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1 CHROMIUM PLATING REPLACEMENT AT SIKORSKY AIRCRAFT ROBERT GUILLEMETTE JOHN BARTALOTTA MATERIALS AND PROCESSES ENGINEERING APRIL 26, 2001
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2 OUTLINE I. Current chrome plating applications II. Past & current efforts with thermal spray coatings III. Methodology for qualification of thermal spray coated components
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3 US ARMYUS NAVY US AIR FORCE US MARINES
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4 Current Applications for Chromium Plate Airframe Drive System Rotors Flight Controls
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5 H-60 Airframe Chromium Plate Replacement AXLE
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6 H-60 Drive System Chromium Plate Replacement
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7 H-60 Main Gearbox Chromium Plate Replacement SEAL SLEEVE, MAIN ROTOR SHAFT
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8 H-60 Intermediate Gearbox Chromium Plate Replacement
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9 H-60 Tail Gear Box Chromium Plate Replacement INBOARD RETENTION PLATE SLEEVE OUTPUT GEAR TORQUE WASHER INPUT
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10 H-60 Main Rotor Head Chromium Plate Replacement
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11 Flight Controls Chromium Plate Replacement: non- hydraulic and hydraulic components Boost Servos Primary Servos
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12 Base Metals Plated With Chromium Steels –4340 (150-280 ksi) –300M (280 ksi) Stainless Steels –17-4 –15-5 –PH13-8Mo Aluminum –7075-T73 Titanium –None Carburized Steels –None
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13 PRIMARY ALTERNATIVES DETONATION GUN SUPER DETONATION GUN PLASMA HVOF
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14 Detonation Gun Over 35 years experience with detonation gun thermal spray coating Excellent track record Specified for difficult, critical applications Chromium replacement primarily done for improved performance, now environmental driven
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15 Current Super DGun Technology Several applications on S-92 and RAH-66 Comanche Implemented reduced weight designs by taking advantage of improved fatigue strength of DGun over chromium electroplate Comparison testing shows Super DGun has superior fatigue properties to HVOF
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16 HVOF Coating Evaluated at Sikorsky Aircraft Diamond Jet –Aluminum Silicon –tungsten carbide JP5000 Tungsten Carbide Jet Kote tungsten carbide
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17 Base metals coated with thermal spray coatings
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18 Detonation Gun Tungsten Carbide reduces fretting fatigue at bearing journals (implemented 1987) Thermal Spray Tungsten Carbide Results in Substantial (6x) Life Improvement for H-60 Main Rotor Shaft
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19 HVOF Aluminum Silicon for Rework of Magnesium Transmission Housings (implemented 1992)
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21 SH-60 DAMPER IMPROVEMENTS – ZERO LEAKAGE FROM THE STATIC SEAL AREA HAS BEEN ACHIEVED SINCE THE INCORPORATION OF THE TUNGSTEN CARBIDE COATING. – THE TRIBALOY AND TUNGSTEN CARBIDE COATINGS ARE SHOWING A GREAT IMPROVEMENT OVER THE CHROME AT 750 HOURS. ISSUES – DAMPER BENCH TEST STOPPED AT ~750 HOURS DUE TO LEAKAGE FROM DYNAMIC END OF DAMPER AND FAILURE OF THE NON- METALLIC BUSHING. – AWAITING STRONGER NON-METALLIC BUSHING FROM SUPPLIER. THE BUSHINGS ARE EXPECTED TO BE DELIVERED LATE MARCH 2001.
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22 Tail Landing Gear Piston
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23 SH-60B Tail Landing Gear Piston, Cleveland Pneumatic PN 2012C4, Base Metal: 300M Steel, Coated with SDG2057 tungsten carbide chromium
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Qualification Test matrix for Navy H-60 Tail Gear Piston Coating adhesion Tensile Fatigue (HCF) Fatigue (LCF) Cyclic stress/strain Metallurgical Wear test (bench scale) Drop test (full scale) Corrosion –open section –crevice testing First article destructive evaluation/validation NAVAIR review Lead-the-fleet testing
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25 UH-60 Tail Landing Gear Fork
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UH-60 TAIL LANDING GEAR Fork
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Qualification Test Matrix for UH-60 tail landing gear fork Adhesion (coupon) Metallurgical (coupon & full scale) –hardness –porosity/uniformity –heat/mechanical effect on substrate Fatigue (coupon) Fatigue after exposure to salt fog (coupon) Wear test (data from Garlock) Corrosion testing (full scale) Army AMCOM review Lead-the-fleet testing
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28 Guidelines for qualification of components with chrome plate replacement Parts have frozen process planning. Change of supplier may require full scale testing Difficulty exist with across-the-board substitution by similarity qualification Lead-the-fleet (actual service operations) often needed as part of qualification Flight Safety parts to be addressed by Flight Safety Change Board
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29 CONCLUSION Chromium replacement for multi-service helicopters is a continuing effort at Sikorsky Aircraft Criteria for qualification is a major challenge
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