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Phase 1 - TO and Drawing Review, Database Development, Test Requirement Development

Program established to assist Oklahoma City Air Logistics Center Airborne Accessories Directorate Avionics and Accessories Division (OC-ALC/LII) in development and implementation of replacement repair and overhaul procedures for hydraulic actuators across multiple weapon systems.

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Phase 1 - TO and Drawing Review, Database Development, Test Requirement Development

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  1. Program established to assist Oklahoma City Air Logistics Center Airborne Accessories Directorate Avionics and Accessories Division (OC-ALC/LII) in development and implementation of replacement repair and overhaul procedures for hydraulic actuators across multiple weapon systems.

  2. Phase 1 - TO and Drawing Review, Database Development, Test Requirement Development • 124 Air Force Technical Orders Reviewed • 100% complete • 729 Engineering Drawings Reviewed • 60.4% complete • 276 Chrome plated parts and 195 potentially chrome plated parts have been identified.

  3. Phase 2 - Material, Rig, and Flight Testing • Flight Control Actuators • 87 distinct part numbers • Revised estimate: 8-10 will require delta-qualification • Candidate items selected

  4. Phase 2 - Material, Rig, and Flight Testing • Utility Actuators • 73 distinct part numbers • Revised estimate: 10 will require delta-qualification • 1 candidate items selected • Snubbers • 12 distinct part numbers • Estimate 3 will require delta-qualification

  5. 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.

  6. 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

  7. 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.

  8. Phase 2 - Material, Rig, and Flight Testing, rod coating surface finish and seal selection • Options under consideration: • Electroplated Chrome with AGT seals (baseline) • HVOF WC-CoCr with AGT seals • HVOF WC-CoCr with new Greene Tweed seals • HVOF WC-CoCr with new Shamban seals

  9. Phase 2 - Material, Rig, and Flight Testing • C-130 Rudder Booster Assembly • HVOF coatings superfinished - Ra: 2-4 • Chrome ground - Ra: 8-16

  10. Phase 3 - Data Evaluation • Results of Testing will be evaluated and a solution finalized.

  11. Phase 4 - Implementation • The solution developed during evaluation will be implemented.

  12. Lessons learned • Some parts may NOT be suitable for HVOF. Other coatings may be required coatings. • Piston heads • Trunnion ID

  13. Lessons learned • There is more to this than HVOF. • Surface finishing • Application process • Seal choices

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