Non-Line of Sight Hard Chrome Alternatives Project April 2001 Joe Kolek AFRL/MLQL (937)

2 Reason for Project HVOF Thermal Spray is a line-of-sight process and will be limited to % of Air Force depot chrome plated workload. The Non-Line of Sight (NLOS) project focuses on chemical and electrochemical processes that can be readily implemented for the remaining %

3 NLOS Project Phase I (Completed) – Identified AF Depot NLOS chrome plating requirements – Identified 54 possible alternatives – Downselected to 7 candidates for Dem/Val

4 Decision Matrix Developed to Screen Alternatives Based on the Following Criteria NLOS applicability Hardness Corrosion resistance Thickness limitations Environmental concerns Fatigue Temperature resistance Maximum process temperature Adhesion to steel Wear resistance Capital cost Cost per mil/ft 2 Deposition rate Grindability Process complexity Strippability Maturity Process type and chemistry Licensing requirements

5 NLOS Project (cont’d.) 2 Electroless Nickel Phosphorous processes MacDermid: Niklad 797 Stapleton Technologies: Infinity Hx 1 Electroless Nickel Boron process Sirius Technologies: Millenium KR

6 NLOS Project (cont’d.) 2 Electroless Nickel Composite processes Surface Technology: Niplate 700 (SiC) Surface Technology: Niplate 800 (CDC) 1 Electrolytic Nickel-Tungsten process Enthone: Enloy Electrodeposited nickel-based nanocrystalline particle process Babcock & Wilcox: Nanoplate

7 NLOS Project (cont’d.) Phase II (Ongoing) Processing to be conducted at vendor sites and observed by NLOS Team member Coated panels to be evaluated at NDCEE Multi-level screening (easy things first) 1.AdhesionComposition ThicknessProfilometry Hardness

8 NLOS Project (cont’d.) 2.Corrosion Wear 3.Grindability Strippability Fatigue Hydrogen Embrittlement

9 NLOS Project (cont’d.) Phase II (cont’d.) Further evaluation of best technology(ies) will involve – In-house processing at NDCEE – NLOS component coating and testing – Economic analysis and viability of AF Depot implementation Phase III (Following Phase II) – Prepare implementation plan(s) for technology(ies) selected in conjunction with Air Logistics Centers Phase IV (Pending) – Facilitate implementation and provide training

10 Current Status Surface Technology: Niplate 800 dropped from consideration due to proprietary issues Finding an available/affordable licensed vendor to apply Enthone’s Enloy 500 has been difficult The other five coatings have been applied to specimen and Level I testing is underway