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Thursday, June 10, 2004 - 2:00 PM
EMP3.2

Application of Alternative Wear-Resistant Metallic Coatings for Landing Gear Components Using the Kinetic Metallization Process

R. M. Tapphorn, M. H. Gabel, Inovati, Santa Barbara, CA

Executive Order EO13148 requires a significant reduction in the use of hard chrome (HC) coatings on landing gear components by 2006. Environmental Management Groups within the Department of Defense are currently seeking alternative materials and processes for hard chrome replacement coatings on aircraft landing gear components that meet or exceed requirements for uniformity, adhesion, and hardness of HC coatings. Recently, the Kinetic Metallization (KM) process developed and patented by Inovati was endorsed as promising new industrial processes by the Propulsion Environmental Working Group (PWEG) for validation and testing of potential coatings applicable to aircraft engines and components. This endorsement came after a preliminary Air Force study was conducted on the fatigue properties of “cold spray” coatings and the KM coating was determined to be a promising impact consolidation coating that would meet the General Electric Aircraft Engines (GEAE) specifications. The low temperature KM process offers several advantages over the HVOF process for spray coating the surface of thermally sensitive or chemically reactive materials. Not only is the KM process 20-30% less expensive than HVOF and safer to operate, it permits application of coatings without prior surface pretreatment including grit blasting, shot peening, or preheating. This paper presents the applicability of KM cermet coatings comprising tungsten carbide in a cobalt matrix as an alternative wear-resistant coating for high-strength steel alloys. Test results of this cermet coating obtained to date including a summary of the Air Force tests will be presented as part of the paper.