Alternatives to hexavalent Chromium in the aerospace .... Alternatives to Hex Chrome... ·...

Alternatives to hexavalent Chromium

in the aerospace supply chain

New ideas for CAA anodizing process replacement

TUESDAY 14 June 2011

A.Viola

11

This document and the information contained are Safran property and shall not be copied or disclosed to any third party without Safran prior written authorization.

1

DM&P / A.VIOLA / IMFAIR June 2011

AGENDA

1) INTRODUCTION

2) SAFRAN

3) ALTERNATIVE PROCESSES

4) ANODIZING

5) CONCLUSIONS

22


2


AGENDA

Tier-1 equipment supplier

An international high-technology group

Safran

Aerospace

Defence

Security

33


3


26 %

12 %52 %

10 %

Key

Revenues: 10.8 billion euros

Recurring operating income: 878 million euros

Net income – Group share: 508 million euros

2010 revenues

figuresAircraft Equipment

DefenceAerospacePropulsion

Security

44


4


An international high technology group

Revenues of 10.8 billion euros*

More than 54,000 employees in over 50 countries

3 core businesses:

Safran

Aerospace

Defence

Security

at a glance* As of December 31, 2010

55


5


Capital shareholdingAs of December 31, 2010

56 %

French State

30.2%

Areva

2%

Public

47.6%

Treasury shares

4.2%Employees

16%

66


6


56 %

Europe

Morocco

Design

office

Industrial

site

HQ Office

United States

Mexico

Colombia

Brazil

Uruguay

Canada

South Africa United Arab Emirates

China

India

Japan

Malaysia

Services

Singapore

Australia

Safran worldwide

employees

54,000More than

77


7


7

LARGE BROAD OF PRODUCTS (1)AEROSPACE ENGINES

Civil aircraft

helicopter

Military aircraft Spatial

Futur civil

engines

http://www.safran-group.com/spip.php?page=popin-photo&id_document=334&type=1&lang=fr


88


8


8

LARGE BROAD OF PRODUCTS (1)AEROSPACE ENGINES

Civil aircraft

helicopter

Military aircraft Spatial

Futur civil

engines



99


9


Ariane 5

Vinci®

(Under

development)

HM7B™Thrust:

22,000 lb

Vulcain®2

Thrust:

297,000 lb

Ariane 5

AEROSPACE ENGINES

HTE

1010


10


10

EQUIPEMENTS (1)AEROSPACE EQUIPMENTS and PARTS

V:/Intranet/Vie pratique/Photothèque/Programmes spatiaux/VP VINCI 1.jpg

V:/Intranet/Vie pratique/Photothèque/Programmes spatiaux/BEVM Vinci.jpg

1111


11


OUR CUSTOMERS

1212


12


12

« Ce document et les informations qu’il contient sont la propriété de Snecma. Ils ne doivent pas être copiés ni communiqués à un tiers sans l’autorisation préalable et écrite de Snecma. ».

Fan blades, booster and Fadec on GEnx engine

Landing gear

Wheels and carbon brakes

Electric brake actuation controller (EBAC)

Wiring

DREAMLINERBoeing 787

1313


13


13


XWBAirbus A350

Integrated landing and braking system

Main landing gear

Wheels and carbon brakes

Fuselage and engine pylon wiring

Components for onboard information system and flight control system

1414


14


14


Vulcain main stage engine

HM7B upper stage engine

Solid booster motors, via Europropulsion

Launch vehicle

ARIANE

1515


15


Safran and GE

71% share of engine market for single-aisle commercial jets

World’s largest fleet: 20,000 CFM56 engines delivered to date

A textbook case of a successful transatlantic partnership in the

aviation industry (and industry in general): the CFM56 is the world’s

best selling aircraft engine

Backlog of orders exceeding 5 years of production

A CFM56-powered plane takes off every 2.5 seconds

5,000 takeoffs between engine overhaul


1616


16


ALTERNATIVE PROCESSES

1717


17


GENERAL REQUIREMENTS

Choice criterias for a satisfactory aluminium surface treatment

• Fatigue properties

• Painted performances

• Corrosion resistance

• Process monitoring

• Patent rights

• Waste, pollution

• Bonding properties

• Chemicals resistance

Electrical properties

Touch up process

Supply chain diffusion

Cost

1818


18


SOME REPRESENTATIVE PARTS

Painted nacelle beam

Painted wheel

Painted nose wheel landign gear

Unpainted gear boxe housing

Painted piston housing

1919


19


ALTERNATES

• Conversion coatings

• E Coating (PPG)

• Electro Ceramic Coating (Henkel)

• Aquence Technology (Henkel)

• Micro Arc Oxydation (Ceratronic)

• Sol Gel Technologies ( Millidyne – ICS – NCT)

• Anodizing processes(SAA, PAA, TFSAA, DSA, TSA, SPA, BSAA, Duplex…)

https://extranet.safran.fr/MBPortail/portletmanager/,DanaInfo=intranet.messier-bugatti.snecma+34028?_nfpb=true&portletPhotoAlbum_1_actionOverride=%2Fportlets%2FphotoAlbum%2FchangePhoto&_windowLabel=portletPhotoAlbum_1&portletPhotoAlbum_1%7BactionForm.photoPath%7D=%2FphotoAlbum%2FPhototheque_produits%2FBo%C3%AEtiers+d%27accrochage%2Fboitier4_a340.jpg&portletPhotoAlbum_1%7BactionForm.position%7D=1

https://extranet.safran.fr/MBPortail/portletmanager/,DanaInfo=intranet.messier-bugatti.snecma+34028?_nfpb=true&portletPhotoAlbum_1_actionOverride=%2Fportlets%2FphotoAlbum%2FchangePhoto&_windowLabel=portletPhotoAlbum_1&portletPhotoAlbum_1%7BactionForm.photoPath%7D=%2FphotoAlbum%2FPhototheque_produits%2FBo%C3%AEtiers+d%27accrochage%2Fboitier_a330_a340.jpg&portletPhotoAlbum_1%7BactionForm.position%7D=1

https://extranet.safran.fr/MBPortail/portletmanager/,DanaInfo=intranet.messier-bugatti.snecma+34028?_nfpb=true&portletPhotoAlbum_1_actionOverride=%2Fportlets%2FphotoAlbum%2FchangePhoto&_windowLabel=portletPhotoAlbum_1&portletPhotoAlbum_1%7BactionForm.photoPath%7D=%2FphotoAlbum%2FPhototheque_produits%2FBo%C3%AEtiers+d%27accrochage%2Fboitier_a340.jpg&portletPhotoAlbum_1%7BactionForm.position%7D=1

https://extranet.safran.fr/MBPortail/portletmanager/,DanaInfo=intranet.messier-bugatti.snecma+34028?_nfpb=true&portletPhotoAlbum_1_actionOverride=%2Fportlets%2FphotoAlbum%2FchangePhoto&_windowLabel=portletPhotoAlbum_1&portletPhotoAlbum_1%7BactionForm.photoPath%7D=%2FphotoAlbum%2FPhototheque_produits%2FBo%C3%AEtiers+d%27accrochage%2Fboitier_sur_avion.jpg&portletPhotoAlbum_1%7BactionForm.position%7D=1

https://extranet.safran.fr/MBPortail/portletmanager/,DanaInfo=intranet.messier-bugatti.snecma+34028?_nfpb=true&portletPhotoAlbum_1_actionOverride=%2Fportlets%2FphotoAlbum%2FchangePhoto&_windowLabel=portletPhotoAlbum_1&portletPhotoAlbum_1%7BactionForm.photoPath%7D=%2FphotoAlbum%2FPhototheque_produits%2FBo%C3%AEtiers+d%27accrochage%2Fboitier_tous_programmes.jpg&portletPhotoAlbum_1%7BactionForm.position%7D=1

2020


20


ALTERNATE (1)

Mainly chromium III based ( Surtec, Henkel 5923..)

Permanganate based (Sanchem)

Necessity to have an enhanced technology for 2000 and 7000

aluminium series (corrosion resistance equal to hexavalent

technology)

Conversion coating + inhibitor + eventually additional layer (Lanthane

613.3 +)

Conversion coatings

2121


21


ALTERNATE (1) Conversion coatings

This process finally reach the CCC corrosion resistance

2222


22


ALTERNATE (2) E Coatings

2323


23


ALTERNATE (2) E Coatings

2424


24


ECC CoatingsALTERNATE (3)

• Hardness: 600 - 800 vickers

• Abrasion resistance: cycles ( CS-10 Wheel, 10,000 cycles) TWI 1.5

• Flexibility, pass 1-2T bend (ASTM D 4145)

• Coefficient of Friction: 0.1-0.2 dry

• Thermal resistance, 600 ºC, 84 hours – no change in adhesion

• Titanium oxide coating (TiO2) Corrosion Resistance > 3000 hours

Alodine EC²

ECC Coatings

Electroceramic Coating

2525


25


ALTERNATE (3) ECC Coatings

Alodine EC²

2626


26


ALTERNATE (3) ECC Coatings

Alodine EC²

2727


27


ALTERNATE (4) E.A.U. CoatingsEpoxy Acrylic Urethane Coating

2828


28


ALTERNATE (4) Epoxy Acrylic Urethane Coating

Not available yet for aluminium

2929


29


ALTERNATE (5) MAO / PEO Coatings

Plasma Electrolytic CoatingI (t) [A]

IP

T

time

IN

Main parameters control :

• Treating duration

• Signal shape (cyclic ratio)

Qp / Qn

• Positiv intensity (5-210 A)

• Frequency (100 à 1000 Hz)

Electrolyte type (conductivity, composition, temperature…)

3030


30



Plasma Electrolytic Coating

Thickness range

Hardness

Fatigue properties

Corrosion resistance

3131


31



3232


32


ALTERNATE (6)

Degreasing

Rinsing Rinsing

1 . Pickling

Socosurf A1858 (25%)

+ A1806 (10%)

30°C 15min

Rinsing

2 . SAA

H2SO4 200g/L

18°C

Rinsing

3 . Sealing

Lanthane 613.3

part A (100mL/L)

+ part B (75mL/L)

40°C 10min

Post-sealing

H2O (dionised)

98°C 30min

Painting

Painting

Chromic acid Cr2O3Actually Chromic acid Cr2O3 K DIchromateCr2O3

Anodizing processes

3333


33


ALTERNATE (6)

Socosurf Socomore

Etch Coventya

Isoprep 161 Mc Dermid

Novaclean Al85 Henkel

Smut Go NC Henkel

295 GD Chemetall

Pickling

Tested on following alloys:

2024, 2014, 2016, 2017A, 2214, 2219, 2618A

5056, 5086

6061, 6063

7010, 7075, 7175, 7040, 7050, 7449

AU5NKZr, A357, AS7U1G

3434


34


7175 T73 Fatigue Properties Anodizing

3535


35



3636


36



3737


37


FATIGUE PERFORMANCES (oxyde layer) thicknesse

effect)

2 nd step : SAA oxide layer thickness on forged 2214 T6 and 7050 T74 aluminium alloy

Fatigue was performed under a imposed max stress

@ Kt=1.035, R=0.1 [etching Phospho-sulfonic solution]

There is no influence of the oxide layer thickness on fatigue performance in the range of 7 to 15 µm on this aluminium alloys

3838


38


Sulfuric Acid Anodizing

SAA is a promising and cost efficient solution for CAA replacement

• Fatigue properties : equal or better than CAA

• Painted performances : class 0 before and class 0-1 after ageing

• Corrosion resistance : no pit before 500 h on sealed SAA

• Process monitoring : easy process monitoring, widespread solution

• Patent rights : none

• Waste, pollution : less constraints than actual CAA (ex. no chromate treatment)

When a higher thickness (than CAA) is design acceptable

3939


39


IF NOT ACCEPTABLE

• CORROSION / UN PAINTED APPLICATIONS

• Sulfo Tartaric (Airbus)

• Sulfo Boric (Boeing)

• Thin Film Sulfuric (SAA or DSA)

• BONDING APPLICATIONS

• Phosphoric, Sulfo phosphoric

• SAFRAN TARGETS: Have a Properties Process Specification

4040


40


ALTERNATE (6)

Chrome III salts + HTW post dip

Sol Gel sealing (Alcoa Patented Process)

Ammonium or Sodium Molybdates salts

SEALING

Co - polymeric PTFE sealing

The most promising process is Lanthane 613.3 + post dip process

4141


41


ALTERNATE (7)

Millidyne – VTT (Finland)

NTC – ICS (Germany)

Socosurf (Socomore F)

NanoOxide™ Coating – (Alcoa US)

Sol Green (Cirimat F) -

SOL GEL

4242


42


CONCLUSIONS

End of this year we should have resolved our major issues

Dip Hex C.C. on aluminium alloys replaced by dip chromium III conversion

For the whole anodizing process

Sulfo chromic bathes issue is already resolved

CAA anodizing bathes quite also

Dichromate K or Na sealing bathes also as

• Adhesion promoter

• For a high corrosion resistance of non painted parts

Other new technologies are still in progress for the next generations of

aluminium alloy protections

4343


43


QUESTIONS

Alternatives to hexavalent Chromium in the aerospace .... Alternatives to Hex Chrome... ·...

Documents

Transcript of Alternatives to hexavalent Chromium in the aerospace .... Alternatives to Hex Chrome... ·...