A Hard Chrome Alternatives for Hydraulic Components Program established to assist United States Air Force Airborne Accessories Directorate Avionics and Accessories Division (OC-ALC/LII) in development and implementation of replacement repair and overhaul procedures for hydraulic actuators across multiple weapon systems.

A Hard Chrome Alternatives for Hydraulic Components Phase 1 - TO and Drawing Review, Database Development, Test Requirement Development –124 Air Force Technical Orders Reviewed 100% complete –697 Engineering Drawings Reviewed 57.7% complete –276 Chrome plated parts and 203 potentially chrome plated parts have been identified.

A Hard Chrome Alternatives for Hydraulic Components Phase 2 - Material, Rig, and Flight Testing –Flight Control Actuators 87 distinct part numbers Estimate 6 will require delta-qualification 6 candidate items selected

A Hard Chrome Alternatives for Hydraulic Components Phase 2 - Material, Rig, and Flight Testing –Utility Actuators 73 distinct part numbers Estimate 15 will require delta-qualification 1 candidate items selected –Snubbers 12 distinct part numbers Estimate 3 will require delta-qualification

A Hard Chrome Alternatives for Hydraulic Components Phase 2 - Material, Rig, and Flight Testing –C-130 Rudder Booster Assembly All chrome plated components are within one SRU (rudder booster actuator) Rudder booster actuator was qualified, and rudder booster assembly was not. Delta-qualification will be performed only on the rudder booster actuator.

A Hard Chrome Alternatives for Hydraulic Components Phase 2 - Material, Rig, and Flight Testing –C-130 Rudder Booster Assembly Rudder booster actuator manufactured by Kaiser Fluid Technologies. Qualified by Lockheed Martin. Delta-Qualification will be performed by Kaiser Fluid Technologies. Expected to take 12 months.

A Hard Chrome Alternatives for Hydraulic Components

A Phase 2 - Material, Rig, and Flight Testing –C-130 Rudder Booster Assembly Delta Qualification will consist of the following tests: –Operation and Leakage –Low Temperature Operation –Rapid Warm Up –High Temperature Operation –Endurance –Salt Fog (ASTM B117-95)

A Hard Chrome Alternatives for Hydraulic Components Phase 2 - Material, Rig, and Flight Testing –C-130 Rudder Booster Assembly Delta Qualification will omit following tests from qualification: –Proof Pressure and Leakage –Vibration –Slam Test –Piston Rod Column –Burst

A Hard Chrome Alternatives for Hydraulic Components Phase 2 - Material, Rig, and Flight Testing –C-130 Rudder Booster Assembly –Sand and Dust –Salt Spray (Federal Test Standard 151) –Impact Shock –Fungus Resistance

A Hard Chrome Alternatives for Hydraulic Components Phase 2 - Material, Rig, and Flight Testing –C-130 Rudder Booster Assembly 4 chrome plated surfaces. –Piston rod »3 sections, with piston heads separating them –Piston head (2 piston heads on the unit) »Not part of the piston rod –Trunnion OD »Mates with an aluminum-bronze bushing –Trunnion ID »Not wearing part

A Hard Chrome Alternatives for Hydraulic Components

A Phase 2 - Material, Rig, and Flight Testing, rod coating surface finish and seal selection –Existing seals are elastomeric T-seals contacting chrome plated rod –Various testing to date shows: Elastomeric seals do not wear as well against ground HVOF coated surfaces as they do against chrome. Elastomeric seals do not wear as well as teflon capped seals against HFOV coated surfaces. Additional Greene Tweed testing indicates that superfinishing of the coated rod surfaces reduces elastomeric seal life during endurance tests.

A Hard Chrome Alternatives for Hydraulic Components Phase 2 - Material, Rig, and Flight Testing, rod coating surface finish and seal selection –Options under consideration: Use existing seals and as-ground coating surface, 4-8 Ra. Use existing seals and strictly control surface finish to Greene Tweed or Shamban recommendations (Ra, Rz, Rpk, Rsk, Tp). Use teflon capped seals and as-ground coating surface, 4-8 Ra. Use existing seals on one end, teflon capped seals on other end, as-ground coating surface, 4-8 Ra. Use existing seals on one end, teflon capped seals on other end, and strictly control surface finish to Greene Tweed or Shamban recommendations (Ra, Rz, Rpk, Rsk, Tp).

A Hard Chrome Alternatives for Hydraulic Components Phase 2 - Material, Rig, and Flight Testing –C-130 Rudder Booster Assembly Best technical coatings –Piston rod: 82W-10Co-4Cr-3.5C »AMS –Piston head: Tribaloy 400 »AMS –Trunnion OD: 82W-10Co-4Cr-3.5C »AMS –Trunnion ID: 82W-10Co-4Cr-3.5C »AMS

A Hard Chrome Alternatives for Hydraulic Components Phase 2 - Material, Rig, and Flight Testing –C-130 Rudder Booster Assembly Best coatings with no chrome –Piston rod: 88W-6Co-5.1C »AMS –Piston head: Cu-37Ni-5In »BAC 5851, Type XIV –Trunnion OD: Cu-37Ni-5In »BAC 5851, Type XIV –Trunnion ID: Cu-37Ni-5In »BAC 5851, Type XIV

A Hard Chrome Alternatives for Hydraulic Components Phase 3 - Data Evaluation –Results of Testing will be evaluated and a solution finalized.

A Hard Chrome Alternatives for Hydraulic Components Phase 4 - Implementation –The solution developed in Evaluation will be implemented.

A Hard Chrome Alternatives for Hydraulic Components