Engineered Thermal Spray Coating Solutions for Landing Gear ID Application

ABSTRACT: ReliaCoat Technologies, LLC, in conjunction with program collaborators of Boeing Company and Sulzer Metco propose to develop an innovative engineered thermal spray coating solution for landing gear ID application. EHC coating replacement effort has led to HVOF WC-CoCr coating for landing gear application that often associates with poor machinability due to excessive surface hardness. Wear resistant ID coating processing poses additional challenges of spatial confinement, entrapment of loose particles and gas turbulence that are non-existent in conventional OD processing. To address this concern, ReliaCoat is proposing a two pronged approach of developing a functionally graded composite structure along with using more cost effective ID deposition processes that do not use HVOF processes. The combination of novel materials design and coating process selection will yield required solution within the cost constraints. ReliaCoat will use its advanced coating design expertise and novel process sensors to optimize state of stress and surface characteristics to as provide the solution. Developed coatings will be benchmarked with both EHC and WC-CoCr coatings in mechanical and corrosion performances as well as surface lubricity and hydraulic fluid compatibility. BENEFIT: Thermal sprayed wear resistant coatings (WC-CoCr) have proven effective for EHC replacement for various applications including OD and ID landing gear application. Both US military and commercial aerospace industry uses a vast array of thermal spray coatings both in original equipment manufacturer and in overhaul and repair. This represents a multi-billion dollar industry in the US. The integration of in-situ coating property monitoring with the most suitable ID deposition methodology and its optimal coating performance will open up tremendous opportunities in numerous non-line of sight TS coating applications. Its biggest benefactor of this technology will be the aerospace landing gear applicators of coating, both landing gear shafts and inner-cylinder walls. These advances in design and monitoring, together with partnership with equipment and materials OEM such as Sulzer Metco will allow accelerated insertion of advanced materials and processing concepts.