
25-26 April 01
Long Beach, CA
HARD CHROME PLATING ALTERNATIVES
POLLUTION PREVENTION SUB-IPT
C-17 POLLUTION PREVENTION PROGRAM
• Objective is reduction or elimination of hazardous
materials from C-17 weapon system
• Evaluate and implement non-hazardous materials as
replacements
• Completed over 60 projects to date since March 1995
• Work recognized by the U.S. Air Force, regional regulatory
agencies, and within Boeing Company
• Awarded 1997 Pollution Prevention Continuous
Improvement Award by Region IX U.S. Environmental
Protection Agency (EPA)
• Awarded 1997 and 2000 Air Force Material Command
Single Manager Pollution Prevention Awards
HCAT MEETING
25-26 April 01
Long Beach, CA
HARD CHROME PLATING ALTERNATIVES
POLLUTION PREVENTION SUB-IPT
HAZARDS of CHROMIUM
• Chrome plating applied by suppliers and depots.
• Plating bath contains mostly hexavalent chromium (CrVI)
carcinogenic and hazardous to health and environment.
• Compliance regulated by OSHA Standard, NESHAP, TRI
and reduction targeted as EPA and C-17 COC.
• Federal EPA plans an 89% reduction on limit for
wastewater.
– State and local to follow
• Federal OSHA plans a 50-100 fold reduction in PEL
permissible exposure limit.
– CAL OSHA already reduced to 0.5 ppm.
• Increasing costs of worker protection and surveillance,
environmental compliance and waste disposal.
HCAT MEETING
25-26 April 01
Long Beach, CA
HARD CHROME PLATING ALTERNATIVES
POLLUTION PREVENTION SUB-IPT
ANTICIPATED BENEFITS of HVOF ALTERNATIVE
• Application materials and spray process are nonhazardous to environment and worker.
• Improved performance in fatigue, wear, porosity and
corrosion properties.
• Improved durability and life extension in field repair
and overhaul procedures.
• Not susceptible to hydrogen embrittlement, requires
no embrittlement relief bake.
• Labor costs are lower for HVOF, but operating costs
are higher.
• Long term costs of HVOF will drop given market
competition and environmental factors.
HCAT MEETING
25-26 April 01
Long Beach, CA
HARD CHROME PLATING ALTERNATIVES
POLLUTION PREVENTION SUB-IPT
COMPLETED -- C-17 EVALUATION EFFORT
• Identify specifications and requirements.
• Identify and review landing gear production and
support documentation.
• Search literature and survey industry for alternatives.
• Compare alternative technologies and identify most
promising candidates for successful implementation.
• Characterize parts and recommend alternatives
based on size, complexity, and internal surfaces.
• Conduct supplier and program cost and schedule
impact analysis.
• Perform Environmental, Health & Safety Analysis.
HCAT MEETING
25-26 April 01
Long Beach, CA
HARD CHROME PLATING ALTERNATIVES
POLLUTION PREVENTION SUB-IPT
CURRENT -- C-17 ANALYSIS EFFORT
• Perform Life Cycle Cost analysis on landing gear.
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Environmental and worker safety impact
Development of material and process change
Material and labor for production and overhaul
Reliability, maintainability and availability
Equipment procurement, maintenance and operation
Revision of production and support documentation
• Deliver Risk Assessment Analysis report.
– Summary of environmental, performance,
documentation, cost and schedule impacts.
HCAT MEETING
25-26 April 01
Long Beach, CA
HARD CHROME PLATING ALTERNATIVES
POLLUTION PREVENTION SUB-IPT
PLAN -- C-17 FATIGUE COUPON TESTING
• Prepare specimens for fatigue testing
– Develop test plan
– Fabricate NC310 HSS (310 KSI) specimens
– Apply Type 17 WC/CoCr HVOF thermal coating
• Perform fatigue testing
– Perform testing for smooth fatigue, tensile and
bond-tensile
– Verify HVOF coating performs as well as chrome
plating
• Perform inspections before and after testing
– Magnetic particle, dye penetrant, and ultrasonic
HCAT MEETING
25-26 April 01
Long Beach, CA
HARD CHROME PLATING ALTERNATIVES
POLLUTION PREVENTION SUB-IPT
PLAN -- HYDRAULIC ACTUATOR TESTING
• Develop test plan to evaluate hydraulic actuators
– Identify functional and performance requirements
– Identify test equipment and procedures
– Focus on piston rod/gland interfaces and
interactions
– Not address piston head to cylinder bore interactions
– Select coating and seal material, finish, and
geometry
– Evaluate compatibility with hydraulic fluids
– Select combination for maximum wear resistance
and life of components, mating parts and seals
HCAT MEETING
25-26 April 01
Long Beach, CA
HARD CHROME PLATING ALTERNATIVES
POLLUTION PREVENTION SUB-IPT
PLAN -- C-17 LANDING GEAR TESTING
• Prepare parts for durability testing
– Develop test plan and select parts to test
– Purchase 300M high strength steel (280 KSI)
landing gear pins and bolts
– Apply Type 17 WC/CoCr HVOF thermal spray
coating
• Perform durability rig testing
– Complete extension program to six lifetimes
– Perform inspections for delamination or failure
of HVOF coating
– Verify HVOF coating performs as well as chrome
plating
HCAT MEETING
25-26 April 01
Long Beach, CA
HARD CHROME PLATING ALTERNATIVES
POLLUTION PREVENTION SUB-IPT
OTHER C-17 LANDING GEAR ISSUES
• Some problems on main landing gear
components
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Post shelf wear and wheel axles
Base material 300M high strength steel
Finished with hard chrome plating
Plating surfaces with some wear, galling,
chipping, burning, or corrosion pitting
– Good candidate components to evaluate
HVOF as alternatives
– Expect HVOF hard coatings to improve wear
performance and extend life of components
HCAT MEETING
25-26 April 01
Long Beach, CA