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, a forging typically has the longest logistic lead time, and is usually the most expensive manufacturing method. Many aluminum landing gear components are designed and manufactured from 2000 and 7000 series aluminum forgings. ES3 proposes to develop a new design approach, using advanced, high quality casting processes; coupled with very high strength stainless alloys, to potential replace many aluminum forged components. ES3 will subcontract with Questek Innovations LLC, to further research and develop two stainless alloys for this approach. The first potential alloy, EFV has exhibited in early development, strength properties in a casting that are very high. For use in landing gear applications, an EFV alloy variation that trades lower strength for higher toughness will be researched. The second alloy will be the research of a castible variation of S53, a very high strength stainless alloy being developed under project PP-0304 of the Environmental Security Technology Certification Program/ Strategic Environmental Research and Development Program (ESTCP/SERDP). For Phase I, ES3 proposes to identify the design requirements for a cast landing gear component, establish successful alloy parameters for the two alloy candidates, begin initial development of the most successful alloy candidate, to set the stage for preliminary design work for the candidate item with the applicable OEM.