CHROMIUM PLATING REPLACEMENT AT SIKORSKY AIRCRAFT - PowerPoint PPT Presentation

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CHROMIUM PLATING REPLACEMENT AT SIKORSKY AIRCRAFT

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chromium plating replacement at sikorsky aircraft robert guillemette john bartalotta materials and processes engineering april 26, 2001 outline i. current chrome ... – PowerPoint PPT presentation

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Title: CHROMIUM PLATING REPLACEMENT AT SIKORSKY AIRCRAFT


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

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
(No Transcript)
21
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.

22
Tail Landing Gear Piston
23
SH-60B Tail Landing Gear Piston, Cleveland
Pneumatic PN 2012C4, Base Metal 300M Steel,
Coated with SDG2057 tungsten carbide chromium
24
Qualification Test matrix for Navy H-60 Tail Gear
Piston
  • 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

25
UH-60 Tail Landing Gear Fork
26
UH-60 TAIL LANDING GEAR
Fork
27
Qualification Test Matrix for UH-60 tail landing
gear fork
  • 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

28
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

29
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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