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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
ORENDA AEROSPACE CORPORATION
Presentation Outline
• Introduction / Objectives
• Progress Summary
• HVOF Evaluation and Qualification of Axial Fatigue
Test Results
• Acknowledgements
ORENDA AEROSPACE CORPORATION
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
ORENDA AEROSPACE CORPORATION
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.
ORENDA AEROSPACE CORPORATION
PROGRESS REVIEW MEETING
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
ORENDA AEROSPACE CORPORATION
PROGRESS REVIEW MEETING
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.
ORENDA AEROSPACE CORPORATION
PROGRESS REVIEW MEETING
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.
ORENDA AEROSPACE CORPORATION
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
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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
ORENDA AEROSPACE CORPORATION
PROGRESS REVIEW MEETING
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
ORENDA AEROSPACE CORPORATION
PROGRESS REVIEW MEETING
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
ORENDA AEROSPACE CORPORATION
PROGRESS REVIEW MEETING
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.
ORENDA AEROSPACE CORPORATION
PROGRESS REVIEW MEETING
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.
ORENDA AEROSPACE CORPORATION
PROGRESS REVIEW MEETINGCHCAT AXIAL FATIGUE TESTING
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
ORENDA AEROSPACE CORPORATION
PROGRESS REVIEW MEETINGCHCAT AXIAL FATIGUE TESTING
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
ORENDA AEROSPACE CORPORATION
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
ORENDA AEROSPACE CORPORATION
PROGRESS REVIEW MEETING
Low Temperature fatigue tests:
• Although the coating continues to spall off, HVOF is consistently outperforming EHC on 300 M and Aermet 100.
ORENDA AEROSPACE CORPORATION
PROGRESS REVIEW MEETING
CHCAT AXIAL FATIGUE TESTING
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)
ORENDA AEROSPACE CORPORATION
PROGRESS REVIEW MEETING
CHCAT AXIAL FATIGUE TESTING
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