Landing Gear

Canadian Aeronautics and Space Institute 50th AGM and Conference 16th Aerospace Structures and Materials Symposium Montral 28-30 April 2003

Replacement of Chrome Plating with HVOF (High Velocity Oxy-Fuel) applied WC-Co-Cr coatings on Airbus A380 Landing Gear applications
Roque Panza-Giosa, Chief Material and Process Technology Goodrich Landing Gear - Oakville

April 29, 2003

Abstract Hard Chrome plating has been used for decades in Landing Gear applications as the primary protection against wear and corrosion. Alternatives to hard Chrome plating are being considered by the aerospace industry, primarily for performance enhancements and environmental acceptability reasons. High Velocity Oxy-fuel (HVOF) applied coatings have matured to the point of offering enhanced performance over Chrome plating, at a comparable price. Among the coatings that can successfully be applied by the HVOF process, WC-16%Co and WC-10%Co-4%Cr boast higher hardness, corrosion and wear resistance than Chrome plating deposits, without the environmental concerns associated with hexavelent Chromium. Extensive testing of WC-Co-Cr coatings in hydraulic sealing applications has demonstrated that HVOF applied coatings perform better than Chrome plating, but require a finer finish. The corrosion resistance of WC-Co-Cr appears to be somewhat better than that of WC-Co coatings, and either of these HVOF coatings displays significantly better corrosion behaviour than Chrome plating in salt fog environments. Field assessments of landing gear components incorporating HVOF coatings revealed considerably longer wear life in fretting, sliding and rotation wear regimes. Qualification and validation tests of hydraulic actuators and complete landing gears are underway at Goodrich as part of the Canadian Hard Chrome Alternative Team (CHCAT). A direct comparison between Chrome plating and HVOF coating in bending fatigue is also in progress. This comparison involves 5 and 10 diameter simulated pistons fatigue tested to failure. For each piston diameter, 3 specimens are coated with WC-Co-Cr and 3 specimens are Chrome plated. These full size tests have demonstrated good correlation with laboratory coupon tests, while at the same time they have highlighted a number of major differences in behaviour which are of importance in Landing gear design philosophy. This paper presents a summary of available test data, provides an update of ongoing tests, and an overview of how the lessons learned are being implemented by Goodrich in the Body and Wing landing gears design of the Airbus A380.

OUTLINE
HVOF PROCESS - PROPERTIES - LIMITATIONS COATING CHOICES - PROCESS CONTROL CHROME VS WC-Co/WC-Co-Cr EFFECT ON FATIGUE

Landing Gear

HCAT (Hard Chrome Alternatives Team) INVOLVEMENT Dash-8 S400 MLG Fatigue High Cycle Endurance Test of Actuator (seal wear) Bending Fatigue of Simulated Pistons HVOF INTEGRITY TETSING PIN TESTS aimed at A380
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Thermal Spray Coatings

Plasma Process

High Velocity Oxyfuel Process (HVOF)

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Mechanism of HVOF Coating Formation

Very High Temperatures Very High Velocities High Kinetic Energy (Molten/Semimolten Particles) Limited Oxidation
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Properties of HVOF Applied Coatings

High adhesive strength Low porosity Low oxide formation Excellent for Carbides, Tungsten Carbide coatings High degree of coating process control High repeatability (Robotics Control) Minimum excess required for grinding

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Limitations Of HVOF Process

Line of sight process
Miniature Plasma and HVOF guns Extensive development for coating Internal Diameters

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Coating Choices
Tungsten Carbide 17% Cobalt (WC-17Co) Tungsten Carbide 10% Cobalt 4%Chrome (WC-10Co-4Cr) Nickel Aluminides Chrome Carbides Triballoys
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POWDER CONTROL
Method of manufacture (aglomerated,sintered, crashed) Chemistry Size Morphology Impurities

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Process Control
Adhesive Strength 10,000psi Metallography
Porosity <1% Oxide Content <1% Hardness >1000 Knoop/Vickers Thickness ( 0.1 mm/0.004)

Flexibility/Adhesion Residual Stress (Almen N)

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Chrome Plating Vs. WC-Co/WC-Co-Cr

Environmental drive
Hexavalent Cr. is a carcinogen Chrome baths emit Hex Cr. mist into the air Level of toxicity higher than Cadmium and Arsenic Current Permissible Exposure Limit (PEL) 0.1 mg/m3 Levels are reduced to 0.005 or 0.0005 mg/m3 Many Chrome plating facilities will close, price will increase, disposal cost will rise

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Chrome Plating Vs. WC-Co/WC-Co-Cr

Performance Drive
Environmentally compliant Non embrittling Higher hardness Better corrosion resistance Better wear resistance (surface critical) Shorter production cycles More repeatable process (robotic control)

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Effect on Fatigue
Low Cycle Fatigue Rectangular Kb

Hourglass

Smooth Gage

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Effect on Fatigue

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Effect on Fatigue

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Effect on Fatigue

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RISK MANAGEMENT
Goodrich is using HVOF technology on A380 program, NO Chrome plating Developed Process Specifications: Application, Grinding, (Powders) Developed Relationship with Suppliers Experienced with WC-Co/WC-Co-Cr systems Active participant in the HCAT/CHCAT Program (HARD CHROME ALTERNATIVE TEAM)
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Landing Gear
HCAT
Military Customers
Basic process and material development

C-HCAT OEMs
Landing gear specific HVOF - WC-CoCr

Airlines
Commercial Customers
HVOF for overhaul landing gear

Limited military flight testing

Full scale testing

Commercial flight testing

Landing gear coating performance data

Depot maintenance specs - Military

Manufacturers specs

Airline overhaul specs - Commercial

AMCOM Air Force NAVAIR

Heroux Goodrich

MessierDowty Delta

Lufthansa United

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CHCAT Status - Feb. 2003

CONDUCTING THREE TESTS: 1. Fatigue of entire MLG - Dash-8 Series 400. 2. High Cycle (Dithering) wear test on hydraulic actuator. 3. Fatigue of MLG pistons 5 and 10 OD (Cr vs. WC-Co-Cr). HVOF coating is WC-Co-Cr.
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CHCAT ACTIVITIES
Full Scale Fatigue Qualification of Complete Main Landing Gear Assembly.

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TEST 1: MLG FATIGUE TEST

CURRENT STATUS
14 parts have been HVOF coated (piston, axle, and pins). Components sprayed by Vac Aero and Southwest Aeroservice. Gear has been fatigue test for 2 lives; currently being inspected.

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Landing Gear

TEST 1: MLG FATIGUE TEST

CURRENT STATUS Testing - 10 layers of testing = 5 lives. Each layer includes 32 blocks of test conditions (load location, magnitude, direction and number of cycles). 1 layer of fatigue consists of 30 blocks of ground load conditions (= 30,000 flight cycles), 1 block of retraction lug test conditions (66,000 gear extend and 33,000 gear retract flight cycles) and 1 block of stabilizer brace lock link test conditions (99,000 lock and 33,000 unlock flight cycles).

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CURRENT STATUS Testing considered successful when the gear withstands 5 lives of fatigue loads without initiation of detectable fatigue cracks. 1st life inspection revealed no issues. Test has accrued 2.0 lives (40% complete). Some delays with the test rig and changing seals. Testing began with elastomeric T-type seals but the seals failed after 330,000 cycles. Second type of elastomeric seal failed after 480,000 cycles. New Seal Design has recently been installed.
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Landing Gear

CHCAT ACTIVITIES
High Cycle Endurance Qualification Test on Landing Gear Actuator
-failure of seals at 50% life -surface finish was 20Ra -surface finish improved to 3Ra

Similar experience reported by G-Tweed Shamban, Delta , etc.

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TEST 2: HIGH CYCLE WEAR TEST

Purpose: Testing performance of HVOF coating on an aircraft actuator and demonstrate it can withstand constant cycles under endurance stress level for a civil aircraft actuator. 3 actuators being tested, 2 chrome plated, 1 WC-Co-Cr coated. Chrome finished 8-16 Ra. HVOF finished 3 Ra.

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CURRENT STATUS Test program is approximately 95% complete. To date, scheduled inspections have found the HVOF coating acceptable with no evidence of scratches, cracks or other unacceptable indications. No evidence of leakage or wear on the seals.

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CHCAT ACTIVITIES
b b
3

Full Scale Cycle-toFailure Fatigue Test on Simulated Landing Gear Pistons, 5 and 10 OD Flexural Fatigue, full load reversal to failure

Upper Bearing

Lower Bearing

Pillow Block

Notch

Test Piston

Pin Adapter

Support Beam Load Cell

2 2 2 2

Actuator

SK6093 / SK6094

41.65

60.20 56.70 (.400) 2 x R 3.50 4.00

3 - 5 and 3 - 10 Cr 3 - 5 and 3 - 10 HVOF

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9.35 9.015 9.005

30
o

2 x R .060

R 4.000 SECTION A-A DETAIL B (NOTCH) 71.700

9.188 9.183

R 1.50 (30.05)

4.200 DETAIL B

(4.00)

2X 60.70 9.997 9.994

15o

A R 3.265 59.50

.125

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TEST 3: PISTON FATIGUE TEST

CURRENT STATUS First test: 5 OD Piston (3 Cr and 3 HVOF) - simulate a commercial regional aircraft. Second test: 10 OD Piston ( 3 Cr and 3 HVOF) - simulate large commercial jet.
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SCOPE OF TEST
Purpose: to compare the fatigue performance of simulated LG piston coated with HVOF applied WC-Co-Cr and electrolytic chrome plating. This test is aimed at deriving fatigue life design factors The test will be performed until failure of the simulated LG pistons occurs.
SCOPE OF TEST WAS ALTERED FOR 3rd HVOF 5 PISTON
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Test Conditions
Bending loads based on fatigue analysis and landing gear fatigue requirements. Bending stresses approx. 100 ksi at R= -1. 50,000 cycles = 1 block of tests. Inspection after every block. Expected lives: 285,000 for 5 pistons, 330,000 for 10 pistons.
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CURRENT STATUS
5 OD pistons have been HVOF sprayed (Vac Aero), ground and superfinished to 4 Ra by Goodrich (with assistance from Jon Devereaux, US Navy). Chrome plated pistons were processed in-house by Goodrich. Finished to better than 16 Ra. 10 OD pistons are complete, but not HVOF coated.

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TEST RESULTS
1st chrome plated piston: 285,000 + 122,000 cycles. ~100ksi at notch No spalling of coating prior to failure. Some surface wear noted on chrome plating. Piston failed at notch. Crack initiated near the piston inner diameter at an inclusion - extended circumferentially outward.

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CHROME PLATED 5 INCH PISTON

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CHROME PLATED 5 INCH PISTON

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TEST RESULTS
1st HVOF coated piston: 570,000 cycles, i.e. 2 lives, ~ 100ksi at notch 184,500 cycles, ~ 110ksi Small area of failed coating (approximately .150 x .350), between 250,000 - 285,000 cycles at bottom. Visual, MPI, LPI and Barkhausen Noise inspection after 570,000 cycles did not find evidence of substrate cracking. Piston failed at bearing contact point
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Bearing area Notch area Seal area

HVOF COATING AFTER 285,000 CYCLES

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HVOF COATING AFTER 285,000 CYCLES

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HVOF COATING AFTER 570,00 CYCLES

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BUSHING CONFIGURATION
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TEST RESULTS
2nd Chrome plated piston: 1,000,000 cycles. ~110ksi at notch 20,000 cycles. ~135ksi at notch Piston failed at notch 3rd Chrome plated piston: 62,000 cycles. ~125ksi at notch Piston failed at notch

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TEST RESULTS
2nd HVOF coated piston: 33,000 cycles. ~125ksi at notch Piston failed at bearing contact point, large area of coating failure 2x0.25- top and bottom

SCOPE OF TEST ALTERED

Coating Application? (different coating supplier) Understanding of coating failure mechanism Comparison of LG spectrum to test conditions
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TEST RESULTS
Origin

Internal Notch

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TEST RESULTS
2nd HVOF coated specimen HVOF coating remains

Initiation region

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TEST RESULTS
Bearing Seal

Piston HVOF Piston Failure Chrome Piston Failure

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TEST RESULTS
3rd HVOF piston, coated by SouthWest Aero :
2,000 cycles ~125 ksi 5,000 cycles - some cracking top and bottom 10,000 cycles - significant circumferential cracking 15,000 cycles - coating separation evident 20,000 cycles - coating blistering 2 x 0.15 25,300 cycles - failure at the bearing contact point initiating at bottom

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X~10 Bearing area Appearance of coating after 10,000 cycles

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TEST RESULTS

Blistering

Appearance of coating after 25,000 cycles

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SUMMARY Piston
1st Cr 2nd Cr 3rd Cr 1st HVOF 2nd HVOF 3rd HVOF

Landing Gear

Stress (bending)
100 ksi 110 ksi 135 ksi 125 ksi 100 ksi 110ksi 125 ksi 125 ksi

Cycles Failure Mode

407K 1M 20K 62K 570K 185K 33K 25K ID, @ notch (inclusion) ID, @ notch ID, @ notch
coating failed (250K)

OD, @ bearing OD, @ bearing OD, @ bearing

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SUMMARY
HVOF pistons failed at contact point with bearing - Failure originated at OD; Chrome plated pistons failed at notch - Failure originated at ID. Cracking of coating is circumferential, localized and appears to occur relatively early ~5 K cycles @125ksi Coating failure is cohesive (substrate still coated). Coating application and finish - not a factor. Commercial Landing Gear Stresses are comparable to test - but # of cycles much smaller.
LG spectrum 125 ksi -- 575 cycles/5 lives (120 one life) Test regime 125 ksi -- 5,000 - 7,000 cycles

Test conditions more severe, not representative of LG.

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Landing Gear FUTURE ACTIONS

Test conditions too severe, not representative of LG. 1) Rigid bearing reaction 2) Single stroke position 3) Monotonic cycling Scope of test changed to simulate LG conditions - 10 test 10 Rig will be re-designed to represent LG lower bearing Simple spectrum loading will be implemented Representative bearing will be implemented
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Cylinder added

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Landing Gear TEST DESCRIPTION

TEST SPECIMENS A total of three test pins will be tested for each of the joint configurations. All pins (specimens) shall be manufactured from a single heat of material, processed, heat treated and coated as a single batch. LOAD SPECTRUM A simplified fatigue spectrum shall be used to cyclically load the
specimens. This spectrum will be subdivided into load blocks, which will be repeated until five fatigue lives are accumulated. The fatigue spectrum will be representative of a commercial landing gear.

INSPECTIONS Visual inspections for coating wear or damage will be conducted after each block, with detailed joint inspections after each life. Detailed joint inspections will consist of complete joint disassembly and NDT inspection of pins and relevant hardware. EVALUATION The results of the tests will be evaluated by Stress, Design and M&PT and used to validate the use of HVOF on the A380 pins.
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SUMMARY
HVOF applied coatings are considered the primary replacement for hard chrome plating in landing gear applications to combat wear and corrosion. Performance evaluation of HVOF coatings appear superior to Chrome plating Spalling and cracking characteristics are very different for Chrome and HVOF coatings, hence a number of tests are underway to understand this behaviour and reduce the risk on the A380 landing gear.
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