HELICOPTER DYNAMIC COMPONENTS JTP FATIGUE TESTING

HCAT Review Meeting 23-25 January New Orleans, LA

SUBSTRATES/HT CONDITION
4340: HRc 32-37 (UTS 150-170 ksi) PH13-8Mo: H1050 per AMS 5629 (UTS 175 ksi) 9310: HRc 35-40 core with HRc 59-62 carburized case
Specimens carburized to 0.030 case depth then finish ground to a final case depth of 0.024

7075-T7351 (UTS 65-75 ksi) Steel specimens peened per AMS 2432, 100% coverage, 8-10A intensity, CW14 shot 7075 peened in 2 lots
Per AMS 2430, 12-16A intensity, ASR 230 shot (Metal Improvement) Per AMS-S-13165-97, 0.00849A intensity, S230 shot (SW United)

(Bare specimens tested as-peened)

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COATINGS
HVOF (Hitemco)
WC-Co WC-Co-Cr T400+WC-Co: 0.007-0.009+0.003-0.004 T400: Sprayed by not tested

EHC (SOUTHWEST UNITED)

IAW MIL-STD-1501 & QQ-C-320 No underlayer or sealer
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SUBSTRATE/COATING MATRIX
COATING EHC WC-Co WC-Co-Cr T400+WC-Co EHC WC-Co WC-Co-Cr Bare/Peened (T-400) BOTH THICKNESS .010-.011 010-.011 010-.011 010-.011 .003-.004 .003-.004 .003-.004 10 10 10 10 10 10 10 10 10 10 PH13-8Mo 10 10 10 9310 10 10 10 7075-T7351 10 10 10 10 10 10 10 10 10 3 5 3 3 4340 5 3 3

COATING & FINISHING

Target coating finish
HVOF: 8-10 Ra EHC: 12-16 Ra Final ground & polished coating thickness 0.0035-0.0040 & 0.0105-0.0110

First group of 0.003 EHC on 7075 had insufficient thickness for grind & polish. A 2nd set of specimens (20) was peened by SWU followed by EHC plating on 10 specimens. To be tested.

0.5 Coating Patch

FATIGUE TEST CONDITIONS

Room temperature Stress ratio: R = 0.1 Frequency: 60 Hz without encountering heating above 125F 10 specimens/curve for 13-8, 9310, & 7075 3-5 specimens/coating for 4340 @ 105 cycles (130 ksi).

2360-83163 Fatigue Data Room Temp, R = 0.1, PH 13/8 Mo

200 190 180 M ax Stress (ksi) 170 160 150 140 130 1.0E+02 1.0E+03 1.0E+04 1.0E+05 Cycles bare/peened W C-CoCr (0.003 in) EHC (0.011 in) W C-Co (0.011 in) EHC (0.003 in) W C-Co (0.003 in) W C-CoCr (0.011 in) T-400 1.0E+06 1.0E+07 1.0E+08

Large data points (6) indicate cracking observed at <10,000 cycles

2360-83163 Fatigue Data Room Temp, R = 0.1, 9310 (steel)

220 215 210 205 200 Max Stress (ksi) 195 190 185 180 175 170 165 160 155 1.0E+03 1.0E+04 bare/peened W C-CoCr (0.003 in) 1.0E+05 EHC (0.011 in) W C-Co (0.011 in) 1.0E+06 Cycles EHC (0.003 in) W C-Co (0.003 in) 1.0E+07 W C-CoCr (0.011 in) 1.0E+08

Large data points (3) indicate cracking observed at <10,000 cycles

2360-83163 Fatigue Data Room Temp, R = 0.1, 7075-T7351

85 80 75 70 65 Max Stress (ksi) 60 55 50 45 40 35 30 25 20 1.0E+03 1.0E+04 bare/peened (MRI) EHC (0.003 in) W C-Co (0.011 in) 1.0E+05 Cycles bare/peened (SW ) W C-CoCr (0.011 in) W C-Co (0.003 in) 1.0E+06 1.0E+07 EHC (0.011 in) W C-CoCr (0.003 in) T400+W C-Co (0.011 in) 1.0E+08

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0.011" COATINGS ON 4340

155

150

Max Stress (ksi)

145

140

2 pts. each
135

130

125 1.0E+03 1.0E+04 1.0E+05 Cycles 1.0E+06 1.0E+07 1.0E+08

EHC

WC-Co-Cr

WC-Co

Large data point indicates cracking observed at <10,000 cycles

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0.003" COATINGS ON 4340

145

140 Max Stress (ksi)

135

130

125 1.0E+04 1.0E+05 1.0E+06 Cycles 1.0E+07 1.0E+08

EHC

WC-Co

WC-Co-Cr

Large data point indicates cracking observed at <10,000 cycles

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FATIGUE BEHAVIOR OBSERVATIONS

Fatigue life rankings by substrate
HVOF >> EHC on 9310 HVOF > EHC on PH13-8Mo HVOF EHC on 7075

The difference between HVOF and EHC is greatest at lower stresses near the fatigue limit Fatigue life rankings by coating
WC-Co WC-Co-Cr on all 3 substrates T400+WC-Co other HVOF coatings on 7075

Fatigue life rankings on 4340 substrate

0.003: WC-Co-Cr > WC-Co EHC 0.011: WC-Co-Cr WC-Co >> EHC
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Cracking detected at 2,300 cycles

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POST-TEST COATING BEHAVIOR

COATING EHC WC-Co WC-Co-Cr T400+WC -Co EHC WC-Co WC-Co-Cr THICK .010-.011 010-.011 010-.011 010-.011 .003-.004 .003-.004 .003-.004 Crack 0/10 Spall 0/10 Crack 10/10 Spall 10/10 Crack 10/10 Spall 10/10 Crack 1/10 Spall 0/10 Crack 8/10 Spall 5/10 Crack 8/10 Spall 9/10 PH13-8Mo 9310 7075-T7351 Crack 0/10 Spall 0/10 Crack 1/10 Spall 1/10 Crack 1/10 Spall 3/10 Crack 0/10 Spall 0/10 TBD Crack 1/10 Spall 1/10 Crack 0/10 Spall 0/10 Crack 0/5 Spall 0/5 Crack 3/3 Spall 0/3 Crack 1/3 Spall 0/3
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4340 Crack 0/5 Spall 1/5 Crack 0/3 Spall 0/3 Crack 2/3 Spall 0/3

Crack 0/10 Crack 0/10 Spall 10/10 Spall 10/10 Crack 3/10 Spall 9/10 Crack 10/10 Spall 9/10 Crack 0/10 Spall 10/10 Crack 9/10 Spall 6/10

COATING BEHAVIOR OBSERVATIONS

Post-test cracking overwhelmingly circumferential (ring) type. No indications of spalling during tests. Limited detection of cracking during tests, despite frequent post-test evidence of cracks. Some indications of load-carrying capability of HVOF coatings vs. non-load bearing EHC.
Nf for 0.011 HVOF > 0.003 HVOF Nf for 0.011 EHC < 0.003 EHC More frequent end-of-patch failure for 0.011 HVOF vs. 0.003 coating. Low occurrence for EHC

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SUMMARY REMARKS
As in prior HCAT programs, the fatigue performance of HVOF coatings is equal to or exceeds that of EHC plating. The HVOF coatings exhibit moderate to severe spalling (coating debonding) at fracture, whereas plating loss for EHC generally is limited to the nearfracture region. The fatigue performance of the HVOF coatings apparently is not compromised by cracking (ringtype) relatively early in the test (<10K cycles).

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