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  • ESTCPCost and Performance Report

    ENVIRONMENTAL SECURITYTECHNOLOGY CERTIFICATION PROGRAM

    U.S. Department of Defense

    (WP-0127)

    Replacement of Chromium Electroplating on Helicopter Dynamic Components Using HVOF Thermal Spray TechnologyNovember 2009

  • Report Documentation Page Form ApprovedOMB No. 0704-0188Public reporting burden for the collection of information is estimated to average 1 hour per response, including the time for reviewing instructions, searching existing data sources, gathering andmaintaining the data needed, and completing and reviewing the collection of information. Send comments regarding this burden estimate or any other aspect of this collection of information,including suggestions for reducing this burden, to Washington Headquarters Services, Directorate for Information Operations and Reports, 1215 Jefferson Davis Highway, Suite 1204, ArlingtonVA 22202-4302. Respondents should be aware that notwithstanding any other provision of law, no person shall be subject to a penalty for failing to comply with a collection of information if itdoes not display a currently valid OMB control number.

    1. REPORT DATE NOV 2009

    2. REPORT TYPE N/A

    3. DATES COVERED -

    4. TITLE AND SUBTITLE Replacement of Chromium Electroplating on Helicopter DynamicComponents Using HVOF Thermal Spray Technology

    5a. CONTRACT NUMBER

    5b. GRANT NUMBER

    5c. PROGRAM ELEMENT NUMBER

    6. AUTHOR(S) 5d. PROJECT NUMBER

    5e. TASK NUMBER

    5f. WORK UNIT NUMBER

    7. PERFORMING ORGANIZATION NAME(S) AND ADDRESS(ES) Environmental Security Technology Certification Program 901 NorthStuart St., Suite 303 Arlington, VA 22203

    8. PERFORMING ORGANIZATIONREPORT NUMBER

    9. SPONSORING/MONITORING AGENCY NAME(S) AND ADDRESS(ES) 10. SPONSOR/MONITORS ACRONYM(S)

    11. SPONSOR/MONITORS REPORT NUMBER(S)

    12. DISTRIBUTION/AVAILABILITY STATEMENT Approved for public release, distribution unlimited

    13. SUPPLEMENTARY NOTES The original document contains color images.

    14. ABSTRACT

    15. SUBJECT TERMS

    16. SECURITY CLASSIFICATION OF: 17. LIMITATION OF ABSTRACT

    SAR

    18. NUMBEROF PAGES

    49

    19a. NAME OFRESPONSIBLE PERSON

    a. REPORT unclassified

    b. ABSTRACT unclassified

    c. THIS PAGE unclassified

    Standard Form 298 (Rev. 8-98) Prescribed by ANSI Std Z39-18

  • i

    COST & PERFORMANCE REPORT ESTCP Project: WP-0127

    TABLE OF CONTENTS

    Page

    1.0 EXECUTIVE SUMMARY ........................................................................ 1 1.1 BACKGROUND ............................................................................ 1 1.2 OBJECTIVES OF THE DEMONSTRATION ........................................ 1 1.3 REGULATORY DRIVERS .............................................................. 1 1.4 DEMONSTRATION RESULTS: ........................................................ 2 1.5 STAKEHOLDER/END-USER ISSUES ................................................ 3

    2.0 TECHNOLOGY DESCRIPTION ................................................................ 5 2.1 TECHNOLOGY DEVELOPMENT AND APPLICATION ........................ 5 2.2 PROCESS DESCRIPTION ............................................................... 6 2.3 PREVIOUS TESTING OF THE TECHNOLOGY ................................... 9 2.4 ADVANTAGES AND LIMITATIONS OF THE TECHNOLOGY .............. 9

    3.0 DEMONSTRATION DESIGN ................................................................... 11 3.1 PERFORMANCE OBJECTIVES....................................................... 11 3.2 SELECTION OF TEST FACILITY ................................................... 12 3.3 TEST FACILITY HISTORY/CHARACTERISTICS ............................... 12 3.4 PHYSICAL SETUP AND OPERATION ............................................. 13 3.5 SAMPLING/MONITORING PROCEDURES ....................................... 13 3.6 ANALYTICAL METHODS ............................................................. 13

    3.6.1 Specimen Production ............................................................. 13 3.6.2 Fatigue .............................................................................. 14 3.6.3 Fretting Fatigue ................................................................... 15 3.6.4 SO2 Salt Fog Corrosion (ASTM G85-98 Annex 4) ......................... 15

    4.0 PERFORMANCE ASSESSMENT .............................................................. 17 4.1 PERFORMANCE CRITERIA .......................................................... 17 4.2 PERFORMANCE DATA ................................................................ 17

    4.2.1 Materials TestingFatigue...................................................... 17 4.2.2 Materials TestingFretting Fatigue ........................................... 18 4.2.3 Materials TestingCorrosion .................................................. 19 4.2.4 Component TestingRig Test .................................................. 19 4.2.5 Qualification and Lead-the-Fleet Testing ..................................... 21

    4.3 DATA EVALUATION ................................................................... 21

    5.0 COST ASSESSMENT ............................................................................. 23 5.1 COST REPORTING ...................................................................... 23

    5.1.1 Data Provided by NADEP Cherry Point for Hard Chrome ............... 24

  • TABLE OF CONTENTS (continued)

    Page

    ii

    5.1.1.1 Assumptions for Hard Chrome ................................... 25 5.1.1.2 Capital Costs ......................................................... 25 5.1.1.3 Operating Costs...................................................... 25

    5.1.2 Data Provided by NADEP Cherry Point and the Equipment Vendor for HVOF ................................................................ 26 5.1.2.1 Assumptions .......................................................... 26 5.1.2.2 Capital Costs ......................................................... 27 5.1.2.3 Operating Costs...................................................... 28

    5.2 COST ANALYSIS ........................................................................ 29 5.3 COST COMPARISON ................................................................... 30

    6.0 IMPLEMENTATION ISSUES ................................................................... 33 6.1 COST OBSERVATIONS ................................................................ 33 6.2 PERFORMANCE OBSERVATIONS ................................................. 33 6.3 SCALE-UP ISSUES....................................................................... 33 6.4 LESSONS LEARNED .................................................................... 34 6.5 END-USER/OEM ISSUES .............................................................. 34 6.6 APPROACH TO REGULATORY COMPLIANCE AND

    ACCEPTANCE ............................................................................ 35

    7.0 REFERENCES ...................................................................................... 37 APPENDIX A POINTS OF CONTACT......................................................................... A-1

  • iii

    LIST OF FIGURES

    Page Figure 1. Schematic of HVOF gun and process (Sulzer Metco DiamondJet). ...................... 5 Figure 2. HVOF spray of test specimens at FRC-E. .............................................................. 6 Figure 3. Air handler and dust filter installation at FRC-E. ................................................... 7 Figure 4. Interior of thermal spray booth at FRC-E ..............................................................13 Figure 5. Smooth fatigue specimen-inch diameter. ...................................................... 14 Figure 6. Principle of fretting fatigue system design ............................................................15 Figure 7. Fatigue of shot peened 7075 T73 Al, HVOF and EHC coatings, R=0.1, in

    air and room. ......................................................................................................... 18 Figure 8. Fretting fatigue of 7075-T73 Al versus 52100 steel. Coatings - EHC and

    HVOF WC-Co. ..................................................................................................... 19 Figure 9. H-46 generator gear ...............................................................................................21 Figure 10. Hard chrome process flow at FRC-E, Cherry Point. ............................................ 23 Figure 11. HVOF process flow at FRC-E, Cherry Point........................................................ 24

  • iv

    LIST OF TABLES

    Page Table 1. Advantages and limitations of HVOF as a chrome replacement. ............................9Table 2. Corrosion ranking per ASTM B537-70. ................................................................15Table 3. H1 helicopter components qualified for HVOF WC-Co in place of hard

    chrome by Bell Helicopter testing. ........................................................................20Table 4. Base Scenario: Annual operating costs for hard chrome plating process for

    aircraft components. ...............................................................................................26Table 5. Base Scenario: Annual operating costs for HVOF thermal spray process for

    aircraft components ................................................................................................28Table 6. Scenario 1: Annual operating costs for HVOF thermal spray process for

    dynamic components .............................................................................................28Table 7. Annual operating costs fo

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