1. TESTING STANDARDIZATION Standardization of Testing and Process Evaluation John P. Sauer JoPSauer@Fuse.Net SAUER ENGINEERING December 13, 2000

2. TESTING STANDARDIZATION HCAT December Update 2 December 13, 2000 Sauer Engineering www.SauerEngineering.com Workscope –Standardization/Correlation Almen/Temp Measurement Bar Configuration Almen Range Testing Conditions –NDT –Residual Stress Analysis –4 Point Bend Analysis (strain to failure)

3. TESTING STANDARDIZATION HCAT December Update 3 December 13, 2000 Sauer Engineering www.SauerEngineering.com Common goal –Replace hard chrome Different reasons/methods –Application –Past database for evaluation –Varying philosophy

4. TESTING STANDARDIZATION HCAT December Update 4 December 13, 2000 Sauer Engineering www.SauerEngineering.com Protocols NWU-Generic Landing Gear JTP –HCAT –CHCAT Propeller Hub PEWG Actuator

5. TESTING STANDARDIZATION HCAT December Update 5 December 13, 2000 Sauer Engineering www.SauerEngineering.com Test Methods Almen Temp measurement Metallography (Automatic) Tensile Fatigue Wear Corrosion

6. TESTING STANDARDIZATION HCAT December Update 6 December 13, 2000 Sauer Engineering www.SauerEngineering.com Reaching for –Standardization Same methods Realistic target –Correlation Different methods Common evaluation set Tie protocols together

7. TESTING STANDARDIZATION HCAT December Update 7 December 13, 2000 Sauer Engineering www.SauerEngineering.com Fatigue Standard Almen/Temp Method Standard Bar Configuration/Coating Location Realistic Almen Range for Each Coating Standard Test Conditions

8. TESTING STANDARDIZATION HCAT December Update 8 December 13, 2000 Sauer Engineering www.SauerEngineering.com Almen Measurement –Data from conversations with HCAT members –Spraying at VAC AERO, CTS, Southwest, and Hill AFB –Procedure written

9. TESTING STANDARDIZATION HCAT December Update 9 December 13, 2000 Sauer Engineering www.SauerEngineering.com Almen Measurements –Fixtures Magnetic Screw type Rotating? –Normalize None Thickness.005” –Orientation Crosswise Lengthwise –Grit Blasting None One side Both sides

10. TESTING STANDARDIZATION HCAT December Update 10 December 13, 2000 Sauer Engineering www.SauerEngineering.com Decision made to standardize on the method as highlighted Must have correlation to HCAT method Run side by side comparison Almen Measurement

11. TESTING STANDARDIZATION HCAT December Update 11 December 13, 2000 Sauer Engineering www.SauerEngineering.com Recent work has shown: –Grit blast one side(non HCAT) vs. both sides (HCAT) 4 mil difference –Lengthwise (non HCAT) vs. crosswise (HCAT) 1-2 mil difference Almen Measurement

12. TESTING STANDARDIZATION HCAT December Update 12 December 13, 2000 Sauer Engineering www.SauerEngineering.com Temperature Measurement Spot size Develop method for compensation(Really bigger) Emissivity Develop setting and leave alone Real and Catch all Recording Use RS 232 port for continuous recording and set intervals as fast as possible (.015 sec/reading) Background Consistency (Black block of wood possibility)

13. TESTING STANDARDIZATION HCAT December Update 13 December 13, 2000 Sauer Engineering www.SauerEngineering.com Temperature Measurement –Calibration Method –Contact probe –Maximum temperature –300 vs. 350 F

14. TESTING STANDARDIZATION HCAT December Update 14 December 13, 2000 Sauer Engineering www.SauerEngineering.com Standard Bar Configuration –Smooth Coating Location –Patch coating

15. TESTING STANDARDIZATION HCAT December Update 15 December 13, 2000 Sauer Engineering www.SauerEngineering.com Almen Range WCCo6-12 mils WCCoCr6-10 mils Simulate part spray thermal history or just a process check??

16. TESTING STANDARDIZATION HCAT December Update 16 December 13, 2000 Sauer Engineering www.SauerEngineering.com Testing Conditions R = - 1.0?? Load range of 180 ksi to runout??

17. TESTING STANDARDIZATION HCAT December Update 17 December 13, 2000 Sauer Engineering www.SauerEngineering.com Degree of Correlation Good Correlation –NWU to HCAT Landing Gear Minimal Correlation –CHCAT LG (Plans to address) –Propeller Hub JTP (Small test bar sample)

18. TESTING STANDARDIZATION HCAT December Update 18 December 13, 2000 Sauer Engineering www.SauerEngineering.com Degree of Correlation Difficulty –Problem solving issue-cannot rely on past –Different sets of data are non-usable to others

19. TESTING STANDARDIZATION HCAT December Update 19 December 13, 2000 Sauer Engineering www.SauerEngineering.com NDT Two individual inspections FPI on chrome more for “grinding damage” and circumferential “gross” defects MPI on substrate thru chrome-any indication is rejectable Two possible inspection times During initial production May also be an inspection after service

20. TESTING STANDARDIZATION HCAT December Update 20 December 13, 2000 Sauer Engineering www.SauerEngineering.com NDT –Two issues Can current methods find same substrate defects detected under chrome also under the HVOF? What is the degree of concern on this issue?

21. TESTING STANDARDIZATION HCAT December Update 21 December 13, 2000 Sauer Engineering www.SauerEngineering.com Listing of views from varied sources Cherry Point No problem-assume HVOF will behave just like chrome with current inspection scheme Jacksonville Will not perform any repair inspection as received from field-only after stripping, HVOF and regrinding Hill AFB There are requirements for base metal under chrome-don’t find defects because they believe inspection will find nothing under.125-.250”

22. TESTING STANDARDIZATION HCAT December Update 22 December 13, 2000 Sauer Engineering www.SauerEngineering.com Listing of views from varied sources Delta No real history on HVOF yet-for chrome, always stripped so no real data on exists for in use cracking thru chrome plating Boeing Seattle Looking at Barkhausen as method for inspection Boeing St Louis Concern over lack of understanding for this subject- research is planned and funding being sought

23. TESTING STANDARDIZATION HCAT December Update 23 December 13, 2000 Sauer Engineering www.SauerEngineering.com Bottom Line –No unified answer on what we need to find-no definition of POD and process capability –No real “level of concern” for base metal defects-no current issues exist-have usaually stripped chrome in rework –No standards or samples exist for chrome and HVOF for testing –No new vendors on possible NDT methods are willing to spend time on a “moving” target

24. TESTING STANDARDIZATION HCAT December Update 24 December 13, 2000 Sauer Engineering www.SauerEngineering.com NDT methods –Work in progress at Boeing/MDC (Barkhausen)Wes Graham/Clint Surber AFRL( Current techniques)Joe Kolek/Stefan Susta Varied other sources( Heroux ) –Developing standards for future use –Using new methods will probably only be for spot/high stress areas

25. TESTING STANDARDIZATION HCAT December Update 25 December 13, 2000 Sauer Engineering www.SauerEngineering.com Residual Stress –What are the true levels in the parts? –Almen is a guideline but not real magnitude –What is best test method? XRD, MLRM, ??? –Preliminary work is needed to provide baseline data

26. TESTING STANDARDIZATION HCAT December Update 26 December 13, 2000 Sauer Engineering www.SauerEngineering.com

27. TESTING STANDARDIZATION HCAT December Update 27 December 13, 2000 Sauer Engineering www.SauerEngineering.com Residual Stress Planning limited work correlating Almen vs. as sprayed blocks Establish relationship with major gun suppliers on 2-3 runs-then rely on Almens

28. TESTING STANDARDIZATION HCAT December Update 28 December 13, 2000 Sauer Engineering www.SauerEngineering.com 4 Point Bend Can be used to establish strain to failure data for coating Method usually involves use of acoustic emission on a (.25 x.5-1.0 x 6.0-10.0”) specimen to determine onset of cracking

29. TESTING STANDARDIZATION HCAT December Update 29 December 13, 2000 Sauer Engineering www.SauerEngineering.com 4 Point Bend General number currently being quoted is about.5-.7% for WCCo and WCCoCr Plans in progress to perform some current analysis at Hamilton Sundstrand and as part of HCAT/CHCAT spalling investigation

30. TESTING STANDARDIZATION HCAT December Update 30 December 13, 2000 Sauer Engineering www.SauerEngineering.com 4 Point Bend Striving to determine standard test specimen/method Presentation later by Shane Arthur/John Quets of Praxair