CANADIAN HARD CHROME ALTERNATE TECHNOLOGIES

ORENDA AEROSPACE CORPORATION

CANADIAN HARD CHROME ALTERNATE TECHNOLOGIES

THE CANADIAN HARD CHROME ALTERNATIVES TEAM (HCAT) JOINT PROGRAM

HVOF PROCESS DEVELOPMENT, EVALUATION AND QUALIFICATION

Jason Dyer, P.Eng.

Advanced Materials and Energy SystemsOrenda Aerospace Corporation

April 25-26, 2001 Long Beach, California, USA


Outline

•Introduction / Objectives

•Canadian HCAT Program

–Project Review

–HVOF Evaluation and Coupon Qualification

•Action Items for Next PRM

•Acknowledgements


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, 1999.

• Contract Technical Authority is Mr. Ken McRae, Head of the Air Vehicle Research Dept. of the Defence Research & Development Branch(DRDB) of the Department of national Defence Canada.


Messier-Dowty BFGoodrich Heroux

HVOF PROCESS DEVELOPMENT,

EVALUATION AND QUALIFICATION

ORENDANRCVAC-AERO

CF-18 E/F Dash-8 CF-18 & CC130

DND

IC/TPC


Project Review

• Official Start Date: February 24, 1999

• Most Recent Canadian Progress/Technical Review Meeting: • March 28, 2001• Represented: ORENDA, NRC-IAR, NRC-IMI, DND, VAC-

AERO

• Next Scheduled Progress/Technical Review Meeting: • June 27, 2001• Ottawa, Ontario, Canada


HVOF Evaluation and Coupon Qualification

•All specimens have been machined, coated and received by Orenda. The phase II wear rods have been coated by VAC-Aero and have been sent to NRC-IC for testing. The chrome specimens have just been received from Technicrome. Orenda will be shipping to NRC-IC after inspection.



Axial Fatigue Evaluation

• All specimens (HVOF and chrome) have been received and testing had commenced. Most of the chrome tests have been completed (detailed results outlined in following sections).

• Testing of the HVOF coating was frozen in late August 2000, when preliminary results showed delamination and spalling of the coating. It was decided that further investigation outside of the JTP was required. Details of this further investigation were outlined in the last Progress Review Meeting.

• Testing has restarted and results are to follow.


HVOF Evaluation and Coupon QualificationSUMMARY OF ADDITIONAL TESTING

Mechanical Properties

Test type Material Environment Coatingthickness

Reasoning Results

Reduction of stresslevel, R-ratio keptconstant

300 M Roomtemperature, air

0.003” 1) To determine the lower thresholdfor coating delamination.

2) To overlap the Canadian testresults with the US test results.

Room temperature tests showed a “threshold” at 180ksi.

Results between Canada and the US overlapped.


300 M Roomtemperature, air

0.010” To determine the lower threshold forcoating delamination

Room temperature tests showed a “threshold” at 125 ksi


300 M Roomtemperature, NaClenvironment


Tests were taken to 125 ksi, coating was corroding beforespalling and failure was continuing to occur.


300 M Roomtemperature, NaClenvironment


Tests have been conducted (see results)

Variation of R-ratio 300 M Roomtemperature, air

0.003” To determine the effect of R-ratio ontest results

Tests showed an increase in fatigue life for a givenstress level.

Coating damage was reduced at the R-ratio wasreduced for a given stress level.

Delamination did not occur once R-ratio went positiveexcept at failure.

Variation of R-ratio 300 M Roomtemperature, air

0.010” 1) To determine the effect of R-ratioon test results.

2) To determine a stress level atwhich specimens could be testedand have material failure prior tocoating failure.

Tests showed an increase in fatigue life for a givenstress level.

Coating damage was reduced at the R-ratio wasreduced for a given stress level.

Tests were stopped at an R-ratio of –0.5 due tolengthy test duration.


HVOF Evaluation and Coupon QualificationSUMMARY OF ADDITIONAL TESTING

Metallurgical Properties

Pre determined cyclecount, R-ratio = -1

300M

Roomtemperature, air

0.003” To determine crack propagationproperties and failure modes

Tests were stopped at approximately 3 000, 12 000, 100 000cycles. Specimens were sectioned and mounted for SEManalysis.

Results presented by Dr. Peter Au, NRC.Pre determined cyclecount, R-ratio = -1

300M


0.010” To determine crack propagationproperties and failure modes

Results presented by Dr. Peter Au, NRC.

Pre determined loadand R-ratio

300M


0.003” To determine the effect of specimengeometry on life and coating failure

Tests scheduled, specimens requested from US for comparativeanalysis.




Room temperature tests:

• Orenda has completed the baseline material and chrome fatigue tests for 300M and Aermet 100. The HVOF results are complete for 300 M. The Aermet 100 tests are being conducted. Current results are presented in the graphs to follow.

• As mentioned before, a “threshold” for spalling of the HVOF coating, for this configuration, was found to be 180 ksi for the 0.003” thick coating and 125 ksi for the 0.010” thick coating. Both “thresholds were determined at R=-1.

• The C-HCAT results overlapped the US results when plotted together (see graph)




Room temperature tests:

• Chrome tests indicated a fatigue debit over the baseline. The fatigue debit was more predominant in the Aermet 100.

• HVOF coatings showed a slight fatigue debit in the Aermet 100 but showed a slight increase in life over the baseline in the 300 M.

• The 0.010” thick coating preformed slightly better than the 0.003” thick coating for both materials. 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.



CHCAT AXIAL FATIGUE TESTINGMaterial: 300 M, 70 oF, Lab Air, freq = 5 Hz, R-ratio = -1

R2 = 0.9481

R2 = 0.9555

R2 = 0.9028

R2 = 0.9338

R2 = 0.9877

155

165

175

185

195

205

215

0 10000 20000 30000 40000 50000 60000

Cycles to Failure

Max

. Str

ess

(ks

i)

Baseline lab air

Cr (3) lab air

Cr (10) lab air

HVOF(3) lab air

HVOF (10) lab air



CHCAT AXIAL FATIGUE TESTINGMaterial: Aermet 100, 70oF, freq=5Hz, R-ratio=-1, Lab Air

R2 = 0.9017

R2 = 0.9552

R2 = 0.974

R2 = 0.9493

R2 = 0.9187

150

160

170

180

190

200

210

220

230

240

250

260

0 10000 20000 30000 40000 50000 60000

Cycles to Failure

Max. A

lt. S

tres

s (k

si)

Baseline Lab Air

Cr (3) Lab Air

Cr (10) Lab Air

HVOF (3) Lab Air

HVOF (10) Lab Air



CANADIAN AND US HCAT AXIAL FATIGUE TESTINGMaterial: 300 M, 70 oF, Lab Air, freq = 5 Hz, R-ratio = -1

120

130

140

150

160

170

180

190

200

210

220

1000 10000 100000 1000000

Cycles to Failure

Max

. Str

ess

(ks

i)

CDN_Cr (3)

CDN_HVOF(3)

US_Cr(3)_SM

US_HVOF(3)_SM




Corrosion fatigue tests:

• Orenda has completed the baseline material and chrome corrosion fatigue tests for 300M and Aermet 100. HVOF testing is being conducted. Current results are presented in the graphs to follow.

• A “threshold” for the 0.003” thick HVOF coatings in a NaCl testing environment was determined to be 125 ksi on 300 M.

• The C-HCAT results overlapped the US results when plotted together (see graph)




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.



CHCAT AXIAL FATIGUE TESTINGMaterial: 300M, 70 oF, 3.5% NaCl solution, freq = 5 Hz, R-ratio = -1

R2 = 0.9166

R2 = 0.8324

R2 = 0.9503

R2 = 0.9489

R2 = 0.8946

R2 = 0.9533

90

100

110

120

130

140

150

160

170

180

190

200

210

220

0 10000 20000 30000 40000 50000 60000Cycles to Failure

Ma

x.

Str

es

s (

ks

i)

Baseline Lab Air

Uncoated 3.5% NaCl

Cr (3) 3.5% NaCl

Cr (10) 3.5% NaCl

HVOF (3) 3.5% NaCl

HVOF (10) 3.5% NaCl



CHCAT AXIAL FATIGUE TESTINGMaterial: Aermet 100, 70oF, freq=5Hz, R-ratio=-1, 3.5% NaCl solution

R2 = 0.9017

R2 = 0.974

R2 = 0.9799

R2 = 0.9619

R2 = 0.971

80

90

100

110

120

130

140

150

160

170

180

190

200

210

220

230

240

250

260

0 10000 20000 30000 40000 50000 60000

Cycles to Failure

Max. A

lt. S

tres

s (k

si)

Baseline Lab Air

Uncoated 3.5% NaCl Solution

Cr (3) 3.5% NaCl Solution

Cr (10) 3.5% NaCl solution

HVOF (3) 3.5% NaCl solution



CANADIAN AND US HCAT AXIAL FATIGUE TESTINGMaterial: 300M, 70 oF, 3.5% NaCl solution, freq = 5 Hz, R-ratio = -1

R2 = 0.9503

R2 = 0.8946

R2 = 0.9769

R2 = 0.9941

90

100

110

120

130

140

150

160

170

180

190

200

210

220

0 20000 40000 60000 80000 100000 120000 140000 160000 180000 200000Cycles to Failure

Ma

x.

Str

es

s (

ks

i)

Baseline Lab Air

Uncoated 3.5% NaCl

Cr (3) 3.5% NaCl

HVOF (3) 3.5% NaCl

US_Cr(3) 3.5% NaCl_HG

US_HVOF(3) 3.5% NaCl_HG




Low Temperature fatigue tests:

• Orenda has completed the baseline material and the chrome low temperature fatigue tests for 300M and Aermet 100. HVOF testing has commenced. Current results are presented in the graphs to follow.

• In general, there is approximately an 8% (Aermet 100), decrease in strength at low temperature over the baseline material at room temperature for a given life (~20,000 cycles). 300 M shows very little difference.

• Although the coating continues to spall off, HVOF is consistently outperforming EHC on 300 M.


HVOF Evaluation and Coupon QualificationCHCAT AXIAL FATIGUE TESTING

Material: 300 M, -40oF, Lab Air, freq = 5 Hz, R-ratio = -1

R2 = 0.9141

R2 = 0.9627

R2 = 0.8538

R2 = 0.928

R2 = 0.9425

165

175

185

195

205

215

0 10000 20000 30000 40000 50000 60000 70000

Cycles to Failure

Ma

x. S

tre

ss

(k

si)

Uncoated Low Temp

Cr (3) Low Temp

Cr (10) Low Temp

HVOF (3) Low Temp

HVOF (10) Low Temp


Action Items For Next PRM:

• Continued testing.

• Test specification for Wear to be completed.

• Salt Spray corrosion testing to be completed.


ACKNOWLEDGEMENTS

Orenda would like to acknowledge the continued support and hard work from:

NRC-Institute for Aerospace ResearchJ.P. Immarigeon, P. Au, D. Dudzinski

NRC-Industrial Materials InstituteJ.G. Legoux, S. Serghini

VAC-Aero InternationalJ. Pritchard, S. Rush

Documents

CANADIAN HARD CHROME ALTERNATE TECHNOLOGIES