Hard Chrome Alternatives Team Joint Group on Pollution Prevention Propulsion Environmental Working Group PROGRAM REVIEW MEETING 25-26 April 2001 Long Beach,

Hard Chrome Alternatives TeamHard Chrome Alternatives Team

Joint Group on Pollution PreventionJoint Group on Pollution Prevention

Propulsion Environmental Working GroupPropulsion Environmental Working Group

PROGRAM REVIEW MEETINGPROGRAM REVIEW MEETING

25-26 April 200125-26 April 2001

Long Beach, CaliforniaLong Beach, California

Acknowledgments -Acknowledgments -Principal HCAT Program SponsorsPrincipal HCAT Program Sponsors

Department of Defense Department of Defense Environmental Security Environmental Security Technology Certification Technology Certification ProgramProgram

Department of Defense Department of Defense Joint Group on Joint Group on Pollution PreventionPollution Prevention

Department of Defense Department of Defense Propulsion Environmental Propulsion Environmental Working GroupWorking Group

Next HCAT MeetingNext HCAT Meeting

28-30 August 200128-30 August 2001

Crowne Plaza Toronto Centre HotelCrowne Plaza Toronto Centre Hotel

225 Front Street West225 Front Street West

Toronto, OntarioToronto, Ontario

416-597-1400416-597-1400

Block of rooms not yet reserved, so don’t call yet for Block of rooms not yet reserved, so don’t call yet for reservations; e-mail will be sent when block confirmedreservations; e-mail will be sent when block confirmed

Single and double room rate of Canadian $189 per night (U.S. Single and double room rate of Canadian $189 per night (U.S. Government per diem is U.S. $163)Government per diem is U.S. $163)

Breakout of ESTCP Chrome Replacement Breakout of ESTCP Chrome Replacement Project Into Four Separate Projects Project Into Four Separate Projects (March 2001)(March 2001)

Project 199608:Project 199608: Replacement of Chromium Electroplating on Replacement of Chromium Electroplating on Aircraft Landing Gear Using HVOF Thermal Spray Aircraft Landing Gear Using HVOF Thermal Spray Technology (retains “generic” portion of project; specific LG Technology (retains “generic” portion of project; specific LG effort began in FY1998); ESTCP funding to end FY02effort began in FY1998); ESTCP funding to end FY02

Project 199922:Project 199922: Replacement of Chromium Electroplating on Replacement of Chromium Electroplating on Propeller Hubs Using HVOF Thermal Spray Technology; Propeller Hubs Using HVOF Thermal Spray Technology; ESTCP funding to end FY02ESTCP funding to end FY02

Project 200038:Project 200038: Replacement of Chromium Electroplating on Replacement of Chromium Electroplating on Hydraulic Actuators Using HVOF Thermal Spray Technology; Hydraulic Actuators Using HVOF Thermal Spray Technology; project scheduled to run through FY03project scheduled to run through FY03

Project 200127:Project 200127: Replacement of Chromium Electroplating on Replacement of Chromium Electroplating on Helicopter Dynamic Components Using HVOF Thermal Spray Helicopter Dynamic Components Using HVOF Thermal Spray Technology; project scheduled to run into FY04Technology; project scheduled to run into FY04

Total FY2001 Funding: $500KTotal FY2001 Funding: $500K

Requested FY2002 Funding: $550KRequested FY2002 Funding: $550K

Recent Activities That Could ImpactRecent Activities That Could ImpactHard Chrome Plating at DoD FacilitiesHard Chrome Plating at DoD Facilities

EPA recently issued new proposed allowable discharge EPA recently issued new proposed allowable discharge concentrations of metals and other compounds under Metal concentrations of metals and other compounds under Metal Products & Machinery (MP&M) regulations. For most metals, the Products & Machinery (MP&M) regulations. For most metals, the concentrations have been drastically reduced (e.g., in captive concentrations have been drastically reduced (e.g., in captive shops, 30-day average for Cr reduced from current 1.71 mg/L to shops, 30-day average for Cr reduced from current 1.71 mg/L to 0.55 mg/L for existing sources and 0.07 mg/L for new sources, 0.55 mg/L for existing sources and 0.07 mg/L for new sources, including major upgrades). Metal finishing industry anticipates including major upgrades). Metal finishing industry anticipates if new limits stand, many shops will go out of business and if new limits stand, many shops will go out of business and costs will skyrocketcosts will skyrocket

August 2000 issue of American Journal of Industrial Medicine August 2000 issue of American Journal of Industrial Medicine published report on study of 2,357 workers over a 30-year period published report on study of 2,357 workers over a 30-year period correlating incidence of cancer with hex-Cr exposure. Analysis correlating incidence of cancer with hex-Cr exposure. Analysis of study by Navy Environmental Health Center appears to of study by Navy Environmental Health Center appears to support lowering of PEL to less than 0.001 mg/msupport lowering of PEL to less than 0.001 mg/m33 from current from current 0.1 mg/m0.1 mg/m33. Appears likely that OSHA will have to act in near . Appears likely that OSHA will have to act in near future to lower PEL, with major impact on chrome platingfuture to lower PEL, with major impact on chrome plating

HVOF and Hard Chrome Coatings on 4340 SteelAtmospheric Exposure For 3 Years

After Cleaning

PROTECTION RATINGS FOR 4 MIL COATINGS OVER 4340 STEEL (PLATES)

0 2 4 6 8 10 12

WC/Co *

Triballoy 400 **

Hard Chrome, with nickelsublayer

Protection Ratings (10 = Best)

Edge

Face

** "T-400" (Stellite): 60% Co, 28% Mo, 9% Cr, 3% Si* Diamalloy 2005 (Sulzer-Metco): 83%WC, 17% Co

PROTECTION RATINGS ON 4340 STEEL IN ASTM B 117

0

1

2

3

4

5

6

7

8

9

103mil Cr, No Ni, No Sealer

3mil Cr, Nickel,No Sealer

3mil Cr, No Ni, Sealer

10mil Cr, No Ni, No Sealer

10mil Cr,Nickel, No Sealer

10mil Cr, No Ni, Sealer

3mil WC/Co, No Sealer

3mil WC/Co, Sealer

10mil WC/Co, No Sealer

10mil WC/Co, Sealer

3mil WC/Co/Cr, No Sealer

10mil WC/Co/Cr, No Sealer

Summary of B117 and GM9540 Corrosion Summary of B117 and GM9540 Corrosion Testing for Landing Gear ProgramTesting for Landing Gear Program

EHC coated substrates had a higher corrosion resistance EHC coated substrates had a higher corrosion resistance than WC/Co coated substrates.than WC/Co coated substrates.

The introduction of chromium into WC/Co coatings The introduction of chromium into WC/Co coatings improve their corrosion resistance compared to WC/Co improve their corrosion resistance compared to WC/Co coatings.coatings.

All of the WC/Co and WC/Co-Cr coatings showed a All of the WC/Co and WC/Co-Cr coatings showed a degree of general corrosion.degree of general corrosion.

Some of the WC/Co coatings showed cracking with Some of the WC/Co coatings showed cracking with corrosion of the base material causing undercutting and corrosion of the base material causing undercutting and delaminationdelamination

The corrosion performance of the WC/Co coatings on The corrosion performance of the WC/Co coatings on Aermet 100 was better than the same coating on the other Aermet 100 was better than the same coating on the other substrates.substrates.

Additional Corrosion TestingAdditional Corrosion TestingTo address significant discrepancy between previous B117 and To address significant discrepancy between previous B117 and

atmospheric testing on flat plates, and LG B117 testing on rods, atmospheric testing on flat plates, and LG B117 testing on rods, additional corrosion tests are being conducted as follows:additional corrosion tests are being conducted as follows:

Substrate Materials:Substrate Materials: 4340 rods, 1” diameter, 6” long4340 rods, 1” diameter, 6” long

4340 plates, 3” x 4” x 3/16”4340 plates, 3” x 4” x 3/16”

300M rods, 1” diameter, 6” long300M rods, 1” diameter, 6” long

Coatings:Coatings: WC/17Co, WC/10Co4Cr, EHCWC/17Co, WC/10Co4Cr, EHCOn rods, coatings to be applied on curved surfaceOn rods, coatings to be applied on curved surface

On plates, only coat one faceOn plates, only coat one face

Deposition parameters to match Landing Gear JTP, plus must follow Deposition parameters to match Landing Gear JTP, plus must follow Boeing Spec. Sheet 160T1000 which requires that HVOF coatings not Boeing Spec. Sheet 160T1000 which requires that HVOF coatings not terminate with a square edge, but shall taper from full to zero terminate with a square edge, but shall taper from full to zero thickness over a minimum length of 0.006 inchesthickness over a minimum length of 0.006 inches

EHC coatings ground to 16 Ra finish; some HVOF coatings ground to 8 EHC coatings ground to 16 Ra finish; some HVOF coatings ground to 8 RaRa

Non-coated areas to be cadmium plated (including chromate Non-coated areas to be cadmium plated (including chromate conversion coating) with slight overlap of EHC and HVOF coatingconversion coating) with slight overlap of EHC and HVOF coating

Additional Corrosion TestingAdditional Corrosion TestingSubstrate Materials:Substrate Materials: 4340 rods, 1” diameter, 6” long4340 rods, 1” diameter, 6” long

4340 plates, 3” x 4” x 3/16”4340 plates, 3” x 4” x 3/16”

300M rods, 1” diameter, 6” long300M rods, 1” diameter, 6” long

Coatings:Coatings: WC/17Co, WC/10Co4Cr, EHCWC/17Co, WC/10Co4Cr, EHCOn rods, coatings to be applied on curved surface, terminating 1” On rods, coatings to be applied on curved surface, terminating 1”

from one end and 1/4” from other end (length of coating 4-3/4 from one end and 1/4” from other end (length of coating 4-3/4 inches)inches)

On plates, only coat one face; 3”-wide dimension coated edge-to-On plates, only coat one face; 3”-wide dimension coated edge-to-edge, on 4”-wide dimension, coating to terminate 1/2-inch from edge, on 4”-wide dimension, coating to terminate 1/2-inch from edge (coated area is 3” x 3”)edge (coated area is 3” x 3”)

Deposition parameters to match Landing Gear JTP, plus must follow Deposition parameters to match Landing Gear JTP, plus must follow Boeing Spec. Sheet 160T1000 which requires that HVOF coatings Boeing Spec. Sheet 160T1000 which requires that HVOF coatings not terminate with a square edge, but shall taper from full to zero not terminate with a square edge, but shall taper from full to zero thickness over a minimum length of 0.006 inchesthickness over a minimum length of 0.006 inches

Coatings to be applied by both Hitemco and Southwest AeroserviceCoatings to be applied by both Hitemco and Southwest Aeroservice

EHC coatings ground to 16 Ra finish; some HVOF coatings ground EHC coatings ground to 16 Ra finish; some HVOF coatings ground to 8 Rato 8 Ra

Non-coated areas to be cadmium plated (including chromate Non-coated areas to be cadmium plated (including chromate conversion coating) with slight overlap of EHC and HVOF coatingconversion coating) with slight overlap of EHC and HVOF coating

Additional Corrosion TestingAdditional Corrosion Testing4340 rods4340 rodsCoatingCoating ThicknessThickness GroundGround Spray Co.Spray Co. # of samples# of samples

WC/CoWC/Co 0.003” 0.003” Y Y Hitemco Hitemco 2 2

WC/CoWC/Co 0.003” 0.003” Y Y Southwest Southwest 2 2

WC/CoWC/Co 0.003” 0.003” N N H H 2 2

WC/CoWC/Co 0.003” 0.003” N N S S 2 2

WC/CoWC/Co 0.010” 0.010” Y Y H H 2 2

WC/CoWC/Co 0.010” 0.010” Y Y S S 2 2

WC/CoCrWC/CoCr 0.003” 0.003” Y Y H H 2 2

WC/CoCrWC/CoCr 0.003” 0.003” Y Y S S 2 2

WC/CoCrWC/CoCr 0.003” 0.003” N N H H 2 2

WC/CoCrWC/CoCr 0.003” 0.003” N N S S 2 2

WC/CoCrWC/CoCr 0.010” 0.010” Y Y H H 2 2

WC/CoCrWC/CoCr 0.010” 0.010” Y Y S S 2 2

EHCEHC 0.003” 0.003” Y Y S S 2 2

EHCEHC 0.010” 0.010” Y Y S S 2 2

TotalTotal 28 28

Repeat this exact matrix for the 4340 plates and the 300M rods.Repeat this exact matrix for the 4340 plates and the 300M rods.

WC/CoInitial

4340 Substrate, 3 mil coatings

WC/Co250 hours

WC/CogroundInitial

WC/Coground

250 hours

EHC250 hours

EHCInitial

03-140 03-140

4340 Substrate, 3 mil coatings

WC/CoCrgroundInitial

WC/CoCrground

250 hours

03-134 03-134 03-136

WC/CoCrInitial

WC/CoCr250 hours

03-136

EHC250 hours

EHCInitial

03-140 03-140

4340 Substrate, 3 mil coatings

WC/CogroundInitial

WC/Coground

250 hours

WC/CogroundInitial

WC/Coground

250 hours

WC/CoInitial

WC/Co250 hours

WC/CoInitial

WC/Co250 hours

WC/CoCrgroundInitial

WC/CoCrground

250 hours

WC/CoCrgroundInitial

WC/CoCrground

250 hours

03-134 03-134

4340 Substrate, 3 mil coatings

03-136

WC/CoCrInitial

WC/CoCr250 hours

03-136

WC/CoCrInitial

WC/CoCr250 hours

Helicopter Dynamic Components Helicopter Dynamic Components Project Project

Demonstration Sites:Demonstration Sites:• Cherry Point Naval Aviation DepotCherry Point Naval Aviation Depot

• Corpus Christi Army DepotCorpus Christi Army Depot OEMs involved in project include Sikorsky Aircraft and OEMs involved in project include Sikorsky Aircraft and

Boeing PhiladelphiaBoeing Philadelphia DoD project team (ESTCP Project Manager, JG-PP, DoD project team (ESTCP Project Manager, JG-PP,

NAVAIR, Army AMCOM, DCMA) visited Sikorsky on 22 NAVAIR, Army AMCOM, DCMA) visited Sikorsky on 22 March 2001 to get company buy-in to project; Sikorsky March 2001 to get company buy-in to project; Sikorsky stated that it is now company policy to work towards stated that it is now company policy to work towards eliminating hard chromium from their helicopterseliminating hard chromium from their helicopters

DoD project team to visit Boeing Philadelphia on 15 MayDoD project team to visit Boeing Philadelphia on 15 May Navy CH-46 program providing $800K to Boeing for rig Navy CH-46 program providing $800K to Boeing for rig

testing of HVOF-coated aft-vertical shaft and forward testing of HVOF-coated aft-vertical shaft and forward carrier shaftcarrier shaft

Interactions With SikorskyInteractions With Sikorsky

Strong interest in pursuing projectStrong interest in pursuing project Sikorsky has qualified and has been using D-gun and HVOF Sikorsky has qualified and has been using D-gun and HVOF

coatings on selected applications for a number of yearscoatings on selected applications for a number of years Some thermal spray applications replaced chrome plating Some thermal spray applications replaced chrome plating

and in each case performance was enhancedand in each case performance was enhanced Areas on H-60 (Army and Navy) where hard chromium is Areas on H-60 (Army and Navy) where hard chromium is

currently used are indicated in subsequent slidescurrently used are indicated in subsequent slides AMCOM expressed interest in pursuing project within Army AMCOM expressed interest in pursuing project within Army

due to performance enhancement due to performance enhancement ESTCP Project Manager to issue short-term contract to ESTCP Project Manager to issue short-term contract to

Sikorsky to develop test requirements for insertion into a Sikorsky to develop test requirements for insertion into a JTPJTP

Other ActivitiesOther Activities

Interacted with Anniston Army Depot and Interacted with Anniston Army Depot and arranged for HVOF WC/Co coating of M1 Tank arranged for HVOF WC/Co coating of M1 Tank Gas Turbine Engine ComponentsGas Turbine Engine Components

Intermediate Compressor Bearing Housing and Intermediate Compressor Bearing Housing and #2 Anti Friction Housing#2 Anti Friction Housing

Hard chrome normally applied in localized areasHard chrome normally applied in localized areas HVOF thermal spraying required extensive HVOF thermal spraying required extensive

masking and off-angle application for access to masking and off-angle application for access to internal diameterinternal diameter

Processing conducted by Engelhard Surface Processing conducted by Engelhard Surface Technologies Technologies

Anniston to conduct functional test of componentAnniston to conduct functional test of component

M1 Housing, Intermediate CompressorM1 Housing, Intermediate Compressor

Chrome Replaced

Coating finish ground to 4-8 Ra

BAC 5851 Type 1, Class 2Material - WC/Co

No coating in slots,or oil holes

Temperature was maintained below 325F during processing

Smooth transition areas

M1 Housing, Intermediate CompressorM1 Housing, Intermediate Compressor

Fixture setup with gun orientation and cooling jets.

Axial Cooling

Radial Cooling

Fixture run out less then .010in

22 deg

45 deg

Feedback from Anniston Army DepotFeedback from Anniston Army Depot

Everett Pollard at Anniston installed components into slave Everett Pollard at Anniston installed components into slave forward module and ran it for 167 hours with no problemsforward module and ran it for 167 hours with no problems

Will conduct extended two-month evaluation with test cells Will conduct extended two-month evaluation with test cells running approximately 18 hours per day. Will compare running approximately 18 hours per day. Will compare HVOF coatings to normal performance of hard chromeHVOF coatings to normal performance of hard chrome

Anniston metallurgist examined HVOF coatings and was Anniston metallurgist examined HVOF coatings and was “flabbergasted at the quality of the seemingly non-line-of-“flabbergasted at the quality of the seemingly non-line-of-sight HVOF process.” sight HVOF process.”

Anniston already discussing implementing HVOF Anniston already discussing implementing HVOF technologytechnology

New ESTCP Proposal Related toNew ESTCP Proposal Related toElectrospark Deposition (ESD)Electrospark Deposition (ESD)

Title of Proposal:Title of Proposal: Electrospark Deposition as a Depot-Level Electrospark Deposition as a Depot-Level Chromium Plating Replacement, Field-Level Brush Chromium Plating Replacement, Field-Level Brush Plating Replacement and In-Situ Repair Technology on Plating Replacement and In-Situ Repair Technology on Aircraft, Vehicle, and Ship ComponentsAircraft, Vehicle, and Ship Components

(Not a transition of SERDP ESD non-line-of-sight project)(Not a transition of SERDP ESD non-line-of-sight project)

Objectives:Objectives: • To dem/val ESD as a replacement for EHC plating on To dem/val ESD as a replacement for EHC plating on

complex, relatively small-area, line-of-sight applications for complex, relatively small-area, line-of-sight applications for which HVOF is difficult or costly to utilizewhich HVOF is difficult or costly to utilize

• To dem/val ESD as a field repair technology to replace To dem/val ESD as a field repair technology to replace brush-plated Cr, Cd, and Ni, and to repair other coatings brush-plated Cr, Cd, and Ni, and to repair other coatings (such as IVD aluminum) or base materials which have (such as IVD aluminum) or base materials which have localized damage or defectslocalized damage or defects

• Utilize ESD for repair of damaged components for which Utilize ESD for repair of damaged components for which there is no current repair procedurethere is no current repair procedure

ESD ProposalESD Proposal

ESD coatings approved by FAA and are being applied as a ESD coatings approved by FAA and are being applied as a repair process to commercial gas turbine engine repair process to commercial gas turbine engine components includingcomponents including• corrosion-resistant coatings to turbine blade tips where corrosion-resistant coatings to turbine blade tips where

protective diffusion coatings were removedprotective diffusion coatings were removed

• buildup of nickel-base superalloys to reclaim close-tolerance buildup of nickel-base superalloys to reclaim close-tolerance partsparts

• repair of chipped or damaged diffusion coatingsrepair of chipped or damaged diffusion coatings NSWC Carderock (NAVSEA) exploring in-situ repair NSWC Carderock (NAVSEA) exploring in-situ repair

applicationsapplications• wear and corrosion on submarine steering/diving componentswear and corrosion on submarine steering/diving components

• localized corrosion and wear on main propulsion shaft sealslocalized corrosion and wear on main propulsion shaft seals NSWC and NAVAIR Pax River have ESD systems, with NSWC and NAVAIR Pax River have ESD systems, with

Army Research Laboratory acquiring oneArmy Research Laboratory acquiring one• Pax River investigating ESD for cadmium replacementPax River investigating ESD for cadmium replacement

ESD ProposalESD Proposal

PEWG/HCAT conducted ESD demonstration at AESF PEWG/HCAT conducted ESD demonstration at AESF Aerospace Plating Forum in Portland in late March; Aerospace Plating Forum in Portland in late March; discussions held on developing project proposaldiscussions held on developing project proposal

Specific milestones developed for proposed project, with Specific milestones developed for proposed project, with start date of January 2002 and completion in January 2005start date of January 2002 and completion in January 2005

Project will develop one or more Joint Test Plans to Project will develop one or more Joint Test Plans to address materials issues associated with performing address materials issues associated with performing localized repairslocalized repairs

Project has more than fifteen participating organizations Project has more than fifteen participating organizations representing cross-section of aircraft, vehicle, and ship representing cross-section of aircraft, vehicle, and ship repair facilities plus other service commands with repair facilities plus other service commands with cognizance; participating OEMs include Boeing St. Louis cognizance; participating OEMs include Boeing St. Louis and Pratt & Whitneyand Pratt & Whitney