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Transcript of H HCAT Propeller Chrome Plate Replacement Program Edward Faillace - Steve Pasakarnis - Aaron Nardi...
![Page 1: H HCAT Propeller Chrome Plate Replacement Program Edward Faillace - Steve Pasakarnis - Aaron Nardi Hamilton Sundstrand- Engineering August 29, 2001.](https://reader035.fdocuments.in/reader035/viewer/2022062404/5519c79b550346047c8b489c/html5/thumbnails/1.jpg)
H
HCAT Propeller Chrome Plate Replacement Program
Edward Faillace - Steve Pasakarnis - Aaron Nardi
Hamilton Sundstrand- Engineering
August 29, 2001
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H
Program Milestones
Fatigue Testing - completed April 2001 Wear - completed April 2001 Corrosion - completed January 2001 TCLP - completed January 2001 LPS Component Test
Chrome plated - completed August 2001 WC-17Co - coating in process
Full Scale Engine Test of P-3 Hub at HS -Feb. 2002
Original JTP
Added Effort
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H
Proposed Follow-on Work • Compression - Compression Fatigue
– Recent spalling concerns prompted effort – Evaluate effect of compressive fatigue loading on HVOF coating – Funded this year by Navy under Component Improvement Program (CIP)
• Four Point Bend Testing – Evaluate test techniques for QC of coating application – Requested funding for FY 2002
• Residual Stress Evaluation– Evaluate coating/substrate compressive residual stresses using MLRM,
XRD and Hole-drill techniques– Correlate test specimen stresses to actual part stresses– Requested funding for FY 2002
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HSummary Of Fatigue Test Results
• WC-Co exhibit no strength degradation on AISI 4340 HRC 40-44
• WC-Co exhibit superior fatigue properties to both EHC and T-800
• Shot peening had minimal effect on the fatigue strength of WC-Co and T-800
• Unable to discern surface roughness effect due to final specimen condition
• WC-Co is more notch sensitive than T-800
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H
0
50
100
150
200
250
104 105 106 107 108
Cycles
Str
es
s (
ks
i)
Unpeened 4340 Steel
Peened WC - 17% Co .003" 4 Ra Finish
Peened WC - 17% Co .010" 16 Ra Finish
Peened WC - 17% Co .010" 4 Ra Finish
Peened WC - 17% Co .015" 4 Ra Finish
Peened EHC .003" 16 Ra
Peened EHC .010" 16 Ra Finish
Peened EHC .015" 16 Ra Finish
Peened T-800 .003" 8 Ra Finish
Peened T-800 .010" 8 Ra Finish
Peened T-800 .010" 16 Ra Finish
Peened T-800 .015" 8 Ra Finish
Peened Fatigue Data
AISI 4340 HRC 40-44, R=0.1
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H
Macro Cracking from Grinding Operation
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H
0
50
100
150
200
250
10000 100000 1000000 10000000 100000000Cycles
Ma
x S
tre
ss (
ksi)
Bare 4340
Unpeened EHC, 0.003
Unpeened EHC, 0.010
Unpeened EHC, 0.015
Unpeened WC, 0.003
Unpeened WC, 0.010
T-800, Kt=2.70
WC, Kt=2.70
Unpeened and Notched Fatigue Data
AISI 4340 HRC 40-44, R=0.1
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HAlSI4340 HRC 40-44, R=0.1, .010" WC-17Co
Green Points Were Not Peened
140
150
160
170
180
190
200
210
220
230
240
1.0E+02 1.0E+03 1.0E+04 1.0E+05 1.0E+06 1.0E+07 1.0E+08
Cycles
Ma
xim
um
Str
ess
(ks
i)
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H4340 HRC40-44, R=0.1,WC-17Co .003" 4Ra
Green Points Were Not Peened
140
150
160
170
180
190
200
210
220
1.0E+02 1.0E+03 1.0E+04 1.0E+05 1.0E+06 1.0E+07 1.0E+08
Cycles
Ma
xim
um
Str
ess
(ks
i)
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HAISI 4340, HRC 40-44, R=0.1, T-800 .015
Green Points Were Not Peened
110
120
130
140
150
160
170
180
190
200
210
1.0E+02 1.0E+03 1.0E+04 1.0E+05 1.0E+06 1.0E+07 1.0E+08
Cycles
Ma
xim
um
Str
ess
(ks
i)
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HAISI 4340 HRC 40-44, R=0.1,.015" Cr 16Ra
Green Points Were Not Peened
0
50
100
150
200
250
1.0E+02 1.0E+03 1.0E+04 1.0E+05 1.0E+06 1.0E+07 1.0E+08
Cycles
Ma
xim
um
Str
ess
(ks
i)
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HAISI 4340, HRC 40-44, R=0.1, T-800 .010
Green Points Were Not Peened
110
120
130
140
150
160
170
180
190
200
210
1.0E+02 1.0E+03 1.0E+04 1.0E+05 1.0E+06 1.0E+07 1.0E+08
Cycles
Ma
xim
um
Str
ess
(ks
i)
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HAlSI4340 HRC 40-44, R=0.1, .010" Cr
Green Points Were Not Peened
0
50
100
150
200
250
1.0E+03 1.0E+04 1.0E+05 1.0E+06 1.0E+07 1.0E+08
Cycles
Ma
xim
um
Str
ess
(ks
i)
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HAISI 4340, HRC 40-44, R=0.1,.003" T-800
Green Points Were Not Peened
100
120
140
160
180
200
220
1.0E+02 1.0E+03 1.0E+04 1.0E+05 1.0E+06 1.0E+07 1.0E+08
Cycles
Ma
xim
um
Str
ess
(ks
i)
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H
HCAT Propeller Project-Wear Testing
Aaron Nardi
Hamilton Sundstrand- Materials Engineering
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H Wear Testing• Coating Types
• WC-Co
• WC-Co-Cr
• Tribaloy T-800
• Chrome Plate (AMS 2406)
• Nickel Plate (AMS 2423)
• Counterfaces• 4340 Steel
• Beryllium Copper
• Viton Seal Material
• 15% Glass filled PTFE
• Test Variables• Contamination
• Oil Type (Mil-H-83282, Mil-H-87257)
• Stroke Length
• Load
• Surface Finish
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HWear Test Fixture
Load Pin
3000 lb. capacity
Spring Washers
Pivots
Coated Panel Specimen
Flat Counter-face Specimens
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HWear Testing Results
• Coatings against Steel Counterfaces– Wear rates of steel specimens were comparable between EHC and
WC-Co, but generally lower for T-800
– EHC and T-800 performed much poorer than WC-Co with respect to coating performance
– Oil type had negligible effect on wear of steel specimens or coatings
– Lower coating surface finishes produced less steel specimen wear
– Oil contamination caused marco-spalling of EHC and T-800 in a dithering mode, WC-Co exhibited only a small spot of steel adhesion to the coating
– All friction coefficients ranged from 0.1 - 0.15
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HSteel Wear Rate Comparison
-1.5E-12
-1.0E-12
-50.0E-14
00.0E+0
50.0E-14
1.0E-12
1.5E-12
2.0E-12
Low
/Dith
er
Hig
h/Lo
ng
Hig
h/Lo
ng/S
F
Low
/Dith
er/C
Low
/Lon
g/C
Hig
h/Lo
ng/O
Test Condition
Wea
r C
oef
fici
ent
Chrome Plate
Tungsten Carbide
Tribaloy T-800
Lubrication System Failure
Heavy pitting and adhesion of panel coating on steel
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HPanel Wear from Steel Specimens
0
1
2
3
4
5
Test Condition
Chrome Plate
Tungsten Carbide
Tribaloy T-800
No Wear
Mild Wear
Moderate
Heavy
Pitting
Adh
esiv
e /
Abr
asiv
e W
ear
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HDithering Tests With Steel Counterfaces
in Contaminated Mil-PRF-83282
Hard Chrome Plate WC-17Co HVOF T-800 HVOF
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HWear Testing Results (cont’d)
• Coatings against Beryllium Copper Counterfaces– Copper specimens exhibited higher wear rates than steel due to
poor lubrication of copper by the TCP anti-wear additives in the hydraulic oil
– WC-Co far outperformed both EHC and T-800 in Beryllium Copper material wear and panel coating performance
– Surface finish did not play a significant role in the wear performance of either coated panel or Beryllium Copper specimen
– Contamination resulted in minor overall changes in Beryllium Copper specimen wear but resulted in a reduced performance of all coatings
– Friction coefficients were generally higher than for the steel specimens, ranging from 0.1 - 0.2
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HCopper Specimen Wear Rate Comparison
000.0E+0
5.0E-12
10.0E-12
15.0E-12
20.0E-12
25.0E-12
30.0E-12
35.0E-12
40.0E-12
Test Condition
We
ar
Co
eff
icie
nt
Chrome Plate
Tungsten Carbide
Tribaloy T-800
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HPanel Wear from Copper Specimens
0
1
2
3
4
5
Test Condition
Chrome Plate
Tungsten Carbide
Tribaloy T-800
No Wear
Mild Wear
Moderate
Heavy
Pitting
Ad
he
sive
/
Ab
rasi
ve W
ea
r
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HStroking Tests With Copper Counterfaces in
Clean Mil-PRF-83282
Hard Chrome Plate WC-17Co HVOF T-800 HVOF
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HWear Testing Results (cont’d)
• Coatings against Viton Counterfaces– Viton wear rates were generally similar between coatings but will
be evaluated by wear step measurement .
– Mil-PRF-87257 hydraulic oil increased the wear and the friction coefficient of the Viton specimens relative to the Mil-PRF-83282 baseline
– Contamination had no effect on the WC-Co and had a slight effect on the EHC and T-800
– Dither tests exhibited higher friction coefficients than long stroking tests
– Friction coefficients ranged from 0.1 - 0.3
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HViton Wear Rate Comparison
-200.0E-12
-100.0E-12
000.0E+0
100.0E-12
200.0E-12
300.0E-12
400.0E-12
Test Condition
Wea
r C
oef
fici
ent
Chrome Plate
Tungsten Carbide
Tribaloy T-800
Acetone Exposure, weights inaccurate
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HPanel Wear from Viton Specimens
0
1
2
3
4
5
Test Condition
Chrome Plate
Tungsten Carbide
Tribaloy T-800
No Wear
Mild Wear
Moderate
Heavy
Pitting
Adh
esiv
e /
Abr
asiv
e W
ear
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HWear Testing Results (cont’d)
• Coatings against Glass Filled PTFE Counterfaces– WC-Co-Cr out-performed EHN in both coating performance and
PTFE specimen wear
– Nickel exhibited moderate abrasion by the PTFE specimens in both contaminated and non-contaminated oil
– PTFE specimens exhibited slightly more wear with contaminated oil than with clean oil.
– Friction coefficients ranged from 0.04-0.05
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HDithering Tests With Glass Filled PTFE Counterfaces in Clean Mil-PRF-83282
Hard Nickel Plate WC-Co-Cr HVOF
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H
HCAT Propeller Project-Corrosion Testing
Aaron Nardi
Hamilton Sundstrand- Materials Engineering
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HCorrosion Testing
• Salt Fog Corrosion Testing Per ASTM B117– Coating Types
• Nickel Plate (AMS 2423)
• WC-Co
• WC-Co-Cr
• Tribaloy T-800
– Test Variables • As Plated vs. Machined
• Coating Thickness
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HResults From Corrosion Testing
• Nickel Plating was the overall top performer• WC-Co-Cr was marginally the best HVOF coating• In General, the thick coatings performed better
than thin coatings• Machined specimens generally performed worse
than panels in the as coated condition.
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HAs Coated Nickel Corrosion Panels
W-1, 8 days, 0.001 Thick W-6, 8 days, 0.005 Thick
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HAs Coated Tribaloy T-800 Corrosion Panels
T-1, 5 days, 0.001 Thick T-2, 5 days, 0.001 Thick T-3, 5 days, 0.001 Thick
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HAs Coated WC-Co Corrosion Panels
W-1, 12 days, 0.001 Thick W-2, 8 days, 0.001 Thick W-6, 20 days, 0.005 Thick
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HAs Coated WC-Co-Cr Corrosion Panels
WCR-1, 20 days, 0.001 Thick WCR-2, 8 days, 0.001 Thick WCR-3, 8 days, 0.001 Thick
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H
HCAT Propeller Project-Toxicity Characteristic Leaching Procedure
Aaron Nardi
Hamilton Sundstrand- Materials Engineering
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H
Corrosion and TCLP Testing
• TCLP Testing
– Evaluate environmental impact of powder disposal• Unsprayed powder
• Sprayed Powder
– Checks For Leaching of Heavy Metals Into Soil• Chrome
• Nickel
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HTCLP Testing Results
• Spent Material Tested (WC-Co-Cr, T-400, T-800)• Virgin Powder Tested (WC-Co-Cr, T-400, T-800)• NOT HAZARDOUS WASTE• In Connecticut Would Be Considered Non-
Hazardous Regulated Waste