Hard Chrome Alternatives Team Joint Group on Pollution Prevention Propulsion Environmental Working Group PROGRAM REVIEW MEETING 1-2 April 2003 San Diego, California

Acknowledgments - Principal HCAT Program Sponsors n Department of Defense Environmental Security Technology Certification Program n Department of Defense Joint Group on Pollution Prevention n Department of Defense Propulsion Environmental Working Group

HCAT Program OBJECTIVE: Conduct research/development or demonstration/validation on advanced surface engineering technologies that will eliminate or mitigate environmental problems while improving materials performance that will lead to reduced life-cycle costs in military weapons systems n HVOF thermal spray coatings to replace hard chrome plating on external surfaces (approx.80% of total workload) n Plasma spraying using miniature guns for replacement of hard chrome plating on internal surfaces n Electrospark deposition for localized repair of coatings or non-coated components New proposals being generated to respond to DOD needs

HCAT Projects Landing Gear: ESTCP funding ended in FY02ESTCP funding ended in FY02 Cost and Performance Report completed and submitted to ESTCP Program Office (approx. 30- page document summarizing materials and component testing plus cost/benefit analysis)Cost and Performance Report completed and submitted to ESTCP Program Office (approx. 30- page document summarizing materials and component testing plus cost/benefit analysis) Air Force making major commitment to implement HVOF at Ogden ALC for chrome replacementAir Force making major commitment to implement HVOF at Ogden ALC for chrome replacement Navy flight testing and Lockheed-Martin rig testing on P3 should lead to chrome replacement on Navy land-based aircraftNavy flight testing and Lockheed-Martin rig testing on P3 should lead to chrome replacement on Navy land-based aircraft Canadian and U.S. LG OEMs moving towards implementing HVOFCanadian and U.S. LG OEMs moving towards implementing HVOF Issuance of two AMS specs on powder and depositionIssuance of two AMS specs on powder and deposition

HCAT Projects Propeller Hubs: ESTCP funding ended in FY02ESTCP funding ended in FY02 Cost and Performance Report completed and submitted to ESTCP Program Office (approx. 30-page document summarizing materials and component testing plus cost/benefit analysis)Cost and Performance Report completed and submitted to ESTCP Program Office (approx. 30-page document summarizing materials and component testing plus cost/benefit analysis) Materials and rig test favorable; engine test in progress and looks favorable; six-month flight test scheduledMaterials and rig test favorable; engine test in progress and looks favorable; six-month flight test scheduled Anticipate putting HVOF into production on components at NADEP-CP and Warner-Robins ALCAnticipate putting HVOF into production on components at NADEP-CP and Warner-Robins ALC

HCAT Projects Gas Turbine Engines: ESTCP funding through end of FY03ESTCP funding through end of FY03 Materials testing to be completed by end of calendar 2003Materials testing to be completed by end of calendar 2003 Successful TF33 accelerated engine test completed with HVOF WC/17Co-coated componentsSuccessful TF33 accelerated engine test completed with HVOF WC/17Co-coated components Oklahoma City ALC moving towards implementing HVOF into production on all enginesOklahoma City ALC moving towards implementing HVOF into production on all engines NADEP-JAX has HVOF in production on TF34NADEP-JAX has HVOF in production on TF34

HCAT Projects Hydraulic Actuators: ESTCP funding in FY03 and FY04ESTCP funding in FY03 and FY04 Component testing in progress at NAVAIR Pax River; Navy moving towards qualifying HVOF coatings on actuator componentsComponent testing in progress at NAVAIR Pax River; Navy moving towards qualifying HVOF coatings on actuator components AF cognizant activity conducted survey of all chrome- plated actuators; initiated delta qualification on selected actuator systemsAF cognizant activity conducted survey of all chrome- plated actuators; initiated delta qualification on selected actuator systems Materials testing (Joint Test Protocol) to support component testing still being finalizedMaterials testing (Joint Test Protocol) to support component testing still being finalized Anticipate stakeholders meeting (DOD, OEMs, subcontractors) in summer 2003Anticipate stakeholders meeting (DOD, OEMs, subcontractors) in summer 2003

HCAT Projects Helicopter Dynamic Components: ESTCP funding in FY04 and FY05 (zero in FY03)ESTCP funding in FY04 and FY05 (zero in FY03) Sikorsky and Boeing Philadelphia being put under contract to conduct assessment of chrome plating on HDC and define materials and component test requirementsSikorsky and Boeing Philadelphia being put under contract to conduct assessment of chrome plating on HDC and define materials and component test requirements Anticipate stakeholders meeting in Fall 2003Anticipate stakeholders meeting in Fall 2003 Plasma Spraying on Internal Surfaces: SERDP funding in FY04 (zero in FY03)SERDP funding in FY04 (zero in FY03) Coatings successfully deposited on inside surface of specially designed cylindrical specimen holder using miniature plasma spray gunsCoatings successfully deposited on inside surface of specially designed cylindrical specimen holder using miniature plasma spray guns Materials testing in progressMaterials testing in progress Exploring transition opportunities to depotsExploring transition opportunities to depots

HCAT Projects Electrospark Deposition (ESD): ESTCP funding in FY03, FY04, and FY05ESTCP funding in FY03, FY04, and FY05 ESD systems acquired and delivered to NADEP-North Island, Oklahoma City ALC, and Anniston Army DepotESD systems acquired and delivered to NADEP-North Island, Oklahoma City ALC, and Anniston Army Depot Work in progress at Advanced Surfaces and Processes, NSWC Carderock, and Edison Welding Institute on repair of chrome plate and base materialsWork in progress at Advanced Surfaces and Processes, NSWC Carderock, and Edison Welding Institute on repair of chrome plate and base materials

HCAT Program description, copies of published papers, meeting presentations, descriptions of rig tests, materials test data all available at (Enter as user name and hello.hcat as password or send to Keith Legg, for registration of user name) (Enter as user name and hello.hcat as password or send to Keith Legg, for registration of user name)

Next HCAT Meeting Proposed for November 2003 at: Kennedy Space Center or Jacksonville, FL