CANADIAN HARD CHROME ALTERNATE TECHNOLOGIES

1. 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 Systems Orenda Aerospace Corporation April 25-26, 2001 Long Beach, California, USA

2. Outline • Introduction / Objectives • Canadian HCAT Program • Project Review • HVOF Evaluation and Coupon Qualification • Action Items for Next PRM • Acknowledgements

3. 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.

5. 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

6. 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.

7. HVOF Evaluation and Coupon Qualification 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.

8. HVOF Evaluation and Coupon Qualification SUMMARY OF ADDITIONAL TESTING Mechanical Properties

9. HVOF Evaluation and Coupon Qualification SUMMARY OF ADDITIONAL TESTING Metallurgical Properties

10. HVOF Evaluation and Coupon Qualification Axial Fatigue Evaluation 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)

11. HVOF Evaluation and Coupon Qualification Axial Fatigue Evaluation 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.

12. HVOF Evaluation and Coupon Qualification

13. HVOF Evaluation and Coupon Qualification

14. HVOF Evaluation and Coupon Qualification

15. HVOF Evaluation and Coupon Qualification Axial Fatigue Evaluation 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)

16. HVOF Evaluation and Coupon Qualification Axial Fatigue Evaluation 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.

17. HVOF Evaluation and Coupon Qualification

18. HVOF Evaluation and Coupon Qualification

19. HVOF Evaluation and Coupon Qualification

20. HVOF Evaluation and Coupon Qualification Axial Fatigue Evaluation 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.

21. HVOF Evaluation and Coupon Qualification

22. Action Items For Next PRM: • Continued testing. • Test specification for Wear to be completed. • Salt Spray corrosion testing to be completed.

23. 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