Upload
cheveresan123
View
220
Download
0
Embed Size (px)
Citation preview
7/29/2019 2-Legg Test Status Overview
1/37
Keith Legg 847-680-9420
Test Status Overview
HCAT Program Review
NASA, Florida
Dec 13,14, 2000
7/29/2019 2-Legg Test Status Overview
2/37
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
7/29/2019 2-Legg Test Status Overview
3/37
Keith Legg 847-680-9420
Overview
Aircraft use of HVOF coatings
Why are we doing this? -
commercial flight tests
Overall status of JTP tests
JTP - Corrosion, wear,fatigue, embrittlement,
impact
Ancillary - Process specs,
producibility, additional
corrosion, additional fatigue,
failure mechanisms
Conditions seen by real parts
Summary of findings to date
What does all this mean for
actual usage?
Where does it work just fine?
Where do we need to worry?
7/29/2019 2-Legg Test Status Overview
4/37
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
7/29/2019 2-Legg Test Status Overview
5/37
Keith Legg 847-680-9420
Production use of HVOF
WC-Co and WC-CoCr coatings
Component
Coating
Specific-
ation
Notes
Steering collars HVOF, plasma, D-gunWC-Co
BAC 5851 Boeing OEM coating
Slat tracks
Pan castings
Gimbals
HVOF, plasma, D-gun
WC-18Co
BAC 5851 Boeing OEM coating
Bolts
Wear rings
D-gun WC-14Co BAC 5851 Boeing OEM coating
Plungers
Fittings
Plasma Cr2O3 BAC 5851 Boeing OEM coating
Mufflers
Fairings
HVOF, D-gun, plasmaTribaloy 400
BAC 5851 Boeing OEM coating
Landing gear sleeves, pins D-gun, plasma Cu-
37Ni-5In, WC-18Co
BAC 5851 Boeing OEM coating
Boeing 747-400 landing gear HVOF WC-CoCr BAC 5851 Boeing OEM coating
Boeing 737 landing gear HVOF WC-CoCr BAC 5851 Overhaul and repair
Airbus 320 landing gear HVOF WC-CoCr Overhaul and repair
F-18 Main landing gear axle HVOF WC-CoCr AMS 2447 Canadian Air Force flight tested, infinal approval
7/29/2019 2-Legg Test Status Overview
6/37
Keith Legg 847-680-9420
Production use of HVOF
WC-Co and WC-CoCr coatings (cont.)
Sikorsky CH-53 bladedamper
Plasma T400 In final approval for Navy CH-53
fleet
P&W F-119 EngineConvergent Nozzle Actuator
Super D-gun WC-Co
and Plasma T400
HS 4412 Hamilton Sundstrand spec. Engine
likely to be used on JSF
Slat tracks, Boeing Super D-gun WC-18Co BAC 5851 OEM usage
Bombardier Q-400 flaptracks
HVOF WC-Co Bombardier
PPS 24.04
OEM usage
Bombardier Q-400 andGlobal Express door stoppins
HVOF WC-Co BombardierPPS 24.04 OEM usage
Slat and flap tracks HVOF WC-Co BAC 5851 Overhaul and Repair
Flap track repairBombardier Dash 8
HVOF WC-Co RD 8-57-1164
to 1169
Overhaul and Repair
L1011 flap tracks HVOF WC-Co Overhaul and RepairTitaniumalloy
Boeing 737, 757, 767 landing
gear
HVOF WC-Co BAC 5851 Main and nose landing gear O&R at
Delta Airlines
Parker-Hannifin actuators Various OEM usage all new-designhydraulics
Qualified for landing gear repair
7/29/2019 2-Legg Test Status Overview
7/37
Keith Legg 847-680-9420
Production use of HVOF
landing gear coatings - Messier-Dowty
Note
production use
on high
performance
aircraft
Program-p/n Part name Type of coating Area Remarks
F/A-18 E/F74A430702
74A430616
Piston head assyRetract ActuatorNLG
Cover assyGear/manifold
Diamalloy 1004 (Al bronze)Applied perAMS2447
Tribaloy T400
6.612 OD
8.974 ID
Production part
Production part
F/A-18 C/D74A410603 Head, Piston Shock Absorber
MLGF-18 E/FDiamalloy 1004 (Al bronze)
Applied perAMS2447
OD R&O DRED
Hawker 400034520-1 Lock link outboard forward
door mechanism NLGWC-Co per DCMP 210(AMS2447-7)
Flat stops Production part
REO 450626-01
Tube Restrictor Support AMS 2447-4Ni95-Al5
2.623/2.621 OD R&O
74A410509 Axle of the polygon AMS 2447-9 2.931/3.374polygon
In progress
Cl601RJ
17114-1
Shock strut piston MLG WC-Co-Cr per
DCMP 213(AMS 2447-9)
4.614 OD Under evaluation
in service by AirCanada, NIEO
17207-1Shock strut pinMLG
WC-Co-Cr perDCMP 213(AMS 2447-9)
1.498 OD Under evaluationin service by AirCanada, NIEO
A340 CLG37173-10137174-10115173-10115174-101
Sleeve thrust shock strut Tribaloy T400DCMP 203(AMS2447-2)
2.348 ID Production part
BD 100
40672 Pin, Piston Tube
NLG
WC-Co-Cr per
DCMP 213(AMS 2447-9)
0.866 OD Production part
7/29/2019 2-Legg Test Status Overview
8/37
Keith Legg 847-680-9420
Data summary:
Landing Gear JTP - Coupon test data
Data Item Test 25 50 75 100 Pass Fail Notes
Corrosion
C-HCAT salt fog ASTM B-117 x Standard flat
US-HCAT salt fog B117 ??? Modified sample. Retesting
US-HCAT cyclic salt fog GM 9540P/B ??? Modified sample. Retesting
H Embrittlement
US-HCAT Deposition ASTM F-519 x No embrittlement by HVOF
US-HCAT H Evolution ASTM F-519 - - No acceptance criteriaUS-HCAT Environmental Emb. ASTM F-519
Fatigue WC-Co (Hourglass)
US-HCAT in air 0.003" ASTM E-466 x R=-1, 0.1
US-HCAT in air 0.010" ASTM E-466 x R=-1, 0.1
US-HCAT corrosion ASTM E-466 x R=-1, 0.1
Fatigue WC-CoCr (Smooth bar)
C-HCAT air 0.003" thick ASTM E-466 x R=-1. Delamination above 180 ksi load
C-HCAT air 0.010" thick ASTM E-466 ??? R=-1. Delamination above 125 ksi load
C-HCAT corrosion ASTM E-466 ??? R=-1. Rapid corrosion initial tests
C-HCAT low temp. ASTM E-466
Impact
Dropped ball Data being obtained
Gravelometry ASTM D-3170 x Equivalent or better than Cr
Wear
Fretting GEAE Data complete - being analyzed
Osc. piston/bushing Hydraulic simul. Data complete - being analyzed
Completeness
7/29/2019 2-Legg Test Status Overview
9/37
Keith Legg 847-680-9420
Data summary:
Propeller Hub JTP - Coupon test data
Data Item Test 25 50 75 100 Pass Fail Notes
Corrosion
WC-Co, WC-CoCr, T800, Ni plate ASTM B-117 Standard 4"x6" flat panel
Fatigue (Hourglass)
WC-Co, T800, Cr ASTM E-466 HSD hourglass, R=0.1
WC-Co, T800 ASTM E-466 HSD notched hourglass, R=0.1Wear
Large stroke and dither HSD HSD wear plates
Toxicity leaching
WC-CoCr, T400, T800 waste EPA 1311 Acetic acid leach
Com leteness
7/29/2019 2-Legg Test Status Overview
10/37
7/29/2019 2-Legg Test Status Overview
11/37
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
Outstanding issues
Environmental embrittlement measurements in process
Coating may lower Kt - calculations and tests under way atHeroux
7/29/2019 2-Legg Test Status Overview
12/37
7/29/2019 2-Legg Test Status Overview
13/37
Keith Legg 847-680-9420
Wear
Fretting and sliding (hydraulic)
Data evaluation largely complete
HVOF better than or equal to Cr
Rig and flight tests all show better wear performance Less striation, wear, roughening (Delta, Greene Tweed)
Less wear and leakage of seals (Greene, Tweed)
7/29/2019 2-Legg Test Status Overview
14/37
7/29/2019 2-Legg Test Status Overview
15/37
7/29/2019 2-Legg Test Status Overview
16/37
Keith Legg 847-680-9420
Data summary:
Propeller Hub JTP Rig and flight testing
Data Item Test 25 50 75 100 Pass Fail Notes
Rig tests
54H60 low pitch stop lever sleeve Piston stroke WC-Co and T800
Flight tests
P-3 propeller 275 flight hrs Tail shaft hub and sleeve lever
Completeness
7/29/2019 2-Legg Test Status Overview
17/37
Keith Legg 847-680-9420
Hydraulic testing - Greene, Tweed
PTFE (Enercap) much
better performance with
WC
low leakage
low rod wear Elastomer rapidly
damaged
not a problem with long
stroke utility actuators and
landing gear at 4 Ra
5
15
25
35
45
WC-Co, ACT
Tribaloy, ACT
Chrome, ACT
WC-Co-Cr, Enercap
WC-Co, Enercap
Tribaloy, Enercap
Chrome, Enercap
0
500
1000
1500
2000
2500
Leakage
(grams)
Cycles (millions) 4-9 Ra
7/29/2019 2-Legg Test Status Overview
18/37
7/29/2019 2-Legg Test Status Overview
19/37
Keith Legg 847-680-9420
Flight tests
Delta B737, 757, 767 nose and main landing gear
Inner cylinders, axles, axle sleeves
Passed - WC-CoCrqualified for O&R
Boeing 767-400
HVOF WC-CoCrflight qualified and used in production
Canadian F-18 MLG
Messier-Dowty polygon repair
WC-CoCr
Repair scheme approved
Outstanding - NADEP-JAX P3, DND C-130 testing
7/29/2019 2-Legg Test Status Overview
20/37
Keith Legg 847-680-9420
Data summary -
Ancillary tests
Data Item Test 25 50 75 100 Pass Fail Notes
Process parameters
US-HCAT WC-Co DOE - -
C-HCAT NRC WC-CoCr DOE - -
Commercial - SWA, Hitemco - - Boeing QPL processes
Grinding/finishing
NADEP-JAX - - Low stress grind used on samples
Delta Airlines - - Used on flight test landing gear
HerouxStripping
NADEP-CP, S'west Aero x WC-Co and WC-CoCr strip w/Rochelle
CTC water jet x Incomplete stripping
Heroux
R&O Fluid compatibility
Heroux
NDI
Heroux
Delta, Boeing flight tests - - FPI, Barkhausen good; MPI poor
Corrosion
Beach exposure x Flat samples - generic tests
Salt fog B117 x Flat samples - generic tests
Cyclic salt fog GM 9540P/B x Flat samples - generic tests
US-HCAT comparison tests B117 New seal; flat, round, var. vendors, var. cabinets
Fatigue (Smooth bar)
US/C-HCAT WC-CoCr air ASTM E-466
Fracture mechanisms
C-HCAT NRC/Orenda - -
SpecificationsAMS specs - - Powder, grinding, coating
Completeness
7/29/2019 2-Legg Test Status Overview
21/37
7/29/2019 2-Legg Test Status Overview
22/37
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) andJim Nuse (Southwest Aeroservice) - AESF paper
Additional testing under way
Boeing, SW Aero, Sulzer Metco, Engelhard, Praxair, Green
Tweed, Supfina, Delta
7/29/2019 2-Legg Test Status Overview
23/37
Keith Legg 847-680-9420
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
7/29/2019 2-Legg Test Status Overview
24/37
7/29/2019 2-Legg Test Status Overview
25/37
7/29/2019 2-Legg Test Status Overview
26/37
7/29/2019 2-Legg Test Status Overview
27/37
7/29/2019 2-Legg Test Status Overview
28/37
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
7/29/2019 2-Legg Test Status Overview
29/37
7/29/2019 2-Legg Test Status Overview
30/37
7/29/2019 2-Legg Test Status Overview
31/37
7/29/2019 2-Legg Test Status Overview
32/37
Keith Legg 847-680-9420
Fatigue - Loads on Landing Gear
Name Company Maximum
stress
(kpsi)
R ratio Sample type Notes
Gary Erickson Boeing Commercial 170 0.1 Large hourglass Vendor qual test
Roque Panza-Giosa BFG 180 -1 Al alloys 20ksi
Craig Edwards GA/Air Force 180 -1 Actual LG 180kpsi is once-in-a-lifetime
event. 135 normal use
Roger Eybel Messier Dowty 150 A100 test
specimens
Bulk of public domain data -
some at higher load for
interest only
Dave Weldon Messier Dowty 211 Full scale gear Drag Brace Trunnion Pin
Test - max bending stress
Michael Kane NAVAIR 180 Test specimens Limit Ultimate (P3, E6, V22)
Michael Kane NAVAIR 240 Test specimens Design Ultimate (high
performance)Nihad Ben-Salah Heroux 195 0.1, -1 Test specimens 4340 (90% of yield)
207 0.1, -1 Test specimens 300M (90% yield)
225 0.1, -1 Test specimens A100 (90% of y ield)
7/29/2019 2-Legg Test Status Overview
33/37
7/29/2019 2-Legg Test Status Overview
34/37
7/29/2019 2-Legg Test Status Overview
35/37
Keith Legg 847-680-9420
Remaining issues being resolved
US-HCAT corrosion testing to be redone
obviously testing problem
Fatigue testing
Not a structural issue that will cause failure, but a functional
issue that will impose limits
Clearly define fatigue limits and requirements
Understand strain-to-failure, fatigue, residual stress relationships
Definition of load/thickness limits for WC-Co as done for WC-
CoCr WC-CoCr with hourglass specimens to define S/N curve
comparable with WC-Co per JTP?
7/29/2019 2-Legg Test Status Overview
36/37
Keith Legg 847-680-9420
Where does qualification look good?
Commercial
no brainer - in production
Military - general
likely to work with WC-Co
may be near edge ofenvelope for WC-CoCr
High performance military
(primarily fighters)
need to define operational
loads carefully to match qualof existing gear
may need lower hardness,
higher toughness material
Full article tests - rig, flight
7/29/2019 2-Legg Test Status Overview
37/37