Development of Castings for Landing Gear aluminum forgings

Landing gear designs utilize forgings for structural applications, to maximize properties and minimize weight. Although this approach allows for minimal component weight and size, forgings commonly have extended procurement lead time, and are usually an expensive manufacturing method. Phase I of this effort provided compelling evidence that the newly developed Intermetallic-strengthened Martensitic Stainless Steel (ISMSS) alloy could provide sufficient strength properties in a casting as to make it a viable candidate for replacing current aluminum forgings for some landing gear components. However, additional development and design efforts are required to mature the technology to the point where it is ready for part qualification and on aircraft usage. The intent of this Phase II effort is to further develop and test the Phase I component designs as well as establish repeatable material and casting processes. These efforts will provide a consistent product that will offer the reliable characteristics needed to qualify the phase I items as well as future design endeavors. The impacts of replacing traditionally forged items with a casting process are great. Although Phase I identified only 3 potential candidates for casting redesign, the number of potential components that could benefit from this new product/procedure is extensive.