aerospace and defense industry · pdf filekeith legg, [email protected], 847-680-9420...

Keith Legg, [email protected], 847-680-9420

Aerospace and Defense Industry Challenges

Keith LeggRowan Technology Group

NASF Technical Advisory Committee NASF Meeting, Orlando, 2011

Keith Legg, [email protected]

NASF Aerospace and Defense Roadmap

NASF Aerospace and Defense Roadmaphttp://www.nasf.org/AM/Template.cfm?Section=NASF_Roadmap&Template=/MembersOnly.cfm&NavMenuID=1260&ContentID=8193&DirectListComboInd=D

http://www.nasf.org/AM/Template.cfm?Section=NASF_Roadmap&Template=/MembersOnly.cfm&NavMenuID=1260&ContentID=8193&DirectListComboInd=D





Drivers for change in Aerospace and Defense Industry

RoHS and REACHVery serious issue for N American OEMs

US DoD policyNew DoD policies and acquisition regulations

Customer demandIncreasing demand for clean systems to reduce liability risk and regulatory impact

Improved performance, reduced cost of ownership

In reality improved performance/lower life cycle cost is one of the strongest drivers for replacing older materials


Aerospace and Defense Roadmap

2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 2021 2022 20223 2024 2025 2026 2027 2028

Meeting regulatory requirements

Fuel efficiency – next generation GTEs and diesel engines

Fuel efficiency – lighter materials

Cost of ownership – material cost and performance

Cost of ownership – overhaul and repair cost

Underlying issues – Testing, IT and databases, modeling, design

Goals: Routes:

Meeting ESOH regulatory requirements Compliance with REACH, RoHS, OSHA, DoD, customer requirements

Fuel efficiency – next GTEs and diesels Lighter materials, higher operating temperatures, emission and noise reductions

Fuel efficiency – lighter materials Improved manufacture and performance of composites, light alloys

Cost of ownership – materials performance Lower susceptibility to damage and corrosion

Cost of ownership – overhaul and repair Easier, cheaper, faster repair, reclamation


Improve data, testing methods, and modeling of the underlying science of coating processes to improve prediction, reduce time and cost to reach implementation

Other issues Development of specialized coatings

Other issues


Cr6+-free paint systemsCr6+-free Mg treatments (see Corrosion protection for Mg)

Cr6+-free metallic-ceramicsCr6+-free bond primers

Cd, Cr6+-free fasteners, connectorsCr6+-free Al anodizingHard and Thin Dense chrome alternatives

Cd Plating alternativesPb-free anti-fretting

Low VOC topcoats, sealants

Meeting ESOH regulatory requirements

2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 2021 2022 20223 2024 2025 2026 2027 2028

REACH

• Annex XIV additions

RoHS

•Aircraft?•Military electronics?

• REACH Cd restriction, Vehicles

• DoD Cr6+ memo

Meeting ESOH regulatory requirements

Customer ESOH restrictions

• Aircraft• Vehicles• Vessels

Cr6+-free conversion, sealing

Whisker reduction for Pb-free electronics

Goals: Routes:

Cr6+ elimination from materials Trivalent and non‐chrome conversion coatings, sealers, paint systems, etc.

Cr6+ process elimination Non‐Cr plating, anodizing

Cd elimination Cd plating alternative adoption

Pb elimination from anti‐fretting coaitngs Pb‐free alternatives

VOC reduction Low VOC topcoats, sealants, etc.

Beryllium reduction, mitigation Alternative materials (coated powders), isolation coatings

Whisker reduction from electronics Solder modifications, mitigation coatings and treatments

Beryllium reduction, mitigation


Environment and regulation

The biggest issue for the aircraft industry is environment and health regulation

Most aerospace companies putting a lot of effort into this areaEliminating Cd plate and chromates

Chromate primer, chromate conversion, hard chrome plate, etc.Be and other materialsNi coatings are critical to aerospace (wear resistance, rebuild)

Non-Pb solder is a serious problem because the riskWhiskers, fatigue, no settled alternative

Speed of required changeChange often required in 5 yrs, but traditionally takes 20 yrs


Drivers – REACH

Some of the same issues for US and EU OEMsUncertainty over what materials will be restricted or Annex XIV, and whenUncertainty, constantly growing list of SVHCsRegistration issues – aerospace and defense usesCost of developing and qualifying alternativesSpeed of change far faster than traditional timescale for developing, qualifying, adopting alternativesUndefined and unlimited downstream costs

N American companies working hard to meet REACH requirements

Difficulties and disagreements over understandingNot sure there is the same understanding in US and EULack of Defense Exemptions serious issue for EU manufacturers


April 2009 DoD Memo on Cr6+

April 8 ‘09 USD-ATL issued memo to minimize Cr6+ use, unless no cost-effective alternatives with satisfactory performanceMilitary organizations directed to invest in R&D, including funding qualification testingApprove qualified alternativesDocument Cr6+ health risksRequires Program Executive Officer (flag officer) and Corrosion Control and Prevention Executive (CCPE) to certify if no acceptable alternative

Similar to Lockheed approachIntended to force adoption of Cr6+-free coatings and production methodsUSD-ATL issuing a new memo asking for reports on implementation actions

USD-ATL = Undersecretary of Defense –Acquisition, Technology and Logistics


Proposed DFARs – new language in future defense contracts

“…the Contractor shall not provide any deliverables under this contract, or use materials in performance of this contract, that contain hexavalent chromium in a concentration greater than 0.1 percent by weight in any homogeneous material.”

Unless authorized at flag level, or used in legacy systems, “…no DoD contract may include a specification or standard that results in a deliverable containing hexavalent chromium or the use of hexavalent chromium in contract performance.”

Applies to all components, no matter where made. Suppliers see similar language in some contracts already; DFARs will make it universal.

DFAR = Defense Federal Acquisition RegulationContract language for all DoD purchases of equipment, supplies, components

Will this apply to conversion coatings?


Impact of DoD Cr6+ memo

Largest impact will be on aircraft because they useChromated primersChromate conversion coatings/sealers for Al alloy skins and airframes, Cd and other corrosion coatings, etc.Chromic acid anodizingMg alloysVarious washes

Vehicle impact will primarily be onChromate washes for prepaintConversion of Cd and ZnChrome plating on hydraulic actuators, etc.

All systems (inc. ships) use chromate converted Cd on fasteners and electrical connectors, and chrome plating on actuators

Impact will depend strongly on whether or not conversion coatings are exempt


Indirect effects of Cr6+-related regulation

PFOS

Cr6+ in water

• EHC• Process

requal with alternative

• Plating• Conversion• Anodizing• Painting• Mg finishing


WHAT ARE AEROSPACE AND DEFENSE DOING ABOUT Cd AND Cr6+?


HAZMAT alternatives –Hard chrome plating

HCAT (Hard Chrome Alternatives Team)

US/Canadian team of OEMs, DoD, suppliers validated HVOF for Landing Gear, Hydraulic Actuators, GTEs, Helicopter Components, Propeller HubsProcess development, data, rig and flight testing – all publicly availableHVOF WC-CoCr now standard for all new landing gear, inner cylinders, pins, many hydraulic rods

High Velocity Oxy-Fuel thermal spray


Primary reason for success of HVOF is better performance –less wear and corrosion, less seal wear/leakage

Actuator coating is no good if it just wears out the seals


Other hard chrome alternatives

HVOF cannot be used for most internalsPulse plated nanophase Co-P under validation testing

Very similar in performance to chrome

Other electroplatesNanophase Ni-WCo composites

Electroless Ni-P for lower wear applicationsPVD diamondlike coatings for internals

Aerospace evaluations, no qualifications


HAZMAT alternatives –Chromate conversion

All finishing chemical suppliers have trivalent and non-Cr conversion coatings and sealers

NAVAIR developed Tri-Chrome Pretreat (TCP) now licensed widely and qualified for many uses

Adhesion promotersUS Air Force uses Prekote on many systemsBoeing uses AC130/131 (aka Boegel) to prevent rivet rash

None of these adequate for unpainted use


Paint systems, primers

Non-Cr primers becoming quite widely usedUS and European vendors

Fully Cr-free paint systems not generally acceptedTypical approach is to use non-Cr primer with chromate conversion or non-Cr6+ pretreat with chromated primerF-35, AH-64 use chromate conversion with non-Cr primer

Minimizes Cr6+

Aim is to go to Cr6+-free finish if acceptable performanceDeft is testing a new Cr6+-free paint system (pretreat/primer/topcoat)ESTCP program now underway to evaluate non-chrome primers

Typical approach is to use first on low-risk areas (easily monitored areas such as OML) and apply to successively more critical and harder-to-monitor areas, ending with inaccessible internal airframe areas and fuel tanks when confident enoughCr-free finish Boeing 777 now being flown by KLM


HAZMAT alternatives –Cd plating

Aerospace and defense are sole remaining large users of Cd plateAircraft high strength steel, fasteners, electrical connectors

Electroplated Al (AlumiPlate) on some F-35 landing gear components, and other aircraft

Commercially availableNon-aqueous bath – no H embrittlementIonic liquid AlZr in development by Dipsol to avoid toluene bath

MIL specs for MIL-DTL-38999 and other electrical connectors now permit Al, ZnNi, electroless Ni-PTFELHE Zn-14Ni validated and approved by USAF

Hill AFB for landing gearAqueous bathEssentially equivalent to Cd

Military vehicles adopting metal-filled dip-spin coatings for fasteners similar to automotive (Magni, Doerken, etc)Ultrahigh strength CRES landing gear steel developed and validated

Commercially available as Cartech S53 alloy


Thermal Barrier Coatings

Erosion resistant blade coatings

FOD-resistant coatings

Barrier coatings for CMCs, CCCs

High Temperature oxidation barriers

Abradables

Nacelle coatings

Fuel efficiency – next generation GTEs

2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 2021 2022 20223 2024 2025 2026 2027 2028

Goals: Routes:

Thermal Barrier Coatings New formulations, nanophase materials

Erosion resistant blade coatings Multi‐layer coatings systems

FOD-resistant coatings Coatings, compressive layers

Environmental barriers for CMCs Highly stable high temperature coatings to prevent degradation from oxygen, water, etc

High Temperature oxidation barriers

Better oxygen diffusion barriers, including multi‐component oxides

Abradables Improved high temperature abradables, including microballoons

Nacelle coatings Various coating improvements for erosion, abrasion, FOD


Fuel efficiency – lighter airframe materials

2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 2021 2022 20223 2024 2025 2026 2027 2028

Fuel efficiency – Lightweight materials

Composite fan blade erosion, FOD

Composite tooling

Corrosion protection for Mg

Adhesion to Ti

Composite galvanic corrosion and EMI protection

Goals: Routes:

Composite fan blade erosion, FOD

Multi‐layer coatings, metallic coatings

Composite galvanic corrosion and EMI protection

Protective coatings for airframe, metallic coatings for composite electrical components

Composite tooling Coatings for composite tooling to provide wear/abrasion resistance with low CTE

Corrosion protection for Mg Plasma electrolytic oxidation, non‐chromate conversion, cold spray

Adhesion to Ti Etching, surface profiling

Lighweight armor Armor for vehicles, aircraft, personnel


Lightweight materials

C-fiber (and some glass fiber) composites increasingly used for aircraft and vehiclesAbrasion and corrosion: Protection required for exposed composite surfaces such as composite GTE compressor blades and helicopter rotor bladesGalvanic corrosion: Coatings and shim protection required to prevent galvanic corrosion between composite skins and aluminum substructuresMg gearbox corrosion is a perpetual problemIncreasing use of plating on plastics for electronic componentsCoatings being developed to increase modulus and wear resistance for composites and plastics


Cost of ownership – airframe materials

2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 2021 2022 20223 2024 2025 2026 2027 2028

Cost of ownership – material cost and performanceGoals: Routes:

Reduced airframe and vehicle corrosion Better corrosion coatings and paints for hydraulics, fasteners, electrical systems; aircraft frame, skin, landing gear; vehicle frame, armor

Reduced wear Better wear coatings for functional components (landing gear, hydraulics, etc)

Reduced erosion, abrasion, FOD damage More resistant coatings on exposed areas, leading edges, landing gear, radomes

Water drop erosion Better radome coatings for high speed military aircraft

Helicopter blade erosion Coatings resistant to sand erosion

Reduced corrosion (see also ESOH: Chromate alternatives, Cd plating alternatives)

Reduced wear (see ESOH: Hard and thin dense Cr alternatives)

Reduced erosion, abrasion, FOD



2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 2021 2022 20223 2024 2025 2026 2027 2028

Cost of ownership – overhaul and repair costGoals: Routes:

Rebuild automation Automation of the evaluation, tool path, rebuild approach for damaged blades and other components

Rebuild coatings for Mg Method for rebuilding damaged or corroded Mg alloy gearboxes, etc

Strippers GTE, including TiN, TiAlN More effective, less toxic stripping methods for engine coatings

Strippers blade passages Stripping methods for internal blade passages (liquid or gas based)

Depainting and repainting Cleaner, faster methods of stripping and repainting

Rebuild coatings for Mg

Strippers GTE

Strippers blade passages

Strippers paint

Rapid repainting


Cost of ownership

We are always looking for better and cheaper ways of repairing worn, eroded and corroded componentsWe are always looking for paint systems with better long-term performance, slower degradation, better corrosion resistance without chromatesConstant challenge is to rebuild components to restore not just dimensional tolerance, but also strength

Having some success with high velocity, He-based cold spray



2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 2021 2022 20223 2024 2025 2026 2027 2028


Goals: Routes:

Process modeling, control, portability

Understand physical processes of coating, in order to improve portability and reliability of coating processes

Coating integration Integrate coatings with design tools

Build/rebuild automation Automation of the evaluation, tool path, rebuild approach for damaged components

Accelerated implementation Development of better understanding, development, test, business systems for rapid development, qualification and diffusion of coating technologies

Materials modeling and design Modeling physical deposition processes and using models in design of coatings

Prediction Prediction of galvanic and salt water corrosion performance,

Build/rebuild automation

Accelerated implementation

Process modeling, control and portability

Coating integration with design

Materials modeling, coating design

Prediction


Cross-cutting issues

2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 2021 2022 20223 2024 2025 2026 2027 2028

Other issues

Ice-phobic coatings

Coatings for use with alternative fuels

High temperature non-skid coatings

Goals: Routes:

Ice-phobic coatings Coatings for flight surfaces, engine nose cones, etc to reject ice build‐up

Coatings for use with alternative fuels

Engine fuel system and hot section coatings that may be needed for using alternative fuels

High temperature non-skid coatings

Shipboard deck coatings able to withstand engine exhaust of new STOV/VTOL aircraft

Anti-foul hull coatings for reducing drag

Blast mitigation coatings for vehicles, buildings


Need thermal barrier anti-skid needed

New VTOL/STOVL aircraft will overheat decks


Faster, better, cheaper

Need to accelerate design, qual, implementationModeling, accelerated testingBetter tests – faster but more realistic, esp for corrosion

Galvanic corrosion constant issueComplexity of new designs, specialty coatings, new materials leading to galvanic corrosion seesNew computational approach has a lot of potential for avoiding costly galvanic corrosion design errors, integrates with standard CAD design software to show corrosion rate over entire assemblyNew Coatings Database (Granta/Rowan)


Information sources – ASETSDefense


Upcoming Workshops

Programs, briefings, summaries of previous workshops at www.asetsdefense.org, www.nasf.org

http://workshops.serdp-estcp.org/ad11

http://www.nasf.org/Content/NavigationMenu/NASFEventsPage/WashingtonForum/default.htm

http://www.nasf.org/Content/NavigationMenu/NASFEventsPage/SURFIN2011/default.htm



http://workshops.serdp-estcp.org/CMS/index.cfm?elemNum=33&ASETSDefense11=1

http://www.asetsdefense.org/

http://www.nasf.org/

http://workshops.serdp-estcp.org/ad11



aerospace and defense industry · pdf filekeith legg, [email protected], 847-680-9420...

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