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HCAT Propeller Chrome Plate Replacement Program

HCAT Propeller Chrome Plate Replacement Program. Edward Faillace - Steve Pasakarnis - Aaron Nardi Hamilton Sundstrand- Engineering August 29, 2001. Program Milestones. Fatigue Testing - completed April 2001 Wear - completed April 2001 Corrosion - completed January 2001

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HCAT Propeller Chrome Plate Replacement Program

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  1. HCAT Propeller Chrome Plate Replacement Program Edward Faillace - Steve Pasakarnis - Aaron Nardi Hamilton Sundstrand- Engineering August 29, 2001

  2. Program Milestones • Fatigue Testing - completed April 2001 • Wear - completed April 2001 • Corrosion - completed January 2001 • TCLP - completed January 2001 • LPS Component Test • Chrome plated - completed August 2001 WC-17Co - coating in process Full Scale Engine Test of P-3 Hub at HS -Feb. 2002 Original JTP Added Effort

  3. Proposed Follow-on Work • Compression - Compression Fatigue • Recent spalling concerns prompted effort • Evaluate effect of compressive fatigue loading on HVOF coating • Funded this year by Navy under Component Improvement Program (CIP) • Four Point Bend Testing • Evaluate test techniques for QC of coating application • Requested funding for FY 2002 • Residual Stress Evaluation • Evaluate coating/substrate compressive residual stresses using MLRM, XRD and Hole-drill techniques • Correlate test specimen stresses to actual part stresses • Requested funding for FY 2002

  4. Summary Of Fatigue Test Results • WC-Co exhibit no strength degradation on AISI 4340 HRC 40-44 • WC-Co exhibit superior fatigue properties to both EHC and T-800 • Shot peening had minimal effect on the fatigue strength of WC-Co and T-800 • Unable to discern surface roughness effect due to final specimen condition • WC-Co is more notch sensitive than T-800

  5. Peened Fatigue Data AISI 4340 HRC 40-44, R=0.1

  6. Macro Cracking from Grinding Operation

  7. Unpeened and Notched Fatigue Data AISI 4340 HRC 40-44, R=0.1

  8. HCAT Propeller Project-Wear Testing Aaron Nardi Hamilton Sundstrand- Materials Engineering

  9. Wear Testing • Coating Types • WC-Co • WC-Co-Cr • Tribaloy T-800 • Chrome Plate (AMS 2406) • Nickel Plate (AMS 2423) • Counterfaces • 4340 Steel • Beryllium Copper • Viton Seal Material • 15% Glass filled PTFE • Test Variables • Contamination • Oil Type (Mil-H-83282, Mil-H-87257) • Stroke Length • Load • Surface Finish

  10. Wear Test Fixture Load Pin 3000 lb. capacity Flat Counter-face Specimens Spring Washers Pivots Coated Panel Specimen

  11. Wear Testing Results • Coatings against Steel Counterfaces • Wear rates of steel specimens were comparable between EHC and WC-Co, but generally lower for T-800 • EHC and T-800 performed much poorer than WC-Co with respect to coating performance • Oil type had negligible effect on wear of steel specimens or coatings • Lower coating surface finishes produced less steel specimen wear • Oil contamination caused marco-spalling of EHC and T-800 in a dithering mode, WC-Co exhibited only a small spot of steel adhesion to the coating • All friction coefficients ranged from 0.1 - 0.15

  12. Dithering Tests With Steel Counterfaces in Contaminated Mil-PRF-83282 Hard Chrome Plate WC-17Co HVOF T-800 HVOF

  13. Wear Testing Results (cont’d) • Coatings against Beryllium Copper Counterfaces • Copper specimens exhibited higher wear rates than steel due to poor lubrication of copper by the TCP anti-wear additives in the hydraulic oil • WC-Co far outperformed both EHC and T-800 in Beryllium Copper material wear and panel coating performance • Surface finish did not play a significant role in the wear performance of either coated panel or Beryllium Copper specimen • Contamination resulted in minor overall changes in Beryllium Copper specimen wear but resulted in a reduced performance of all coatings • Friction coefficients were generally higher than for the steel specimens, ranging from 0.1 - 0.2

  14. Stroking Tests With Copper Counterfaces in Clean Mil-PRF-83282 Hard Chrome Plate WC-17Co HVOF T-800 HVOF

  15. Wear Testing Results (cont’d) • Coatings against Viton Counterfaces • Viton wear rates were generally similar between coatings but will be evaluated by wear step measurement . • Mil-PRF-87257 hydraulic oil increased the wear and the friction coefficient of the Viton specimens relative to the Mil-PRF-83282 baseline • Contamination had no effect on the WC-Co and had a slight effect on the EHC and T-800 • Dither tests exhibited higher friction coefficients than long stroking tests • Friction coefficients ranged from 0.1 - 0.3

  16. Wear Testing Results (cont’d) • Coatings against Glass Filled PTFE Counterfaces • WC-Co-Cr out-performed EHN in both coating performance and PTFE specimen wear • Nickel exhibited moderate abrasion by the PTFE specimens in both contaminated and non-contaminated oil • PTFE specimens exhibited slightly more wear with contaminated oil than with clean oil. • Friction coefficients ranged from 0.04-0.05

  17. Dithering Tests With Glass Filled PTFE Counterfaces in Clean Mil-PRF-83282 Hard Nickel Plate WC-Co-Cr HVOF

  18. HCAT Propeller Project-Corrosion Testing Aaron Nardi Hamilton Sundstrand- Materials Engineering

  19. Corrosion Testing • Salt Fog Corrosion Testing Per ASTM B117 • Coating Types • Nickel Plate (AMS 2423) • WC-Co • WC-Co-Cr • Tribaloy T-800 • Test Variables • As Plated vs. Machined • Coating Thickness

  20. 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.

  21. As Coated Nickel Corrosion Panels W-1, 8 days, 0.001 Thick W-6, 8 days, 0.005 Thick

  22. 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

  23. 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

  24. 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

  25. HCAT Propeller Project-Toxicity Characteristic Leaching Procedure Aaron Nardi Hamilton Sundstrand- Materials Engineering

  26. Corrosion and TCLP Testing • TCLP Testing • Evaluate environmental impact of powder disposal • Unsprayed powder • Sprayed Powder • Checks For Leaching of Heavy Metals Into Soil • Chrome • Nickel

  27. TCLP Testing Results • 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 Non-Hazardous Regulated Waste

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