1. HCAT PROGRESS REPORT FEBRUARY 2002 GOODRICH LANDING GEAR HCAT STATUS CONDUCTING THREE FULL SCALE TESTS: 1. Fatigue of entire MLG - Dash-8 Series 400. 2. High Cycle (Dithering) wear test on hydraulic actuator. 3. Fatigue of MLG pistons 5” and 10” OD (Cr vs. WC-Co-Cr). HVOF coating is WC-Co-Cr.

2. TEST 1: MLG FATIGUE TEST GOODRICH LANDING GEAR HCAT CURRENT STATUS â 14 parts have been HVOF coated (piston, axle, and pins). â Components sprayed by Vac Aero and Southwest Aeroservice. â Gear has been assembled, installed in the test rig and testing has begun.

3. TEST 1: MLG FATIGUE TEST GOODRICH LANDING GEAR HCAT CURRENT STATUS â Testing - 10 layers of testing = 5 lives. â Each layer includes 32 blocks of test conditions (load location, magnitude, direction and number of cycles). â 1 layer of fatigue consists of 30 blocks of ground load conditions (= 30,000 flight cycles), 1 block of retraction lug test conditions (66,000 gear extend and 33,000 gear retract flight cycles) and 1 block of stabilizer brace lock link test conditions (99,000 lock and 33,000 unlock flight cycles).

4. TEST 1: MLG FATIGUE TEST GOODRICH LANDING GEAR HCAT CURRENT STATUS â Testing considered successful when the gear withstands 5 lives of fatigue loads without initiation of detectable fatigue cracks. â Testing is 15% complete. Some delays with the test rig and changing seals. â Testing began with elastomeric T-type seals but the seals failed after 330,000 cycles. â Second type of elastomeric seal failed after 480,000 cycles. â Cap Seal has recently been installed.

5. TEST 1: MLG FATIGUE TEST GOODRICH LANDING GEAR HCAT

6. TEST 1: MLG FATIGUE TEST GOODRICH LANDING GEAR HCAT

7. TEST 2: HIGH CYCLE WEAR TEST GOODRICH LANDING GEAR HCAT CURRENT STATUS â Purpose: Testing performance of HVOF coating on an aircraft actuator and demonstrate it can withstand constant cycles under endurance stress level for a civil aircraft actuator. â 3 actuators being tested, 2 chrome plated, 1 WC-Co- Cr coated. â Chrome finished 8-16 Ra. â HVOF finished 3 Ra.

8. TEST 2: HIGH CYCLE WEAR TEST GOODRICH LANDING GEAR HCAT CURRENT STATUS â Test program is approximately 80% complete. â To date scheduled inspections have found the HVOF coating acceptable with no evidence of scratches, cracks or other unacceptable indications. â No evidence of leakage or wear on the seals.

9. TEST 2: HIGH CYCLE WEAR TEST GOODRICH LANDING GEAR HCAT

10. TEST 3: PISTON FATIGUE TEST GOODRICH LANDING GEAR HCAT CURRENT STATUS â First test: 5” OD Piston (3 Cr and 3 HVOF) - simulate a commercial regional aircraft. â Second test: 10” OD Piston ( 3 Cr and 3 HVOF) - simulate large commercial jet.

11. GOODRICH LANDING GEAR HCAT TEST 3: PISTON FATIGUE TEST Scope of Test â Testing per QTP-HVOF/X50072: â “The test will be performed until failure of the simulated LG pistons occurs.” â Purpose: “…to compare the fatigue performance of simulated LG piston coated with HVOF applied WC- Co-Cr and electrolytic chrome plating.” â “This test is aimed at deriving fatigue life design factors…”

12. GOODRICH LANDING GEAR HCAT TEST 3: PISTON FATIGUE TEST Test Conditions â Bending loads based on fatigue analysis and landing gear fatigue requirements. â Bending stresses approximately 100 ksi at R= -1. â 50,000 cycles = 1 block of tests. Inspection after every block. â Expected lives: 285,000 for 5” pistons, 330,000 for 10” pistons.

13. TEST 3: PISTON FATIGUE TEST GOODRICH LANDING GEAR HCAT TEST CONFIGURATION

14. TEST 3: PISTON FATIGUE TEST GOODRICH LANDING GEAR HCAT TEST SPECIMEN CONFIGURATION

15. TEST 3: PISTON FATIGUE TEST GOODRICH LANDING GEAR HCAT

16. TEST 3: PISTON FATIGUE TEST GOODRICH LANDING GEAR HCAT

17. TEST 3: PISTON FATIGUE TEST GOODRICH LANDING GEAR HCAT

18. TEST 3: PISTON FATIGUE TEST GOODRICH LANDING GEAR HCAT

19. TEST 3: PISTON FATIGUE TEST GOODRICH LANDING GEAR HCAT CURRENT STATUS â 5” OD pistons have been HVOF sprayed (Vac Aero), ground and superfinished to 4 Ra by Goodrich (with assistance from Jon Devereaux, US Navy). â Chrome plated pistons were processed in-house by Goodrich. Finished to better than 16 Ra. â 10” OD pistons are approximately 50% complete. (Purchasing material delayed program.)

20. GOODRICH LANDING GEAR HCAT TEST 3: PISTON FATIGUE TEST Test Results â 1 chrome plated piston tested to piston failure: 285,000 + 122,000 cycles. â No spalling of coating prior to failure. Some surface wear noted on chrome plating. â Failure occurred in the predicated area. Crack initiated at the piston inner diameter and extended circumferentially form the top surface of the piston. Cracking did not extend around bottom side of piston.

21. GOODRICH LANDING GEAR HCAT TEST 3: PISTON FATIGUE TEST CHROME PLATED 5 INCH PISTON

22. GOODRICH LANDING GEAR HCAT TEST 3: PISTON FATIGUE TEST CHROME PLATED 5 INCH PISTON

23. GOODRICH LANDING GEAR HCAT TEST 3: PISTON FATIGUE TEST CHROME PLATED 5 INCH PISTON

24. GOODRICH LANDING GEAR HCAT PISTON FATIGUE TEST Test Results â 1 HVOF coated piston to be tested to piston failure: To date 570,000 cycles without piston failure, equal to 2 lives. Testing continuing. â Small area of failed coating (approximately.150” x.350”), noted between 250,000 - 285,000 cycles on bottom of piston. â Visual, LPI and Barkhausen Noise inspection after 570,000 cycles did not find evidence of any coating cracking in other locations; delamination; spalling or substrate cracking.

25. GOODRICH LANDING GEAR HCAT TEST 3: PISTON FATIGUE TEST Test Results â The coating failure has not been fully characterized. â It is believed to be a different failure mechanism than the fast, catastrophic high stress failures witnessed in the NAWC tests. â Where failure occurred coating experiences significant stress - bending, point loading, fretting all at same location. â These contact stress are not considered representative of service conditions experienced by parts.

26. GOODRICH LANDING GEAR HCAT TEST 3: PISTON FATIGUE TEST HVOF COATING AFTER 285,000 CYCLES

27. GOODRICH LANDING GEAR HCAT TEST 3: PISTON FATIGUE TEST HVOF COATING AFTER 285,000 CYCLES

28. GOODRICH LANDING GEAR HCAT TEST 3: PISTON FATIGUE TEST HVOF COATING AFTER 570,00 CYCLES

29. GOODRICH LANDING GEAR HCAT TEST 3: PISTON FATIGUE TEST

30. GOODRICH LANDING GEAR HCAT TEST 3: PISTON FATIGUE TEST BUSHING CONFIGURATION

31. COATING INTEGRITY TEST GOODRICH LANDING GEAR HCAT The coating failure raises the question: How do we know the coating has the best achieveable properties? â Coating are produced using different parameters (feed rates, fuel, traverse rates) and different equipment. How do we compare the coatings produced using all these different inputs? â Hardness, microstructure, Almen, tensile - are these tests enough to know parameters have been optimized? â Develop a test that measures coating spallation/fatigue resistance.

32. COATING INTEGRITY TEST GOODRICH LANDING GEAR HCAT â Hope the test is sensitive enough to determine how spraying parameters affect spallation resistance. â Use the integrity test for developing spraying parameters, and possibly to use as a qualification test. Test would allow for the use of different parameters, equipment etc. while ensuring the coating meets minimum requirements.

33. COATING INTEGRITY TEST GOODRICH LANDING GEAR HCAT

34. COATING INTEGRITY TEST GOODRICH LANDING GEAR HCAT