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Phase 1 - TO and Drawing Review, Database Development, Test Requirement Development

Program established to assist United States Air Force Airborne Accessories Directorate Avionics and Accessories Division (OC-ALC/LII) in development and implementation of replacement repair and overhaul procedures for hydraulic actuators across multiple weapon systems.

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Phase 1 - TO and Drawing Review, Database Development, Test Requirement Development

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  1. Program established to assist United States Air Force Airborne Accessories Directorate Avionics and Accessories Division (OC-ALC/LII) in development and implementation of replacement repair and overhaul procedures for hydraulic actuators across multiple weapon systems.

  2. Phase 1 - TO and Drawing Review, Database Development, Test Requirement Development • 124 Air Force Technical Orders Reviewed • 100% complete • 697 Engineering Drawings Reviewed • 57.7% complete • 276 Chrome plated parts and 203 potentially chrome plated parts have been identified.

  3. Phase 2 - Material, Rig, and Flight Testing • Flight Control Actuators • 87 distinct part numbers • Estimate 6 will require delta-qualification • 6 candidate items selected

  4. Phase 2 - Material, Rig, and Flight Testing • Utility Actuators • 73 distinct part numbers • Estimate 15 will require delta-qualification • 1 candidate items selected • Snubbers • 12 distinct part numbers • Estimate 3 will require delta-qualification

  5. Phase 2 - Material, Rig, and Flight Testing • C-130 Rudder Booster Assembly • All chrome plated components are within one SRU (rudder booster actuator) • Rudder booster actuator was qualified, and rudder booster assembly was not. • Delta-qualification will be performed only on the rudder booster actuator.

  6. Phase 2 - Material, Rig, and Flight Testing • C-130 Rudder Booster Assembly • Rudder booster actuator manufactured by Kaiser Fluid Technologies. • Qualified by Lockheed Martin. • Delta-Qualification will be performed by Kaiser Fluid Technologies. • Expected to take 12 months.

  7. Phase 2 - Material, Rig, and Flight Testing • C-130 Rudder Booster Assembly • Delta Qualification will consist of the following tests: • Operation and Leakage • Low Temperature Operation • Rapid Warm Up • High Temperature Operation • Endurance • Salt Fog (ASTM B117-95)

  8. Phase 2 - Material, Rig, and Flight Testing • C-130 Rudder Booster Assembly • Delta Qualification will omit following tests from qualification: • Proof Pressure and Leakage • Vibration • Slam Test • Piston Rod Column • Burst

  9. Phase 2 - Material, Rig, and Flight Testing • C-130 Rudder Booster Assembly • Sand and Dust • Salt Spray (Federal Test Standard 151) • Impact Shock • Fungus Resistance

  10. Phase 2 - Material, Rig, and Flight Testing • C-130 Rudder Booster Assembly • 4 chrome plated surfaces. • Piston rod • 3 sections, with piston heads separating them • Piston head (2 piston heads on the unit) • Not part of the piston rod • Trunnion OD • Mates with an aluminum-bronze bushing • Trunnion ID • Not wearing part

  11. Phase 2 - Material, Rig, and Flight Testing, rod coating surface finish and seal selection • Existing seals are elastomeric T-seals contacting chrome plated rod • Various testing to date shows: • Elastomeric seals do not wear as well against ground HVOF coated surfaces as they do against chrome. • Elastomeric seals do not wear as well as teflon capped seals against HFOV coated surfaces. • Additional Greene Tweed testing indicates that superfinishing of the coated rod surfaces reduces elastomeric seal life during endurance tests.

  12. Phase 2 - Material, Rig, and Flight Testing, rod coating surface finish and seal selection • Options under consideration: • Use existing seals and as-ground coating surface, 4-8 Ra. • Use existing seals and strictly control surface finish to Greene Tweed or Shamban recommendations (Ra, Rz, Rpk, Rsk, Tp). • Use teflon capped seals and as-ground coating surface, 4-8 Ra. • Use existing seals on one end, teflon capped seals on other end, as-ground coating surface, 4-8 Ra. • Use existing seals on one end, teflon capped seals on other end, and strictly control surface finish to Greene Tweed or Shamban recommendations (Ra, Rz, Rpk, Rsk, Tp).

  13. Phase 2 - Material, Rig, and Flight Testing • C-130 Rudder Booster Assembly • Best technical coatings • Piston rod: 82W-10Co-4Cr-3.5C • AMS 2447-9 • Piston head: Tribaloy 400 • AMS 2447-2 • Trunnion OD: 82W-10Co-4Cr-3.5C • AMS 2447-9 • Trunnion ID: 82W-10Co-4Cr-3.5C • AMS 2447-9

  14. Phase 2 - Material, Rig, and Flight Testing • C-130 Rudder Booster Assembly • Best coatings with no chrome • Piston rod: 88W-6Co-5.1C • AMS 2447-7 • Piston head: Cu-37Ni-5In • BAC 5851, Type XIV • Trunnion OD: Cu-37Ni-5In • BAC 5851, Type XIV • Trunnion ID: Cu-37Ni-5In • BAC 5851, Type XIV

  15. Phase 3 - Data Evaluation • Results of Testing will be evaluated and a solution finalized.

  16. Phase 4 - Implementation • The solution developed in Evaluation will be implemented.

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