progress review meeting

ORENDA AEROSPACE CORPORATION

PROGRESS REVIEW MEETING

THE CANADIAN HARD CHROME ALTERNATIVES TEAM (HCAT) JOINT PROGRAM

HVOF PROCESS DEVELOPMENT, EVALUATION AND QUALIFICATION

Task 2.1 Axial Fatigue Evaluation

C. Belter, P. Li, J. Dyer and P.C. Patnaik

Advanced Materials and Energy SystemsOrenda Aerospace Corporation

February 20, 2002 Orlando, Florida


Presentation Outline

• Introduction / Objectives

• Progress Summary

• HVOF Evaluation and Qualification of Axial Fatigue

Test Results

• Acknowledgements


Introduction

Objective: Evaluate and to compare the fatigue properties of HVOF coatings against electrolytic chrome plating. Test environments were:

- ambient air (70 F)- cold air (-40 F)- 3.5% NaCl water solution at room

temperature

All tests were conducted at a frequency of 5Hz and a stress ratio of R=-1


Progress Summary

• Test program contains 620 axial fatigue tests on 300M and Aermet 100 to evaluate four surface conditions at ambient and low temperatures.

• 598 tests completed. 22 tests left. The specimens are being prepared. Completion of the testing program is expected by March 31, 2002.

• Project is within budget and technically progresses smoothly.



Test Matrix: 620 tests in total, 598 completed, 22 left

Thickness Environment 300M AM100Uncoated Air Complete Complete

NaCl Complete CompleteCold Complete Complete

Chrome 0.003" Air Complete Complete0.003" NaCl Complete Complete0.003" Cold Complete Complete0.01" Air Complete Complete0.01" NaCl Complete Complete0.01" Cold Complete Complete

HVOF 0.003" Air Complete Complete0.003" NaCl 16 completed, 4 left Complete0.003" Cold 15 completed, 5 left Complete0.01" Air 7 completed, 13 left Complete0.01" NaCl Complete Complete0.01" Cold Complete Complete

Propylene 0.003" Air Complete N/A

Updated to Feb. 11, 2002



Room temperature tests:

• A “threshold” for spalling of the HVOF coating was found to be 180 ksi and for the 0.003” thick coating and 125 ksi for the 0.010” thick coating using the current configuration.

• In general, the 0.010” thick coating preformed slightly better than the 0.003” thick coating for both the chrome and HVOF coatings. This is expected since the load is calculated based on the original substrate diameter and the 0.010” thick coating would carry more of the load.

• Chrome tests indicated a fatigue debit over the baseline for both Aermet 100 and 300 M. HVOF showed a slight fatigue debit in the Aermet 100 but a slight increase in fatigue in the 300 M. In both cases, the fatigue debit was more predominant in the Aermet 100.



Room temperature tests (continued):

• The C-HCAT results show a good agreement with the US results.

• In general, the HVOF coatings performed as well as or better than the chrome coatings in life to failure for 300 M and Aermet 100.


PROGRESS REVIEW MEETINGCHCAT AXIAL FATIGUE TESTING

Aermet 100, Lab Air, 70 F, f=5Hz, R=-1

R2 = 0.9017

R2 = 0.9552

R2 = 0.974

R2 = 0.9534

R2 = 0.9187

150

160

170

180

190

200

210

220

230

240

250

260

0 10000 20000 30000 40000 50000 60000

Cycles to Failure

Max

. Alt.

Str

ess

(ksi

)

Baseline Lab Air

Cr (3) Lab Air

Cr (10) Lab Air

HVOF (3) Lab Air

HVOF (10) Lab Air



CHCAT AXIAL FATIGUE TESTING

300 M, Lab Air, 70 oF, f = 5 Hz, R = -1

R2 = 0.9481

R2 = 0.9555

R2 = 0.9028

R2 = 0.9338

R2 = 0.8333

R2 = 0.9209

155

165

175

185

195

205

215

0 10000 20000 30000 40000 50000 60000

Cycles to Failure

Max

. Str

ess

(ksi

)

Baseline lab air

Cr (3) lab air

Cr (10) lab air

HVOF(3) lab air

HVOF (10) lab air

Propylene (3) lab air



CANADIAN AND US HCAT AXIAL FATIGUE TESTING

300 M, Lab Air, 70 oF, f = 5 Hz, R = -1

R2 = 0.9555

R2 = 0.9338

R2 = 0.9838

R2 = 0.9006

120

130

140

150

160

170

180

190

200

210

220

1000 10000 100000 1000000

Cycles to Failure

Max

. Str

ess

(ksi

)

CDN_Cr (3)

CDN_HVOF(3) WC-Co-Cr

US_Cr(3)_SM

US_HVOF(3)_SM WC-Co



Corrosion fatigue tests:

• A “threshold” determined for the 0.003” thick HVOF coatings in a NaCl testing environment to be 125 ksi on 300 M.

• In general, there is approximately a 25% (300 M), 45% (Aermet 100) reduction in strength due to corrosion.

• The chrome seems to mitigate this to nearly 0% reduction for 300 M and a 10% reduction for Aermet 100.

• The HVOF coating for the 300 M shows an actual increase in life over the baseline tests and only a 5% reduction in life for the Aermet 100.



Corrosion fatigue tests (continued):

• The C-HCAT results overlapped the US results when plotted together (see graph)

• In both cases, the HVOF coatings performed as well as or better than the chrome coatings in life to failure for 300 M and Aermet 100.



Aermet 100, 3.5% NaCl solution, 70oF, f=5Hz, R=-1

R2 = 0.9017

R2 = 0.974

R2 = 0.9799

R2 = 0.9619

R2 = 0.971

R2 = 0.9568

80

90

100

110

120

130

140

150

160

170

180

190

200

210

220

230

240

250

260

0 10000 20000 30000 40000 50000 60000

Cycles to Failure

Max

. Alt.

Str

ess

(ksi

)

Baseline Lab Air

Uncoated 3.5% NaCl Solution

Cr (3) 3.5% NaCl Solution

Cr (10) 3.5% NaCl solution

HVOF (3) 3.5% NaCl solution

HVOF (10) 3.5% NaCl solution



300M, 3.5% NaCl solution,70 oF, f = 5 Hz, R = -1

R2 = 0.9166

R2 = 0.8324

R2 = 0.9503

R2 = 0.9489

R2 = 0.8946

R2 = 0.9334

90

100

110

120

130

140

150

160

170

180

190

200

210

220

0 10000 20000 30000 40000 50000 60000

Cycles to Failure

Max

. S

tres

s (k

si)

Baseline Lab Air

Uncoated 3.5% NaCl

Cr (3) 3.5% NaCl

Cr (10) 3.5% NaCl

HVOF (3) 3.5% NaCl

HVOF (10) 3.5% NaCl


PROGRESS REVIEW MEETINGCANADIAN AND US HCAT AXIAL FATIGUE TESTING

Material: 300M, 70 oF, 3.5% NaCl solution, freq = 5 Hz, R-ratio = -1

R2 = 0.9503

R2 = 0.8946

R2 = 0.9769

R2 = 0.9941

80

90

100

110

120

130

140

150

160

170

180

190

200

210

220

230

1000 10000 100000 1000000

Cycles to Failure

Ma

x. S

tre

ss

(k

si)

Cr (3) 3.5% NaCl

HVOF (3) 3.5% NaCl WC-Co-Cr

US_Cr(3) 3.5% NaCl_HG

US_HVOF(3) 3.5% NaCl_HG WC-Co



Low Temperature fatigue tests:

• Although the coating continues to spall off, HVOF is consistently outperforming EHC on 300 M and Aermet 100.




Aermet 100, -40 F lab air, f=5Hz, R=-1

R2 = 0.927

R2 = 0.9473

R2 = 0.9305

R2 = 0.9426

R2 = 0.8687

160

170

180

190

200

210

220

230

240

250

260

0 10000 20000 30000 40000 50000 60000

Cycles to Failure

Max

. Alt

. Str

ess

(ksi

)

Baseline Low Temp (-40oF)

Cr (3) Low Temp (-40oF)

Cr (10) Low Temp (-40oF)

HVOF (3) Low Temp (-40oF)

HVOF (10) Low Temp (-40oF)




300 M, -40oF lab air, f= 5 Hz, R= -1

R2 = 0.9141

R2 = 0.9627

R2 = 0.8538

R2 = 0.9292

R2 = 0.9459

165

175

185

195

205

215

0 10000 20000 30000 40000 50000 60000

Cycles to Failure

Max

. Str

ess

(ksi

)

Uncoated Low Temp

Cr (3) Low Temp

Cr (10) Low Temp

HVOF (3) Low Temp

HVOF (10) Low Temp


ACKNOWLEDGEMENTS

Orenda would like to acknowledge the continued support and hard work from:

NRC-Institute for Aerospace ResearchJ.P. Immarigeon, P. Au, D. Dudzinski

NRC-Industrial Materials InstituteJ.G. Legoux, S. Serghini

VAC-Aero InternationalJ. Pritchard, S. Rush

progress review meeting

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