Improved Landing Gear Grinding/Finishing Methods on Hard Wear Resistant Surfaces

The Air Force is currently replacing chrome plating with High Velocity Oxygenated Fuel (HVOF) applied tungsten carbide-cobalt (WC-Co and WC-Co-Cr) coatings. These coatings require diamond wheels for finish grinding as well as aluminum oxide grinding wheels for base metal prep and Chrome plate grinding. The use of two types of wheels creates an undesirable equipment change out during the overhaul and finishing process. In addition, the current use of both diamond and aluminum oxide grinding wheels involves the risk of grind burns to the substrate of landing gear components. ES3 purchased and installed one Belt Grinder in Building 507 in support of ongoing efforts to successfully implement HVOF in place of chrome. It is our intention to verify optimized results from ongoing Process Engineering efforts and quickly move onto a Phase II SBIR where 3 Versagrind Belt Finishers will be purchased and installed for Gap Grinder use. BENEFIT: The implementation of Belt Finishing will have a dramatic impact on the cost and efficiency within the DoD and commercial businesses. This improved grinding method has demonstrated exceptionally fast cutting removal rates, dramatically reduced times associated with belt changes over wheels, in addition the threat of grinding burns to the substrate is virtually eliminated thus reducing a potentially catastrophic failure from occurring. ES3 expects the following benefits from the verification and installation of the Versagrind Belt Finishing machines: • That validation of optimized belts and process variables do not create burns on 300M or 4340 substrates. • That the requirements and equipment for a scaled-up production system will be identified. • All significant production issues will be identified • Safety considerations and equipment requirements will be identified • Success of this installation will enable commercial landing gear OEM’s and other DoD installations to implement the technology using proven methods