ORENDA AEROSPACE CORPORATION PROGRESS REVIEW MEETING THE CANADIAN HARD CHROME ALTERNATIVES TEAM (HCAT) JOINT PROGRAM HVOF PROCESS DEVELOPMENT, EVALUATION AND QUALIFICATION DSS CONTRACT NO. W EH02/001/SV Jason Dyer, P.Eng. Advanced Materials and Energy Systems Orenda Aerospace Corporation August 9, 2001 Ottawa, Ontario, Canada

ORENDA AEROSPACE CORPORATION Outline Introduction / Objectives Canadian HCAT Program –Project Review –Task 2: HVOF Evaluation and Qualification –Progress Schedule Review Action Items for Next PRM Acknowledgements

ORENDA AEROSPACE CORPORATION Introduction The Advanced Materials & Energy Systems Business Unit of Orenda Aerospace Corporation has been tasked by the Department of National Defence Canada to carry out the Materials/HVOF Coating Evaluation Project to assist the utilization of HVOF coatings for Aircraft Landing Gears. Contract startup date was February 24, Contract Technical Authority is Mr. Ken McRae, Acting Head of the Air Vehicle Research Dept. of the Defence Research & Development Branch(DRDB) of the Department of national Defence Canada.

ORENDA AEROSPACE CORPORATION Project Review Official Start Date: February 24, 1999 Most Recent Canadian Progress/Technical Review Meeting: April 20, 2001 Represented: ORENDA, NRC-IAR, NRC-IMI, DND Next Scheduled Progress/Technical Review Meeting: TBD Ottawa, Ontario, Canada

ORENDA AEROSPACE CORPORATION PROGRESS REVIEW MEETING Task 2:HVOF Evaluation and Qualification All specimens have been machined, coated and received by Orenda. The phase II wear rods have been coated and have been sent to NRC-IC for testing.

ORENDA AEROSPACE CORPORATION PROGRESS REVIEW MEETING Task 2.1:Axial Fatigue Evaluation All specimens (HVOF and chrome) have been received and testing had commenced. The tests have been completed as follows:

ORENDA AEROSPACE CORPORATION PROGRESS REVIEW MEETING Task 2.1:Axial Fatigue Evaluation Room temperature tests: Orenda has completed the baseline material, chrome and most HVOF fatigue tests for 300M and Aermet 100. Current results are presented in the graphs to follow. As mentioned before, a “threshold” for spalling of the HVOF coating was found to be 180 ksi for the 0.003” thick coating and 125 ksi for the 0.010” thick coating using the current configuration. The C-HCAT results overlapped the US results when plotted together (see graph)

ORENDA AEROSPACE CORPORATION PROGRESS REVIEW MEETING Task 2.1:Axial Fatigue Evaluation Room temperature tests: Chrome tests indicated a fatigue debit over the baseline for both Aermet 100 and 300 M. HVOF showed a slight fatigue debit in the Aermet 100 but a slight increase in fatigue in the 300 M. In both cases, the fatigue debit was more predominant in the Aermet 100. In general, the 0.010” thick coating preformed slightly better than the 0.003” thick coating for both the chrome and HVOF coatings. This is expected since the load is calculated based on the original substrate diameter and the 0.010” thick coating would carry more of the load. In general, the HVOF coatings performed as well as or better than the chrome coatings in life to failure for 300 M and Aermet 100 to date.

ORENDA AEROSPACE CORPORATION PROGRESS REVIEW MEETING

ORENDA AEROSPACE CORPORATION PROGRESS REVIEW MEETING

ORENDA AEROSPACE CORPORATION PROGRESS REVIEW MEETING

ORENDA AEROSPACE CORPORATION PROGRESS REVIEW MEETING Task 2.1:Axial Fatigue Evaluation Corrosion fatigue tests: Orenda has completed the baseline material and chrome corrosion fatigue tests for 300M and Aermet 100. HVOF testing is currently 60% complete. Current results are presented in the graphs to follow. A “threshold” determined for the 0.003” thick HVOF coatings in a NaCl testing environment to be 125 ksi on 300 M. The C-HCAT results overlapped the US results when plotted together (see graph)

ORENDA AEROSPACE CORPORATION PROGRESS REVIEW MEETING Task 2.1:Axial Fatigue Evaluation Corrosion fatigue tests: In general, there is approximately a 25% (300 M), 45% (Aermet 100) reduction in strength due to corrosion. The chrome seems to mitigate this somewhat, to nearly 0% reduction for 300 M and a 10% reduction for Aermet 100. The HVOF coating for the 300 M shows an actual increase in life over the baseline tests and only a 5% reduction in life for the Aermet 100. In both cases, the HVOF coatings performed as well as or better than the chrome coatings in life to failure for 300 M and Aermet 100 to date.

ORENDA AEROSPACE CORPORATION PROGRESS REVIEW MEETING

ORENDA AEROSPACE CORPORATION PROGRESS REVIEW MEETING

ORENDA AEROSPACE CORPORATION PROGRESS REVIEW MEETING

ORENDA AEROSPACE CORPORATION PROGRESS REVIEW MEETING Task 2.1:Axial Fatigue Evaluation Low Temperature fatigue tests: Orenda has completed the baseline material and the chrome low temperature fatigue tests for 300M and Aermet 100. HVOF testing is currently 80% complete. Current results are presented in the graphs to follow. Although the coating continues to spall off, HVOF is consistently outperforming EHC on 300 M and Aermet 100.

ORENDA AEROSPACE CORPORATION PROGRESS REVIEW MEETING

ORENDA AEROSPACE CORPORATION PROGRESS REVIEW MEETING

ORENDA AEROSPACE CORPORATION PROGRESS REVIEW MEETING Task 3:Final Report NRC-IMI and VAC-Aero are currently preparing their final report for task 1. NRC-IAR has delivered their final report on Corrosion testing. Budget The project is currently within budget limits. Schedule A schedule update in MS Project follows.

ORENDA AEROSPACE CORPORATION PROGRESS REVIEW MEETING

ORENDA AEROSPACE CORPORATION PROGRESS REVIEW MEETING

ORENDA AEROSPACE CORPORATION PROGRESS REVIEW MEETING

ORENDA AEROSPACE CORPORATION Action Items For Next PRM: Continued testing. Fatigue Testing to be completed.

ORENDA AEROSPACE CORPORATION ACKNOWLEDGEMENTS Orenda would like to acknowledge the continued support and hard work from: NRC-Institute for Aerospace Research J.P. Immarigeon, P. Au, D. Dudzinski NRC-Industrial Materials Institute J.G. Legoux, S. Serghini VAC-Aero International J. Pritchard, S. Rush