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CHROMIUM PLATING REPLACEMENT AT SIKORSKY AIRCRAFT

CHROMIUM PLATING REPLACEMENT AT SIKORSKY AIRCRAFT. ROBERT GUILLEMETTE JOHN BARTALOTTA MATERIALS AND PROCESSES ENGINEERING APRIL 26, 2001. OUTLINE. I. Current chrome plating applications II. Past & current efforts with thermal spray coatings

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CHROMIUM PLATING REPLACEMENT AT SIKORSKY AIRCRAFT

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  1. CHROMIUM PLATING REPLACEMENT AT SIKORSKY AIRCRAFT ROBERT GUILLEMETTE JOHN BARTALOTTA MATERIALS AND PROCESSES ENGINEERING APRIL 26, 2001

  2. OUTLINE • I. Current chrome plating applications • II. Past & current efforts with thermal spray coatings • III. Methodology for qualification of thermal spray coated components

  3. US ARMY US NAVY US MARINES US AIR FORCE

  4. Current Applications for Chromium Plate • Airframe • Drive System • Rotors • Flight Controls

  5. H-60 Airframe Chromium Plate Replacement AXLE

  6. H-60 Drive System Chromium Plate Replacement

  7. H-60 Main Gearbox Chromium Plate Replacement SEAL SLEEVE, MAIN ROTOR SHAFT

  8. H-60 Intermediate Gearbox Chromium Plate Replacement

  9. H-60 Tail Gear Box Chromium Plate Replacement OUTPUT GEAR TORQUE WASHER INBOARD RETENTION PLATE SLEEVE INPUT

  10. H-60 Main Rotor Head Chromium Plate Replacement

  11. Flight Controls Chromium Plate Replacement: non-hydraulic and hydraulic components Primary Servos Boost Servos

  12. Steels 4340 (150-280 ksi) 300M (280 ksi) Stainless Steels 17-4 15-5 PH13-8Mo Aluminum 7075-T73 Titanium None Carburized Steels None Base Metals Plated With Chromium

  13. PRIMARY ALTERNATIVES DETONATION GUN SUPER DETONATION GUN PLASMA HVOF

  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

  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

  16. HVOF Coating Evaluated at Sikorsky Aircraft • Diamond Jet • Aluminum Silicon • tungsten carbide • JP5000 Tungsten Carbide • Jet Kote tungsten carbide

  17. Base metals coated with thermal spray coatings

  18. Thermal Spray Tungsten Carbide Results in Substantial (6x) Life Improvement for H-60 Main Rotor Shaft Detonation Gun Tungsten Carbide reduces fretting fatigue at bearing journals (implemented 1987)

  19. HVOF Aluminum Silicon for Rework of Magnesium Transmission Housings (implemented 1992)

  20. 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.

  21. Tail Landing Gear Piston

  22. SH-60B Tail Landing Gear Piston, Cleveland Pneumatic PN 2012C4, Base Metal: 300M Steel, Coated with SDG2057 tungsten carbide chromium

  23. 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 Qualification Test matrix for Navy H-60 Tail Gear Piston

  24. UH-60 Tail Landing Gear Fork

  25. UH-60 TAIL LANDING GEAR Fork

  26. 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 Qualification Test Matrix for UH-60 tail landing gear fork

  27. 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

  28. 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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