1 chromium plating replacement at sikorsky aircraft robert guillemette john bartalotta materials and...
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CHROMIUM PLATING REPLACEMENT AT
SIKORSKY AIRCRAFTROBERT 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 NAVY
US AIR FORCE US MARINES
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Current Applications for Chromium Plate
• 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
INBOARD RETENTION PLATE SLEEVE
OUTPUT GEAR
TORQUE WASHER
INPUT
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H-60 Main Rotor Head Chromium Plate Replacement
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Flight Controls Chromium Plate Replacement: non-hydraulic and hydraulic components
Boost Servos
Primary Servos
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Base Metals Plated With Chromium
• Steels– 4340 (150-280 ksi)
– 300M (280 ksi)
• Stainless Steels– 17-4
– 15-5
– PH13-8Mo
• Aluminum– 7075-T73
• Titanium– None
• Carburized Steels– None
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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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Detonation Gun Tungsten Carbide reduces fretting fatigue at bearing journals (implemented 1987)
Thermal Spray Tungsten Carbide Results in Substantial (6x) Life Improvement for H-60 Main Rotor Shaft
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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 NON-METALLIC 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
• 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
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UH-60 Tail Landing Gear Fork
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UH-60 TAIL LANDING GEAR
Fork
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Qualification Test Matrix for UH-60 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
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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 Safety
Change Board
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CONCLUSION
• Chromium replacement for multi-service helicopters is a continuing effort at Sikorsky Aircraft
• Criteria for qualification is a major challenge