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Low Hydrogen Embrittlement (LHE) Zinc-Nickel (Zn-Ni)
Qualification Test Result and Process Parameters
Development
Dave Frederick, USAFCraig Pessetto, ES3
Steve Gaydos, Boeing
9 February 2011
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Report Documentation Page Form ApprovedOMB No. 0704-0188
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1. REPORT DATE 09 FEB 2011 2. REPORT TYPE
3. DATES COVERED 00-00-2011 to 00-00-2011
4. TITLE AND SUBTITLE Low Hydrogen Embrittlement (LHE) Zinc-Nickel (Zn-Ni) QualificationTest Result and Process Parameters Development
5a. CONTRACT NUMBER
5b. GRANT NUMBER
5c. PROGRAM ELEMENT NUMBER
6. AUTHOR(S) 5d. PROJECT NUMBER
5e. TASK NUMBER
5f. WORK UNIT NUMBER
7. PERFORMING ORGANIZATION NAME(S) AND ADDRESS(ES) ES3 Inc,1346 South Legend Hills Drive,Clearfield,UT,84015
8. PERFORMING ORGANIZATIONREPORT NUMBER
9. SPONSORING/MONITORING AGENCY NAME(S) AND ADDRESS(ES) 10. SPONSOR/MONITOR’S ACRONYM(S)
11. SPONSOR/MONITOR’S REPORT NUMBER(S)
12. DISTRIBUTION/AVAILABILITY STATEMENT Approved for public release; distribution unlimited
13. SUPPLEMENTARY NOTES ASETSDefense 2011: Sustainable Surface Engineering for Aerospace and Defense Workshop, February 7 -10, 2011, New Orleans, LA. Sponsored by SERDP/ESTCP.
14. ABSTRACT
15. SUBJECT TERMS
16. SECURITY CLASSIFICATION OF: 17. LIMITATION OF ABSTRACT Same as
Report (SAR)
18. NUMBEROF PAGES
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19a. NAME OFRESPONSIBLE PERSON
a. REPORT unclassified
b. ABSTRACT unclassified
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Standard Form 298 (Rev. 8-98) Prescribed by ANSI Std Z39-18
Technical Objectives
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•
Small Business Innovative Research (SBIR) Phase I Feasibility Study•
The specific technical objectives of the SBIR Phase II effort are as follows:▪
Successfully pass the following performance parameters, using a prototype tank installation:
•
Installation of a prototype tank for plating demonstration on test coupons and full size components
•
Adhesion•
Hydrogen Embrittlement•
Re-embrittlement•
Liquid and Solid Metal Embrittlement (LME/SME)•
Fatigue•
Corrosion•
Brush Plating for repair of damaged LHE Zn-Ni coatings (Touch Up)•
Torque Tension •
Review requirements for Non Destructive Inspection (NDI)•
Optimize conversion coating•
Option 1: Develop an accelerated hydrogen embrittlement test procedure :
Prototype Tank Implementation
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▪
ES3 implemented a tank of approximately 325 gallons for the purpose of demonstrating the LHE Zn-Ni plating process on some full sized gear components
▪
The demonstration tank was used to develop uniform plating thicknesses and process parameters on test coupons and full scale landing gear components
▪
During the plating operations Quality Assurance testing has been conducted to ensure the alkaline LHE Zn-Ni solution is within proper process limits
Dipsol IZ-C17+ LHE Zn-Ni Plating Tank
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Tri-Chromium Conversion Coat Tank
Prototype Tank ImplementationI[~&~
ES3
5
Bend to Break Adhesion Test Coupons
•
Adhesion of the LHE Zn-Ni coating to the substrate was tested per ASTM B571
•
All adhesion test coupons were manufactured from 1”x 4”x 0.040”
4130 steel sheet
•
Results: All Test coupons passed
Adhesion Test Coupons
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Dipsol™ LHE Zn-Ni Test Panels After Dry and Wet Tape Adhesion Test of Primer
Deft 44-GN-098www.ES3inc.com ●
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Deft 44-GN-072
J
Wet Dry Wet
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Dry and Wet Paint Adhesion Test Results per ASTM D3359
I[~&~
ES3
Scribed Dl'Y and Wet Tape Adhesicm Test Results
4'' x 6" x 0.040" 4130 Steel Sub~tr:ate
DRY TAPE AOH.E!I~ WET TJ!I>E ADHES!ION
PERCENTAGE
P·P~NEJL liD PRETREATMENT COA.TitfG OOATII'IG REMOVED
1 0
2 LJ-lEZn-Ni
0 Plaling
3 Deft
0
44-GN-72 1
Cdl Plated wf 0
2 Hex Or
0 Conversion
3 Coaling
0
4 0
5 LJ-lE Z rr-Ni
0 Pla'ling
6 Deft
0
44-GN-008 0 4
Cdl Plated wf
5 Hex Or
0 Conversion
6 Coaling
0
Panels iiTil'IEf'5ed in cis'llled wat:r at room tempet<XLJ"e for .24 holi"S. [1} ASTM D 335Q Criteria:
5A- No peEling or removal ~A -Trace peefrlg1 or rEmOval along incisions
3A-Jagged remoYal along incisions~ to 1118 inch on a1her side 2A-Jagged remoYal along llllOst af incisiions up to 118 PCh on either side 1 A- RermYal from most ci !he area of 1lle "X' under lfle tape OA- RermYal beymd the .¥ea~ ci the "X"
[2} The primEf' sha'll show no a!liesim failure.
AS.TM, Pass r PERCENTAGE ASTM D$353 Fall COAHiiG D 3353
I' I [21 REMOVED Il l
5A Pass 0 4A
5A Pass 2 4A
5A Pass 0 5A
5A Pass 0 5A
5A Pass 0 5A
5A Pass 0 5A
5A Pass 0 5A
5A Pass 0 5A
5A Pass 10 4A
5A Pass 0 5A
5A Pass 0 5A
5A Pass 0 5A
Pass r Fall PI
Pass
Fail
Pass
Pass
Pass
Pass
Pass
Pass
Fail
Pass
Pass
Pass
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LHE Zn-Ni Hydrogen Embrittlement Testing
•
Coupons manufactured per ASTM F519 specifications (4340)
•
Coupons plated and tested 28th
April, 2009 upon initial installment of LHE Zn-Ni demonstration tank
•
Additional coupons plated and tested at additional dates
•
All coupons tested per ASTM F519 and passed the 200 hour sustained load tests @ 75% of the tensile notch fracture strength
ASTM F519 Type 1A.1 Test Coupons
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Cad Plated in Bldg 505 for 5 mins - 200x
9
HE Plated Cross Section
.772 mils
.274 mils
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LHE Zn-Ni Plated @ 40 ASF for 20 mins - 200x
10
HE Plated Cross Section
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LHE Zn-Ni Re-Embrittlement Testing Machine
LHE Zn-Ni Hydrogen Re-Embrittlement Testing
I[~&~
ES3
12
Re-Embrittlement results: •Coupons tested by an ISO 9001 certified facility. Coupons tested
IAW ASTM F519. The coupons tested immersed in solutions of Water, 3.5% Salt Water, Dilute* Calla 296, Dilute* Calla 602LF, Concentrated Calla 296, and Concentrated Calla 602LF.*NOTE –
Dilute means mix cleaning solution to manufacturer’s recommended use concentration and heat to manufacturer’s maximum recommended use temperature.
• Cleaning solutions used in testing were:Calla 296Calla 602LF
• LHE Zn-Ni performs better than IVD and as well as Cad
Re Embrittlement Test Matrix
Plating
Test Solution
Distilled Water @ Room Temp
Tested 45% NFS for 150Hrs
3.5% Salt Water @ Room Temp
Tested 45% NFS for 150Hrs
Dwg 9825019* Diluted Calla 296 @ Max Temp 180
°F Tested 75% NFS for 200Hrs
Dwg 9825019* Diluted Calla 602 LF Max Temp 160
°F Tested 75% NFS for 200Hrs
Concentrated Calla 296 @ Room Temp tested 45% NFS for 150Hrs
Concentrated Calla 602LF @ Room Temp
tested 45% NFS for 150Hrs
LHE Zn-Ni Pass Failed Pass Pass Pass PassCadmium Pass Failed Pass Pass Pass Pass
IVD Failed Failed Not Tested Not Tested Not Tested Not Tested
*The specimens were immersed in the cleaning compound at the manufacturer's maximum recommended temperature, and appropriate cleaning concentration, for 30 minutes. Removed. Air dried and loaded to 75% NFS for 200Hrs.
LHE Zn-Ni Hydrogen Re-Embrittlement Testing
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Liquid/Solid Embrittlement Testing
•
Liquid and Solid Metal Embrittlement (LME and SME) occur when one metal, either as a liquid or solid, intrudes into the structure of another, potentially causing embrittlement in the base metal
•
Melting points for the coating metals are as follows: ▪
Cadmium ~610°F▪
Zinc ~787°F▪
Nickel ~2650°F
Temp/NFS Material LHE Zn-Ni200Hr
Cad200Hr
LHE Zn-Ni Step Load
Cad Step Load
600F/85% 300M Pass Fail 100% NFS -N/A-500F/85% 300M Pass Fail 100% NFS 87% NFS400F/85% 300M Pass Fail 100% NFS 91% NFS400F/75% 300M Pass Fail 100% NFS 81% NFS
14
LHE Zn-Ni and Cad Type 1a.1 Specimens After ISL Test to Determine the NFS After Exposure to 400oF for 200 Hours
Liquid/Solid Metal Embrittlement Testing
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Fatigue Testing
•
Phase II LHE Zn-Ni fatigue testing is an extension of Phase I work
•
Phase II LHE Zn-Ni fatigue testing continues to broaden the data base and increase the statistical validity of the data
•
Manufacturing of coupons and Fatigue Testing IAW ASTM E466▪
All coupons were plated per manufacture’s plating solution limits
16
Phase I Fatigue Testing (Shotpeened Coupons)
C-17 P2 Program Fatigue Data (2005) (IZ-C17 with Hex conversion coating)
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Phase II Fatigue TestingI[~&~
ES3
t
~~ Stress Loads (KSI) R= -0.3 Total Shotpeened Coupons 160 180 200 Quantity
Bare 5 5 5 15 Cad Plated 5 5 5 15
~n-Ni Plated Tri Chrome 5 5 5 15 ~n-Ni Plated Hex Chrome 5 5 5 15 ~Zn·Ni Plated Atotech Tri Chrome 5 5 5 15
~n-Ni Plated Atotech Hex Chrome 5 5 5 15
Total Fatigue Coupons 90
fk Bake before Tri CC
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Phase II Fatigue TestingI[~&~
ES3
210
200
190
180
Test load (KSI)
R= -0.3
170
160
150 10,000
I
I
Peened Fatigue Coupon Test Results
I I I I I I I I
,., ... ... - TIT
_, ... L , ... 1'*, ...- - - --- I ·- - - - --j
I
._ - .I - - I ...;_ l l -- ---1 -- ,- ~ ~ -·- 1- ·-
I I I I I I I I 100,000 1,000,000
Number of Cycles
+ Bare • cad .AZn-Ni Tri CC (Dipsol) e zn-Ni Hex CC (Dipsol) .A Zn-Ni Tri CC (Atotech) e zn-Ni Hex CC (Atotech)
Phase II Fatigue Testing
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I[~&~
ES3
Means Compared@ 95% limits: 200 ksi Peened I I I I I I
70542 bare r-
33104 Cad r- -
26275 ZnNi3 r-
. ,-... -. .......
30496 ZnNi6 r- -
33482 Atot3 r- -
31037 Atot6 r- -.......
I I I I I I
1 2 3 4 5 6 7 8 The means of groups Cad and bare are significantly different x 104
Phase II Fatigue Testing
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I[~&~
ES3
Means Compared@ 95% limits: 180 ksi Peened
170644 bare
160097 Cad
70904 ZnNi3
100406 ZnNi6
110794 Atot3
112736 Atot6
0 0.5 1 1.5 2 2.5 No groups have means significantly different from Cad x 1 0o
Phase II Fatigue Testing
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I[~&~
ES3
Means Compared@ 95% limits: 160 ksi Peened
661968 bare
746212 Cad
748266 ZnNi3
624663 ZnNi6
581027 Atot3
476921 Atot6
1 2 3 4 5 6 7 8 9 10 11 No groups have means significantly different from Cad x 1 0o
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Corrosion Performance
•
Corrosion tests were conducted on LHE Zn-Ni coupons with cadmium as the baseline
•
Testing was also performed on both cadmium and LHE Zn-Ni coated coupons with a prime/paint topcoat after being scribed (See Table below). All test coupons were 4”x 6”x 0.040”
4130 steel sheet•
All testing was performed per ASTM B117•
Test specimens were both scribed and un-scribed
# of steel Panels Plating Scribed Prime/Paint
3 LHE Zn-Ni Yes No
3 LHE Zn-Ni No No
3 Cd Yes No
3 Cd No No
3 LHE Zn-Ni Yes Yes
3 Cd Yes Yes
Corrosion Test Matrix
Cadmium Coatings – Phase II ASTM B 117 Panels @ Boeing Unscribed)
Cad
miu
m w
ith H
exav
alen
tChr
ome
Con
vers
ion
Coa
ting
Uns
crib
ed–
AST
M B
117
Figu
re 3
Test Panel Removed From
Salt Spray Cabinet –Excess Amount
of Red Rust Detected
Test Panel Removed From
Salt Spray Cabinet –Excess Amount
of Red Rust Detected
Test Panel Removed From
Salt Spray Cabinet –Excess Amount
of Red Rust Detected
Test Panel Removed From
Salt Spray Cabinet –Excess Amount
of Red Rust Detected
Test Panel Removed From
Salt Spray Cabinet –Excess Amount
of Red Rust Detected
1000 hours
3000 hours
5000 hours
Test Panel Removed From
Salt Spray Cabinet –Excess Amount
of Red Rust Detected
Test Panel Removed From
Salt Spray Cabinet –Excess Amount
of Red Rust Detected
Test Panel Removed From
Salt Spray Cabinet –Excess Amount
of Red Rust Detected
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Corrosion Performance
Zinc Nickel Coatings – Phase II ASTM B 117 Panels @ Boeing (Unscribed)
1000 hours
3000 hours
5000 hours
IZ-C
17+
Zn-N
i with
Triv
alen
t Chr
ome
Con
vers
ion
Coa
ting
Uns
crib
ed–
AS
TM B
117
Fi
gure
4
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Corrosion Performance
Cadmium Coatings – Phase II ASTM B 117 Panels @ Boeing (Scribed)
Test Panel Removed From
Salt Spray Cabinet –Excess Amount
of Red Rust Detected
Test Panel Removed From
Salt Spray Cabinet –Excess Amount
of Red Rust Detected
Test Panel Removed From
Salt Spray Cabinet –Excess Amount
of Red Rust Detected
Test Panel Removed From
Salt Spray Cabinet –Excess Amount
of Red Rust Detected
Test Panel Removed From
Salt Spray Cabinet –Excess Amount
of Red Rust Detected
1000 hours
3000 hours
5000 hours
Cad
miu
m w
ith H
exav
alen
tChr
ome
Con
vers
ion
Coa
ting
Scr
ibed
–A
STM
B 1
17Fi
gure
5
Test Panel Removed From
Salt Spray Cabinet –Excess Amount
of Red Rust Detected
Test Panel Removed From
Salt Spray Cabinet –Excess Amount
of Red Rust Detected
Test Panel Removed From
Salt Spray Cabinet –Excess Amount
of Red Rust Detected
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Corrosion Performance
Zinc Nickel Coatings – Phase II ASTM B 117 Panels @ Boeing (Scribed)
1000 hours
3000 hours
5000 hours
IZ-C
17+
Zn-N
i with
Triv
alen
t Chr
ome
Con
vers
ion
Coa
ting
Scr
ibed
–AS
TM B
117
Figu
re 6
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Corrosion Performance
Cadmium Coatings – Phase II ASTM B 117 Panels @ Boeing (Painted/Scribed)
Test Panel Removed From
Salt Spray Cabinet –Excess Amount
of Red Rust Detected
Test Panel Removed From
Salt Spray Cabinet –Excess Amount
of Red Rust Detected
Test Panel Removed From
Salt Spray Cabinet –Excess Amount
of Red Rust Detected
Test Panel Removed From
Salt Spray Cabinet –Excess Amount
of Red Rust Detected
1000 hours
3000 hours
5000 hours
Cad
miu
m w
ith H
exav
alen
tChr
ome
Con
vers
ion
Coa
ting
Scr
ibed
Pai
nted
–A
STM
B 1
17Fi
gure
9
Test Panel Removed From
Salt Spray Cabinet –Excess Amount
of Red Rust Detected
Test Panel Removed From
Salt Spray Cabinet –Excess Amount
of Red Rust Detected
Test Panel Removed From
Salt Spray Cabinet –Excess Amount
of Red Rust Detected
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Corrosion Performance
Zinc Nickel Coatings – Phase II ASTM B 117 Panels @ Boeing (Painted/Scribed)
1000 hours
3000 hours
5000 hours
IZ-C
17+
Zn-N
i with
Triv
alen
t Chr
ome
Con
vers
ion
Coa
ting
Scr
ibed
Pai
nted
–A
STM
B 1
17Fi
gure
10
Test Panel Removed From
Salt Spray Cabinet –Excess Amount
of Red Rust Detected
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Corrosion Performance
G 85 SO2 Corrosion-Cad
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I[~&~
ES3
120 hours
168 hours
336 hours
G 85 SO2 Corrosion-LHE Zn-Ni
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I[~&~
ES3
120 hours
168 hours
336 hours
Brush Plating Repair
•
In order for a brush LHE Zn-Ni plating to qualify it must pass the following tests:▪
Hydrogen Embrittlement (HE) testing per ASTM F519
▪
Bend to break adhesion test per ASTM B571▪
Corrosion testing per ASTM B117•
SIFCO recommended procedures were used to plate several sets of HE type 1a.1 coupons, adhesion coupons, and corrosion coupons, using SIFCO 4018 No Bake LHE Zn-Ni brush plating solution
•
Test Results Summary:▪
Passed HE testing▪
Passed adhesion testing on steel and LHE Zn-Ni plated steel
▪
Corrosion test performance is excellent
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Torque Tension
•
Robins AFB Cad plating replacement on threaded fastener and components▪
Typical chart for run on –
break away test showing Cad vs. LHE Alkaline Zn-Ni
32
Typical Run-On & Breakaway Torque - Cad Bare
-80
-60
-40
-20
0
20
40
60
80
-2500 -2000 -1500 -1000 -500 0
Rotation Degree
Torq
ue (I
N-L
B)
Run 0
Run 1
Run 2
Run 3
Run 4
Typical Run-On & Breakaway Torque - Zn-Ni Bare
-80
-60
-40
-20
0
20
40
60
80
-2500 -2000 -1500 -1000 -500 0
Rotation Degree
Torq
ue (I
N-L
B)
Torque Tension
•
Robins AFB Cad plating replacement on threaded fastener and components▪
Typical chart for Torque Tension Test showing Cad vs. LHE Alkaline Zn-Ni with MIL-PRF-83483 Anti-seize grease lubricant
33
Typical Torque Tension - Cad w/ Anti-Seize Grease
0
2000
4000
6000
8000
10000
12000
0 5 10 15 20 25 30 35 40
Applied Torque (FT-LB)
Tens
ile L
oad
(LB
)
Run 0
Run 1
Run 2
Run 3
Run 4
Typical Torque Tension - Zn-Ni w / Anti-Seize Grease
0
2000
4000
6000
8000
10000
12000
0 5 10 15 20 25 30 35 40
Applied Torque (FT-LB)
Tens
ile L
oad
(LB
)
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Non-Destructive Inspection (NDI)
•
OSHA Permissible Exposure Limits (PELs) for LHE Zn-Ni are high enough, such that, the LHE Zn-Ni plating does not have to be removed during the overhaul process (currently all cadmium plated landing gear components which come into the overhaul facility are stripped and cleaned per OSHA PELs)
•
There is no NDI interference due to the LHE Zn-Ni coating itself, consequently we can do the following inspections without
removing the LHE Zn-Ni coating:▪
Fluorescence Magnetic Particle Inspection (FMPI)▪
Ultra Sonic Inspection▪
Eddy current▪
X-Ray
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Conversion Coating Optimization
•
Testing was conducted to determine the optimal conversion coating (CC) (Hexavalent vs. Trivalent) and parameters:▪
Baking before and after conversion coating•
Hexavalent CC: must be applied after bake•
Trivalent CC: can be applied before or after bake (process time savings)
▪
Paint adhesion performance per ASTM D3359•
Hex-CC –
Passed•
Tri-CC –
Passed▪
Corrosion performance per ASTM B117•
Hex-CC –
Passed•
Tri-CC –
Passed (performs slightly better)▪
Hydrogen embrittlement per ASTM F519•
Hex-CC –
Passed•
Tri-CC –
Passed
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Conversion Coating Optimization
▪
Fatigue Performance per ASTM E466•
Hex-CC –
Passed •
Tri-CC –
Passed▪
Process parameters•
Submerge in conversion coat solution for 1–2 minutes▪
Environmental concerns•
DoD is currently trying to eliminate Hex-CC use
•
Recommend Trivalent CC
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Development of an Accelerated HE Test
•
Accelerated HE Test Development▪
Necessary to production process▪
Accelerated results in < 24 hours▪
Must correlate to 200 hour test•
Three rapid hydrogen embrittlement test methods have been identified for potential use at Hill AFB▪
The Messier-Dowty 16 Hour Hydrogen Embrittlement Test
▪
ASTM F 1940 Rapid Hydrogen Embrittlement Test for High Strength Steel Fasteners
▪
ASTM F 1624 –
09 Determination of Hydrogen Embrittlement Threshold Using the ISL (Incremental Step Load) Test Method Rising Step Load Apparatus
•
The preferred method to carry out a rapid hydrogen embrittlement test is ASTM F1624 which is as follows:▪
Using the incremental test method in ASTM F 1624, determine the NFSF1624
for new –
unplated ASTM F 519 Type 1a.1 test specimens. NFSF1624
will be lower than NFSE8
▪
Qualified rapid hydrogen embrittlement test method (< 20 hrs):
•
Load Type 1a.1 test specimen in Rising Step Load machine and perform step load using ISL conditions (20,5,1) = (20 steps, 5% NFSF1624
per step, hold for 1 hour at each step). Determine load where test specimen breaks, this is threshold load Pth
•
%NFS = 100 x Pth
/ NFSF1624
•
If %NFS >
90% then process is non-
embrittling
38
Rising Step Load Apparatus
Development of an Accelerated HE Test
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Phase III - Efforts
•
Phase III –
tasks consisted of the following:▪
Waste stream characterization and mitigation•
Similar wastewater treatment as cadmium▪
Permitting for hazardous material•
New source sheets ready to submit•
Awaiting finalization of the LHE Zn-Ni plating line (i.e. tank size and location)•
Will apply for Title V air permit when the LHE Zn-Ni plating line is installed▪
Process validation▪
Specification and source control drawings▪
Prototype depot LHE Zn-Ni process line•
With landing gear components▪
Process orders and Process Orders Document and Display System (PODDS) support
▪
Engineering and Program Management Support
•
Critical LHE Zn-Ni process parameters were established for the following:▪
Type of Anode•
Nickel 200▪
Plating fixtures•
Fixture material can be either stainless (prefered) or carbon steel▪
Current density•
40–60 Amps per square foot (ASF)▪
Plating time•
10–20 minutes▪
Plating thickness and type of conversion coating•
Class▫
I –
minimum of 0.0005”
~ (40 ASF for 20 minutes)▫
II –
minimum of 0.0003”
~ (40 ASF for 13 minutes)▫
III –
0.0001 –
0.0002”
~ (40 ASF for 10 minutes)•
Type▫
I –
No conversion coat▫
II –
Trivalent or Hexavalent conversion coat
40
Process Validation Plan
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•
Critical LHE Zn-Ni process parameters were established for the following:▪
Bath chemistry•
Requires bi-weekly chemical analysis of the LHE Zn-Ni plating tank using titration
▫
Zinc▫
Nickel▫
Carbonate▫
Sodium Hydroxide•
Requires bi-weekly chemical analysis of the Trivalent CC tank:▫
pH level▫
Cr level •
Requires quarterly chemical analysis for trace contamination metals for both tanks
▪
Agitation requirements•
Agitation should be sufficient enough to re-circulate the tanks plating solution a minimum of 3 times per hour
•
No air agitation
41
Process Validation Plan
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1669 E. 1400 S ●
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▪
Tank chemical maintenance•
Chemical maintenance for the LHE Zn-Ni process is based on usage and production rates
•
Analysis and adjustment should be performed on an amp-hour used basis, or on a weekly basis
•
Some degree of tracking will be required to establish a historical database of information, which can then be used to recommend regular analysis intervals
•
Specific limits and analysis instructions are provided in the LHE Zn-Ni specification drawing
▪
Effects of precipitation (carbonate) build up•
Carbonate formation will decrease the plating efficiency, and perhaps the adhesion performance
•
The best solution is to continually treat out carbonates rather than batch treat in the winter and deal with cyclic carbonate levels and larger replenishment additions
•
A Carbolux™
system is recommended for treatment of the carbonates▫
It is a mechanism which continually removes solution, precipitates out carbonates, places them in a disposal hopper, and then returns the treated solution back to the plating tank
42
Process Validation Plan
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1669 E. 1400 S ●
Clearfield, UT 84015 (801) 926-1150 ●
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▪
Quality compliance testing•
The following monthly compliance testing is required:▫
Bend to break adhesion coupons per ASTM B571 on plated 1”x 4”x 0.040”
coupons (4ea)
▫
Neutral salt spray corrosion testing per ASTM B117 on plated 4”x 6”
coupons (2ea)▫
Hydrogen embrittlement testing per ASTM F519 on plated Type 1.a1
coupons (4ea)
43
Process Validation Plan
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1669 E. 1400 S ●
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1669 E. 1400 S ●
Clearfield, UT 84015 (801) 926-1150 ●
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Phase III Effort Prototype Process Line
Prototype Part MatrixComponent Part #C-5 MLG Stop Plate 4G11453-101B
F-15 MLG Outer Cylinder 68A412702-1001/1002
B-1 MLG Axle 1881B85
F-15 MLG Lower Drag Brace 68A410792-2001
A-10 MLG Torque Arm 19046-1
F-16 NLG Inner Cylinder 2007644-103
C-5 MLG Rotation Collar 4G13565-101A/-101B
A-10 NLG Axle 18800-3
Phase III Effort Prototype Parts
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A-10 NLG Axle A-10 MLG Torque Arm
Phase III Effort Prototype Parts
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B-1B MLG Axle C-5 MLG Rotation Collar
Phase III Effort Prototype Parts
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F-15 MLG Cylinder F-16 NLG Inner Cylinder F-15 MLG Lower Drag Brace
Phase III Effort Prototype Anode Design
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C-5 MLG Rotation Collar
Plating B-1 Bushings LHE Zn-Ni Plated LHE Zn-Ni B-1 Bushings
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Phase III Effort Prototype B-1 Bushing
50
Phase III Effort Proposed Prototype Plating Line
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I[~&~
ES3
5 I 4 I 3 I 2 I 1 REVISIONS
I OEV. I zONE I DESCRIPTION I DATE I APPROVED
I · I I INITIAl. RELEASE I I G.KESSL£.."'1
D D
r- PROPOSED Zn-Ni PLATING LINE -TANK REQU IREMENTS
c NORTH c
I r- -
WEST Zn-Ni 1ST RINSE 2ND RINSE ACID
RINSE CONVERSION RINSE EAST END PLATING ACTIVATOR COAT END
B B
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UNLESS OTHERWISE SPECIAED oEngineering Software DIMENSIONS AlE IN INCHES
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lfOJIQJOCI, AGE IPH _.o4 PAltTORIC APPROVALS DATE AFPN SHEET 10f3
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Specification Drawing
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w i_
APPLICATION REVISIONS NEXT ASSY I USED ON REV I DESCRIPTION I DATE I APPROVED
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WARNING THIS DOCUMENT CONTAINS TECHNICAL DATA WHOSE EXPORT IS RESTRICTED BY THE ARMS EXPORT CONTROL ACT (T ITLE 22, U.S.C. SEC 2571 EJ SEQ.) OR EXECUT)VE ORDER 12470. VIOLATIONS OF THESE EXPORT LAWS ARE SUBJECT TO SEVERE CRIMINAl PENALTIES. DISSEMINATION OF THIS DOCUMENT IS CONTROLLED UNo~ DOD DIRECTIVE 5230.25 AND AFI 61-204.
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w i_
APPLICATION REVISIONS NEXT ASSY I USED ON REV I DESCRIPTION I DATE I AP PROVED
'-""' I (AIC MLG) I I I )( I I I ~ )( )( )( )(
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t;;!I~TRIB!.!IIQN ~TATI!;M~NI Q DISTRIBUTION AUTHORIZED TO DEPARTMENT OF DEFENSE AND DOD CONTRACTOR~CINLY; CRITICAL TECHNOLOGY. iDATE-TBD). OTHER REQUESTS FOR THIS DOCUMENT SHAll BE REFERRED TO 00-ALC/417 SCMS/GUMB, HILL AFB, UT 84056
WARNING THIS DOCUMENT CONTAINS TECHNICAL DATA WHOSE EXPORT IS RESTRICTED BY THE ARMS EXPORT CONTROL ACT (TITLE 22, U.S.C. SEC 2571 ET SEO.) OR EXECUl)VE ORDER 12470. VIOLATIONS OF THESE EXPORT LAWS ARE SUBJECT TO SEVERE CRIMINAL PENALTIES. DISSEMINATION OF THIS DOCUMENT IS CONTROlLED UNO~ DOD DIRECTIVE 5230.25 AND AFt 61-204.
----E'l Q!;~TR!JQTIQN NQTI~E ~ FOR UNCLASSIFIED, LIMITED DOCUMENTS, DESTROY BY ANY METHOD THAT Will PREVENT DISCLOSURE OF CONTENT OR RECONSTRUCTION ~HE DOCUMENT.
REV 1-SHEET
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