Test Status Overview

Dec 13,14, 2000

Keith Legg 847-680-9420

Rationale

A lot of data has been generated in HCAT/CHCAT program in the past 3 or 4 months Aim is to show overall status - where we are in testing and what we have learned overall

Put current data in a logical order Address what we are doing to resolve some testing issues Suggest some compartments for existing and new data

Keith Legg 847-680-9420

Overview

Aircraft use of HVOF coatings Why are we doing this? commercial flight tests Overall status of JTP tests

Conditions seen by real parts Summary of findings to date What does all this mean for actual usage?

JTP - Corrosion, wear, fatigue, embrittlement, impact Ancillary - Process specs, producibility, additional corrosion, additional fatigue, failure mechanisms

Where does it work just fine? Where do we need to worry?

Keith Legg 847-680-9420

Flight testing Why are we doing this?

Flight testing (Boeing, Delta, Lufthansa etc.) shows acceptable performance with no serious problems

Wear performance much better than chrome

no gouges, striations, flaking, etc. commonly seen in Cr better seal life if Ra~4 (rapid seal damage if rough) some FPI crack pattern indications on Lufthansa aft inner cylinders (Barkhausen showed no crack penetration to substrate), nothing requiring removal from service

Typical chrome damage - axle

Keith Legg 847-680-9420

Production use of HVOF WC-Co and WC-CoCr coatings

Component
Steering collars Slat tracks Pan castings Gimbals Bolts Wear rings Plungers Fittings Mufflers Fairings Landing gear sleeves, pins Boeing 747-400 landing gear Boeing 737 landing gear Airbus 320 landing gear F-18 Main landing gear axle HVOF, D-gun, plasma Tribaloy 400 D-gun, plasma Cu37Ni-5In, WC-18Co HVOF WC-CoCr HVOF WC-CoCr HVOF WC-CoCr HVOF WC-CoCr AMS 2447 BAC 5851 BAC 5851 BAC 5851 BAC 5851 Boeing OEM coating Boeing OEM coating Boeing OEM coating Overhaul and repair Overhaul and repair Canadian Air Force flight tested, in final approval Plasma Cr2O3 BAC 5851 Boeing OEM coating D-gun WC-14Co BAC 5851 Boeing OEM coating

Coating
HVOF, plasma, D-gun WC-Co HVOF, plasma, D-gun WC-18Co

Specification
BAC 5851 BAC 5851

Notes
Boeing OEM coating Boeing OEM coating

Keith Legg 847-680-9420

Production use of HVOF WC-Co and WC-CoCr coatings (cont.)

Sikorsky CH-53 blade damper P&W F-119 Engine Convergent Nozzle Actuator Slat tracks, Boeing Bombardier Q-400 flap tracks Bombardier Q-400 and Global Express door stop pins Slat and flap tracks Flap track repair Bombardier Dash 8 L1011 flap tracks Boeing 737, 757, 767 landing gear Parker-Hannifin actuators Plasma T400 Super D-gun WC-Co and Plasma T400 Super D-gun WC-18Co HVOF WC-Co HVOF WC-Co HS 4412 BAC 5851 Bombardier PPS 24.04 Bombardier PPS 24.04 BAC 5851 RD 8-57-1164 to 1169 In final approval for Navy CH-53 fleet Hamilton Sundstrand spec. Engine likely to be used on JSF OEM usage OEM usage OEM usage

HVOF WC-Co HVOF WC-Co HVOF WC-Co HVOF WC-Co Various

Overhaul and Repair Overhaul and Repair Overhaul and Repair Titanium alloy

BAC 5851

Main and nose landing gear O&R at Delta Airlines OEM usage all new-design hydraulics

Qualified for landing gear repair <0.010

Keith Legg 847-680-9420

Production use of HVOF landing gear coatings - Messier-Dowty

Program-p/n Part name Type of coating Area Remarks

F/A-18 E/F
74A430702 Piston head assy Retract Actuator NLG Cover assy Gear/manifold Head, Piston Shock Absorber MLGF-18 E/F Diamalloy 1004 (Al bronze) Applied per AMS2447 Tribaloy T400 6.612 OD Production part

74A430616

8.974 ID

Production part

F/A-18 C/D
74A410603 Diamalloy 1004 (Al bronze) Applied per AMS2447 WC-Co per DCMP 210 (AMS2447-7) AMS 2447-4 Ni95-Al5 AMS 2447-9 OD R&O DRED

Note production use on high performance aircraft

Hawker 4000
34520-1 REO 45062601 74A410509 Lock link outboard forward door mechanism NLG Tube Restrictor Support Axle of the polygon Flat stops 2.623/2.621 OD 2.931/3.374 polygon 4.614 OD Production part R&O In progress

Cl601RJ
Shock strut piston MLG 17114-1 Shock strut pin MLG WC-Co-Cr per DCMP 213 (AMS 2447-9) WC-Co-Cr per DCMP 213 (AMS 2447-9) Tribaloy T400 DCMP 203 (AMS2447-2) Under evaluation in service by Air Canada, NIEO Under evaluation in service by Air Canada, NIEO Production part

1.498 OD

17207-1

A340 CLG
37173-101 37174-101 15173-101 15174-101 BD 100 40672 Sleeve thrust shock strut 2.348 ID

Pin, Piston Tube NLG

WC-Co-Cr per DCMP 213 (AMS 2447-9)

0.866 OD

Production part

Keith Legg 847-680-9420

Data summary: Landing Gear JTP - Coupon test data

Data Item Corrosion C-HCAT salt fog US-HCAT salt fog US-HCAT cyclic salt fog H Embrittlement US-HCAT Deposition US-HCAT H Evolution US-HCAT Environmental Emb. Fatigue WC-Co (Hourglass) US-HCAT in air 0.003" US-HCAT in air 0.010" US-HCAT corrosion Fatigue WC-CoCr (Smooth bar) C-HCAT air 0.003" thick C-HCAT air 0.010" thick C-HCAT corrosion C-HCAT low temp. Impact Dropped ball Gravelometry Wear Fretting Osc. piston/bushing Test ASTM B-117 B117 GM 9540P/B ASTM F-519 ASTM F-519 ASTM F-519 ASTM E-466 ASTM E-466 ASTM E-466 ASTM ASTM ASTM ASTM E-466 E-466 E-466 E-466 Completeness 25 50 75 100 Pass Fail Notes x Standard flat ??? Modified sample. Retesting ??? Modified sample. Retesting No embrittlement by HVOF No acceptance criteria

x -

x x x x

R=-1, 0.1 R=-1, 0.1 R=-1, 0.1 R=-1. Delamination above 180 ksi load ??? R=-1. Delamination above 125 ksi load ??? R=-1. Rapid corrosion initial tests

ASTM D-3170 GEAE Hydraulic simul.

Data being obtained Equivalent or better than Cr Data complete - being analyzed Data complete - being analyzed

Keith Legg 847-680-9420

Data summary: Propeller Hub JTP - Coupon test data

Data Item Corrosion WC-Co, WC-CoCr, T800, Ni plate Fatigue (Hourglass) WC-Co, T800, Cr WC-Co, T800 Wear Large stroke and dither Toxicity leaching WC-CoCr, T400, T800 waste Test ASTM B-117 ASTM E-466 ASTM E-466 HSD EPA 1311 Completeness 25 50 75 100 Pass Fail Notes Standard 4"x6" flat panel HSD hourglass, R=0.1 HSD notched hourglass, R=0.1 HSD wear plates Acetic acid leach

Keith Legg 847-680-9420

Corrosion

C-HCAT B117

US-HCAT B117

JTP work complete

HVOF performed significantly better than chrome - Pass

Initial test results reported in Ottawa, Aug 00

HVOF coatings worse than Cr - Fail Appears to be a testing issue

Outstanding issues - resolution of US-HCAT results

Retesting under way Different sealing - Boeing Cd method 2 different geometries (Flats and cylinders) 2 different deposition conditions (Southwest Aero, Hitemco) 2 different cabinets
Keith Legg 847-680-9420

Embrittlement

Tests partially complete

Sequence 1 - HVOF does not cause embrittlement - Pass Sequence 2 - Not yet complete

H2 can diffuse through HVOF coating May need longer bake

Sequence 3 begun - no data yet

Environmental embrittlement measurements in process Coating may lower Kt - calculations and tests under way at Heroux

Outstanding issues

Keith Legg 847-680-9420

Fatigue - WC-Co

WC-Co

WC-CoCr

US-HCAT testing complete All WC-Co air fatigue data equal to or better than Cr Pass All WC-Co corrosion-fatigue data equal to or better than Cr - Pass Delamination from some specimens at high cycles

WC-CoCr 0.003 delamination at high load Pass below 180 ksi, Fail above 180 ksi WC-CoCr 0.010 delamination at high load Pass below 125 ksi, Fail above 125 ksi WC-CoCr corrosion-fatigue Fail??

Not a structural issue, but a functional issue (Messier-Dowty) Outstanding issues Results of WC-CoCr fatigue testing

being addressed under Ancillary Testing

Keith Legg 847-680-9420

Wear

Fretting and sliding (hydraulic)

Data evaluation largely complete HVOF better than or equal to Cr

Less striation, wear, roughening (Delta, Greene Tweed) Less wear and leakage of seals (Greene, Tweed)

Rig and flight tests all show better wear performance

Keith Legg 847-680-9420

Impact

Drop ball testing

Under way
Completed - HVOF as good as or better than Cr - Pass

Gravelometry (Boeing)

Keith Legg 847-680-9420

Data summary: Landing Gear JTP - Rig and flight testing

Data Item Rig tests Boeing F-18 LG pins Hydraulic testing M-D F-18 E/F NLG fat. M-D F-18 E/F drag brace fat. BFG Dash-8/400 MLG BFG NLG steering act. BFG simulated piston fat. Boeing C-17 forward MLG Repair scheme rig (Heroux) CF-18 A/B NLG shock strut CF-18 A/B MLG crank assy CC-130 steering collar Flight tests Delta B737, 757, 767 LG M-D CF-18 polygon repair NADEP-JAX P-3 C-HCAT DND C-130 KC-135, MLG, NLG piston F-16 NLG Test Full scale Hydraulic Fatigue Endurance Full scale Full scale Full scale sim Full scale Full scale Full scale Full scale x x Completeness 25 50 75 100 Pass Fail Notes x x HVOF pins included in rig test Greene, Tweed - long stroke and dithering spectrum Without catapult loads Rig complete, awaiting all test item parts Full scale piston fatigue simulation Durability - proposed. Out for coordination HVOF restrictor tube - compression, cyclic loading Torsion loads equivalent to landing loads Endurance life Internal Delta, not HCAT-sponsored Internal Messier-Dowty, not HCAT-sponsored C-HCAT testing Air Force - military typical worst case Air Force - high performance worst case

Keith Legg 847-680-9420

Data summary: Propeller Hub JTP Rig and flight testing

Data Item Test Rig tests 54H60 low pitch stop lever sleeve Piston stroke Flight tests P-3 propeller 275 flight hrs Completeness 25 50 75 100 Pass Fail Notes WC-Co and T800 Tail shaft hub and sleeve lever

Keith Legg 847-680-9420

Hydraulic testing - Greene, Tweed

PTFE (Enercap) much better performance with WC

2500 2000 1500 1000 500 0

Leakage (grams)

15

C hrome, Enercap Tribaloy, Enercap WC-C o, Enercap WC-Co-C r, Enercap Chrome, ACT Tribaloy, ACT WC-Co, ACT

low leakage low rod wear

25

35

Elastomer rapidly damaged

45

Cycles (millions)

4-9 Ra

not a problem with long stroke utility actuators and landing gear at 4 Ra

Keith Legg 847-680-9420

Landing gear rig tests

Boeing F/A-18 E/F landing gear pins

HVOF coatings passed full scale rig fatigue test

darkened, but no wear damage, passed MPI

Outstanding - Additional full scale tests to be done by C-HCAT

Messier-Dowty F-18 E/F NLG fatigue Messier-Dowty F-18 E/F drag brace fatigue

including catapult loads

BFG Dash-8/400 MLG BFG NLG steering actuator BFG simulated piston fatigue

Keith Legg 847-680-9420

Flight tests

Delta B737, 757, 767 nose and main landing gear

Inner cylinders, axles, axle sleeves

Passed - WC-CoCr qualified for O&R

Boeing 767-400

HVOF WC-CoCr flight qualified and used in production Messier-Dowty polygon repair

Canadian F-18 MLG

WC-CoCr Repair scheme approved

Outstanding - NADEP-JAX P3, DND C-130 testing

Keith Legg 847-680-9420

Data summary Ancillary tests

Data Item Test Process parameters US-HCAT WC-Co DOE C-HCAT NRC WC-CoCr DOE Commercial - SWA, Hitemco Grinding/finishing NADEP-JAX Delta Airlines Heroux Stripping NADEP-CP, S'west Aero CTC water jet Heroux R&O Fluid compatibility Heroux NDI Heroux Delta, Boeing flight tests Corrosion Beach exposure Salt fog B117 Cyclic salt fog GM 9540P/B US-HCAT comparison tests B117 Fatigue (Smooth bar) US/C-HCAT WC-CoCr air ASTM E-466 Fracture mechanisms C-HCAT NRC/Orenda Specifications AMS specs Completeness 25 50 75 100 Pass Fail Notes -

Boeing QPL processes Low stress grind used on samples Used on flight test landing gear

x x

WC-Co and WC-CoCr strip w/Rochelle Incomplete stripping

x x x

FPI, Barkhausen good; MPI poor Flat samples - generic tests Flat samples - generic tests Flat samples - generic tests New seal; flat, round, var. vendors, var. cabinets

Powder, grinding, coating

Keith Legg 847-680-9420

Process parameters

WC-Co optimized by Jerry Schell by DOE methods

OO-ALC, Hitemco - JP 5000, DJ Process designed for 8-12 Almen compressive stress

WC-CoCr optimized by Jean-Gabriel Legoux, NRC by DOE methods

DJ-gun at NRC and VacAero Process designed for 8-12 Almen compressive stress Coating parameters different from QPL conditions used by Southwest Aero

Keith Legg 847-680-9420

Grinding and finishing

Overall finding - for seals need 4 or less Ra

Use fine grind or superfinish (specify other parameters?)

Low stress grinding developed by Jon Devereaux at NADEP-JAX

used on all US-HCAT samples

Surface measurement and superfinishing developed for landing gear by Jay Randolph at Delta Testing carried out by John Falkowski (Boeing) and Jim Nuse (Southwest Aeroservice) - AESF paper Additional testing under way

Boeing, SW Aero, Sulzer Metco, Engelhard, Praxair, Green Tweed, Supfina, Delta
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Stripping

Water jet does not work very well Rochelle salt works well for WC-Co and WC-CoCr

SW Aero, Sulzer Metco NADEP-Cherry Point, NTS

Testing at Praxair and others shows no embrittlement with strippers No good method for T400 yet Outstanding - need good chemical strip for Tribaloy

Keith Legg 847-680-9420

Fluid compatibility

Under way shortly at Heroux Will include evaluations of hydrogen embrittlement due to fluids

Keith Legg 847-680-9420

NDI

FPI best method so far

Delta, Boeing

MPI not effective Boeing has used Barkhausen with some success Heroux testing begun Outstanding - how detect cracks in substrate without removing coating?

Keith Legg 847-680-9420

Corrosion

All HCAT generic, C-HCAT, Lufthansa data on flats shows HVOF having better performance than Cr

US-HCAT Landing gear JTP data on rods showed worse than Cr - Fail

Repeating with better edge seal - comparing sample shapes, deposition conditions, test locations

Outstanding - Resolution of poor US-HCAT test performance (under way)

Keith Legg 847-680-9420

Fatigue and fracture

Fatigue of WC-CoCr - the picture folks took back from Ottawa meeting

Keith Legg 847-680-9420

Fatigue and fracture

Findings of cracking by AFRL (Bob Ware) Careful analysis done at NRC (Jason Dyer, Peter Au)

WC-CoCr fails, cracks and delaminates under high compressive load (R=-1) 0.003 coating, failure at 180 ksi and above 0.010 coating, failure at 125 ksi and above (note that thicker coating carries more load) cracks grow down from coating surface and often run parallel to interface (similar mechanism to that designed into composites) cracks do not appear to propagate from coating into substrate

Surfaces of WC-CoCr fatigue specimens from Southwest Aeroservice also show crack pattern and some spalling at failure and runout This shows there may be operational limits of WC-CoCr

Keith Legg 847-680-9420

Questions:

Where should we be testing? What are the real-world requirements? What are the functional limits of WC-CoCr and WC-Co?

Keith Legg 847-680-9420

Fatigue and cracking - historical

Fracture data - John Quets, Shane Arthur

WC-Co initially designed using bend test cracking data WC-CoCr designed to have better corrosion performance, but lower fracture strength So, WC composite coatings balance hardness and wear resistance against brittleness (fracture strength)

1998 - Crack-like indications found by FPI on aft side of WC-CoCrcoated Lufthansa landing gear. Barkhausen analysis by Boeing showed no crack propagation into steel. Returned to service - no reported problems.

Bend test of Praxair WC-CoCr. Reported by Jay Randolph, Delta Airlines, July 1998
Keith Legg 847-680-9420

Landing gear design and fatigue testing

Designers do not design to specimen test data

Coupons provide stress engineers the data to start analyzing for customer and air-worthiness justification
Difficult to translate from load on full scale item to stress on test coupon

Qualification always depends on full-scale item fatigue testing under spectrum loading to 2 or 4 lifetimes

Bulk of public domain data for AerMet 100 was run at 150 ksi or less (Roger Eybel)

a few points were run higher for interest sake

Keith Legg 847-680-9420

Fatigue - Loads on Landing Gear

Name Company Maximum R ratio Sample type stress (kpsi) 170 0.1 Large hourglass 180 -1 180 -1 Actual LG 150 A100 test specimens Full scale gear Test specimens Test specimens Test specimens Test specimens Test specimens Notes

Gary Erickson Boeing Commercial Roque Panza-Giosa BFG Craig Edwards GA/Air Force Roger Eybel Messier Dowty

Dave Weldon Michael Kane Michael Kane Nihad Ben-Salah

Messier Dowty NAVAIR NAVAIR Heroux

211 180 240 195 0.1, -1 207 0.1, -1 225 0.1, -1

Vendor qual test Al alloys 20ksi 180kpsi is once-in-a-lifetime event. 135 normal use Bulk of public domain data some at higher load for interest only Drag Brace Trunnion Pin Test - max bending stress Limit Ultimate (P3, E6, V22) Design Ultimate (high performance) 4340 (90% of yield) 300M (90% yield) A100 (90% of yield)

Keith Legg 847-680-9420

Fatigue - Loads on Landing Gear

Makes no sense to test coatings above levels used in full rig tests Looks as though we have the following maximum needs:

Commercial 170 ksi, R=0.1 Military, typical 180 ksi, R=-1 Military, high performance 240 ksi, R=-1 At what loads/cycles were F-18 landing gear qualified? Do you really go to yield thousands of times?

Questions:

Keith Legg 847-680-9420

Summary of major ongoing work

Corrosion

Producibility testing

Additional tests planned

samples made

Heroux - grinding, stripping, NDI, fluids, etc.

BFG, Messier-Dowty NADEP-JAX P3 DND CC-130

Fatigue

Rig testing Flight testing

C-HCAT testing 0.003 WCCoCr below 180 ksi Rethinking tests for 0.010 WC-CoCr Comparative testing with SW Aero WC-CoCr and WC-Co Environmental embritt.

Embrittlement

Ball impact - in progress

Keith Legg 847-680-9420

Remaining issues being resolved

US-HCAT corrosion testing to be redone

obviously testing problem

Not a structural issue that will cause failure, but a functional issue that will impose limits Clearly define fatigue limits and requirements

Fatigue testing

Understand strain-to-failure, fatigue, residual stress relationships

Definition of load/thickness limits for WC-Co as done for WCCoCr WC-CoCr with hourglass specimens to define S/N curve comparable with WC-Co per JTP?

Keith Legg 847-680-9420

Where does qualification look good?

Commercial

no brainer - in production
likely to work with WC-Co may be near edge of envelope for WC-CoCr

Military - general

High performance military (primarily fighters)

need to define operational loads carefully to match qual of existing gear may need lower hardness, higher toughness material

Full article tests - rig, flight

Keith Legg 847-680-9420

Remaining issues

US-HCAT corrosion testing to be redone

obviously testing problem

define S/N curve comparable with WC-Co per JTP as done for WC-CoCr

Fatigue testing of WC-CoCr with hourglass specimens

Definition of load/thickness limits for WC-Co

Keith Legg 847-680-9420