ORENDA AEROSPACE CORPORATION PROGRESS REVIEW MEETING THE CANADIAN HARD CHROME ALTERNATIVES TEAM (HCAT) JOINT PROGRAM HVOF PROCESS DEVELOPMENT, EVALUATION AND QUALIFICATION Task 2.1 Axial Fatigue Evaluation C. Belter, P. Li, J. Dyer and P.C. Patnaik Advanced Materials and Energy Systems Orenda Aerospace Corporation February 20, 2002 Orlando, Florida

ORENDA AEROSPACE CORPORATION Presentation Outline Introduction / Objectives Progress Summary HVOF Evaluation and Qualification of Axial Fatigue Test Results Acknowledgements

ORENDA AEROSPACE CORPORATION Introduction Objective: Evaluate and to compare the fatigue properties of HVOF coatings against electrolytic chrome plating. Test environments were: - ambient air (70 F) - cold air (-40 F) - 3.5% NaCl water solution at room temperature All tests were conducted at a frequency of 5Hz and a stress ratio of R=-1

ORENDA AEROSPACE CORPORATION Progress Summary Test program contains 620 axial fatigue tests on 300M and Aermet 100 to evaluate four surface conditions at ambient and low temperatures. 598 tests completed. 22 tests left. The specimens are being prepared. Completion of the testing program is expected by March 31, Project is within budget and technically progresses smoothly.

ORENDA AEROSPACE CORPORATION PROGRESS REVIEW MEETING Test Matrix: 620 tests in total, 598 completed, 22 left

ORENDA AEROSPACE CORPORATION PROGRESS REVIEW MEETING Room temperature tests: A “threshold” for spalling of the HVOF coating was found to be 180 ksi and for the 0.003” thick coating and 125 ksi for the 0.010” thick coating using the current configuration. 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. 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.

ORENDA AEROSPACE CORPORATION PROGRESS REVIEW MEETING Room temperature tests (continued): The C-HCAT results show a good agreement with the US results. 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.

ORENDA AEROSPACE CORPORATION PROGRESS REVIEW MEETING

ORENDA AEROSPACE CORPORATION PROGRESS REVIEW MEETING

ORENDA AEROSPACE CORPORATION PROGRESS REVIEW MEETING

ORENDA AEROSPACE CORPORATION PROGRESS REVIEW MEETING Corrosion fatigue tests: A “threshold” determined for the 0.003” thick HVOF coatings in a NaCl testing environment to be 125 ksi on 300 M. In general, there is approximately a 25% (300 M), 45% (Aermet 100) reduction in strength due to corrosion. The chrome seems to mitigate this 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.

ORENDA AEROSPACE CORPORATION PROGRESS REVIEW MEETING Corrosion fatigue tests (continued): The C-HCAT results overlapped the US results when plotted together (see graph) 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.

ORENDA AEROSPACE CORPORATION PROGRESS REVIEW MEETING

ORENDA AEROSPACE CORPORATION PROGRESS REVIEW MEETING

ORENDA AEROSPACE CORPORATION PROGRESS REVIEW MEETING

ORENDA AEROSPACE CORPORATION PROGRESS REVIEW MEETING Low Temperature fatigue tests: 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 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