Browse Topic: Finishing

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AMS120425-1AMS120425-00000000000000000000001 (Current)12/4/2025
AMS120425-1
A-10 Aircraft Oxygen Equipment Committee
Multi-Physics Informed Planning for Hybrid Metal Additive and Subtractive ManufacturingF-0081-2025-03555/20/2025
Hybrid additive manufacturing (AM) and subtractive manufacturing (SM) processes utilize the combination of AM (e.g., LPBF and DED) and SM (e.g., milling and turning operations) to produce the final part. Due to the poor surface roughness resulting from the uneven melting of powders in AM, the subtractive process is a necessary finishing operation to improve the surface roughness of the AM part. The hybrid AM/SM technology combines the benefits of AM and SM processes to create complex geometry while introducing good surface finish and compressive stress to prevent crack initiation. However, the relationship between large process parameter space and the residual stress/distortion in the part is not well understood, which impedes the adoption of hybrid AM/SM to minimize the residual stress in the final product. To expedite the process optimization, we establish a pipeline for the sequential modeling of additive manufacturing (AM) and subtractive manufacturing (SM) processes. Key accomplishments achieved under this study include (1) development of thermal abstraction technique for the AM process to speed up the macroscale level heat transfer analysis based on the manufacturing factors including scanning vector, laser power, dwelling time, etc.; (2) development of the sequentially coupled thermal-mechanical model to predict the residual stress and distortion after AM process by passing the temperature history obtained from heat transfer analysis to the mechanical analysis at each time point; (3) validation of the thermal-mechanical model for AM using thin-wall structure from literature and cantilever beam structure from UNT’s experiments data; (4) conduction of the parametric study on the chamber temperature and part design in the AM process to demonstrate how the temperature gradient and supporting structure affect the residual stress and distortion; (5) exploration of macro and micro scale models to predict the bulk and surface residual stress after cutting; (6) applying the developed modeling framework to tailoring the hybrid AM/SM process. To support model verification and demonstration, we print cantilever beam structure with different supporting structure designs and cutting strategies to study how these factors affect the final part residual stress and distortion. The data collected in the printing and cutting process is used to examine the applicability of the developed simulation tool.
Lua, Jim, Li, Rui, Rajanna, Manoj, Haridas, Ravi Sankar, Mishra, Rajiv
T-Bolt and Eye Bolt, A286 CRES, 1000 °F Fatigue RatedAS4108D (Current)9/1/2021
This specification defines the requirements for A286 CRES T-bolts and eye bolts, with room temperature tensile strength of a minimum of 160000 psi, for use with clamps and V-band couplings at 1000 °F maximum ambient temperature.
G-3, Aerospace Couplings, Fittings, Hose, Tubing Assemblies
Plating, Nickel Low-Stressed DepositAMS2424G (Current)2/26/2021
This specification covers the requirements for electrodeposited low-stressed nickel.
AMS B Finishes Processes and Fluids Committee
CLAMP, LOOP, CUSHIONED, ELONGATED, METRICMA14272A (Current)12/29/2020
G-3, Aerospace Couplings, Fittings, Hose, Tubing Assemblies
NEW FINISH DEVELOPMENT DOCUMENTUSCAR32-1 (Current)11/19/2020
This standard lists variables that shall be investigated and reported as an initial investigation into new or revised surface finishes intended for use on fasteners. This standard provides instruction for producing a final report that will be used to determine if further investigation of a surface finish is justified. Further investigation may include tests and evaluations specific to an individual OEM prior to introduction/approval of the surface finish. The final report shall include the results, observations, and conclusions for all of the variables. The final report may be made up of several individual reports covering each variable. In all cases the laboratory performing the test, the test date and the report approver shall be included in the final report.
USCAR
Bell 505 JRX, 250 Aircraft Delivered and Counting!F-0076-2020-1645010/5/2020
Since certifying the Bell 505 in December 2016, customers on six continents have received delivery of 250 of these light, single-engine aircraft. In three years the worldwide fleet logged more than 35,000 flight-hours, a testament to the Bell 505's customer experience - not only with the aircraft, but with delivery and service. In getting to the 250th delivery, the paper discusses the efforts taken to meet market demand, provide custom finishing, offer kit integration, and even take on additional envelope expansion. Numerous configurations and kits were made available a short time after initial certification, allowing Bell 505 customers to take full advantage of the aircraft capability in a timely manner. The challenges of meeting market demand and transitioning from low rate production to full rate production requires a team effort and this paper shows how it was done for the 505.
Paquin, Patrick, Lavallee, Yann
Steel Tubing, Seamless 0.15 Carbon Maximum AnnealedAMS5050L (Current)8/4/2020
This specification covers a low-carbon steel in the form of seamless tubing.
AMS E Carbon and Low Alloy Steels Committee
Development of a New High Orientation Paint System to Achieve Outstanding Real Metallic Designs2020-01-08994/14/2020
Silver metallic colors with thin and smooth aluminum flake pigments have been introduced for luxury brand OEMs. Regarding the paint formulation for these types of colors, low non-volatile(NV) and high aluminum flake pigment contents are known as technology for high metallic appearance designs. However, there are two technical concerns. First is mottling which is caused by uneven distribution of the aluminum flake pigments in paint film and second is poor film property due to high aluminum pigment concentration in paint film. Therefore, current paint systems have limitation of paint design. As a countermeasure for those two concerns, we had investigated cellulose nanofiber (CNF) dispersion liquid as both the coating binder and rheology control agent in a new type of waterborne paint system. CNF is an effective rheology control agent because it has strong hydrogen bonds with other fiber surfaces in waterborne paint. The CNF shows similar viscosity result with conventional water borne paint though CNF contents is less than 1wt% and NV is less than 5wt%. Furthermore, CNF's surface bonds with isocyanate resin makes strong fiber-reinforced layer caused by penetration from the clearcoat layer. We made a prototype silver color with this new CNF low NV waterborne paint system with vapor deposition aluminum pigments. It can exceed our conventional silver color's Flip Flop (FF) with marketable quality.
Tsukimori, Takao
Alternatives to Cadmium PlatingAIR4160B (Current)3/24/2020
To document and provide access to information obtained by an industry survey.
G-3, Aerospace Couplings, Fittings, Hose, Tubing Assemblies
Slippery Surfaces Allow Sticky Pastes and Gels to SlideTBMG-361923/1/2020
Materials known as yield-stress fluids, including gels and pastes, can be found in consumer products such as food, condiments, and cosmetics, and in products in the energy and pharmaceuticals industries. Unlike other fluids such as water and oils, these materials will not start to flow on their own, even when their container is turned upside-down. Starting the flow requires an input of energy, such as squeezing the container.
Using Plasma Treatments to Improve, Enhance Medical DevicesTBMG-360142/1/2020
Whether attempting to improve adhesion of dissimilar materials, depositing coatings, cleaning surfaces, applying a protective coating that repels water for example or biological fluids or enhancing surface wettability or functional coating, plasma treatments often add significant value to medical devices.
Streamlining Post-Processing in Additive ManufacturingTBMG-3566612/1/2019
Undoubtedly there are many benefits associated with the use of additive manufacturing (AM) as a production technology. On a pan-industrial basis, manufacturers exploit the fact that through the use of AM they can not only build complex parts, in one piece, which were previously impossible, but they can also build stronger, lighter-weight parts, reduce material consumption, and benefit from assembly component consolidation across a range of applications. These advantages have all been well documented during the last 10-20 years as AM has emerged as a truly disruptive technology for prototyping and production, and are invariably seen as being enabled by the additive hardware that builds the parts. In reality, however, this is a partial picture, particularly for serial production applications of AM. AM hardware systems are actually just one part – albeit a vital part – of an extensive ecosystem of technologies that enable AM, both pre- and post-build.
Implantables to Augment Missing Body TissueTBMG-3550911/1/2019
Kanfit3D has entered into a joint research partnership with the University of Brescia (Italy). The project will develop unique implantable structures, using additive layer manufacturing (ALM) technologies, for replacing or augmenting missing body tissue with customized surface treatments for improved osseointegration to achieve a better biological response within a reduced healing time.
New Technologies for Airframe Structural Assemblies2019-01-19159/16/2019
With air traffic demand constantly increasing and several years of aircraft production in their backlog, major aircraft manufacturers are now shifting their focus toward improving assembly process efficiency. One of the most promising solutions, known as “One Side Assembly”, aims to perform the whole assembly sequence from one side of the structure (drilling, temporary fastener installation and removal, blind fastener installation, assembly control) and with a high level of integrated automation. Investments in robotic equipment, automation engineering and innovation are very active and automation capabilities have already increased a lot in the aerospace industry. As an example, drilling operations for large dimensions airframe are clearly moving from manual to automated. However, despite more and more clever and sophisticated robotics, the use of historical fasteners with two side installation method remains a strong limitation to innovative automated assembly sequences. A blind fastener which can provide the same mechanical characteristics than current structural fasteners, while providing automation friendly features and meeting cost objectives is a real “must have” for assembly process efficiency improvements. It is also full of challenges for aerospace fasteners industry. Many research and development activities are on-going to remove fasteners from the equation of aerospace structure assemblies, but we will consider in this article that fasteners will remain a good solution for many years from now, which is shared by a lot of professionals and which doesn’t mean that nothing will change.
Dahane, Mehdi
Development of Regenerative Brake Control Strategy to Remove Brake Rust2019-01-21259/15/2019
This study is the development concept of regenerative braking cooperative control to reduce creep groan noise considering fuel efficiency. Creep groan noise is a traditional brake system noise that has been improved with advances in technology such as brake materials, surface treatment and transfer path. However, recently creep groan noise is again an issue in electronic vehicle which applied a drive motor. Generally, creep groan noise frequently occurs when rust occurs on the friction surface of the brake disc and the brake pad is humidified, but it is easily removed by friction braking several times. However, in the case of electric vehicles which applied regenerative braking system, it is hard to remove. In case of electric vehicle, instead of friction braking, most of brake toques are made by motor regenerative braking. Therefore, even if the same conventional brake system and chassis system are applied, the noise level of the electric vehicle is higher than gasoline or diesel vehicle, and the field claim is also higher. To improve the noise, regenerative braking cooperative control logic was developed that detects long-term vehicle parking condition and control the regenerative brake ratio of total driver demand brake toque considering fuel efficiency. Also several tests are proceeded to review the effect of creep groan noise and fuel efficiency.
Jang, Sora, Kim, Gwichul
Superfinishing of HVOF Applied Tungsten Carbide CoatingsAMS2452 (Current)7/15/2019
This specification covers requirements for the superfinishing of High Velocity Oxygen/Fuel (HVOF) applied tungsten carbide thermal spray coatings.
AMS B Finishes Processes and Fluids Committee
Aerospace Series - Quality Management Systems - Nonconformity Data Definition and DocumentationAS9131D (Current)5/31/2019
This standard defines the common nonconformity data definition and documentation that shall be exchanged between an internal/external supplier or sub-tier supplier, and the customer when informing about a nonconformity requiring formal decision. The requirements are applicable, partly or totally, when reporting a product nonconformity to the owner or operator, as user of the end item (e.g., engine, aircraft, spacecraft, helicopter), if specified by contract. Reporting of nonconformity data, either electronically or conventionally on paper, is subject to the terms and conditions of the contract. This also includes, where applicable, data access under export control regulations.
G-14 Americas Aerospace Quality Standards Committee (AAQSC)
INSERT, SCREW THREAD, SELF LOCKING PLASTIC LOCKING DEVICE, SOLID FILM LUBRICATED SELF-BROACHING KEYS, UNS S66286AS3502A (Current)5/24/2019
E-25 General Standards for Aerospace and Propulsion Systems
Digital Ply Tracing Software for Composite Repairs2019-01-13883/19/2019
With the increasing usage of composites for aerodynamic surfaces, the use of bonded composite repair processes are becoming more common. The repair process remains a largely manual process, with repair technicians scarfing or stepping, tracing the plies, fabricating repair patches and finally bonding the patch. The patch fabrication process becomes increasingly tedious and tiring due to cutting and tracing of each individual ply twice for thermal surveying and the final repair patch. We have developed a system that can replace the tracing and cutting components of the fabrication process using low cost, commercial off the shelf (COTS) tools. We present the ply boundary extraction method used and detail the nesting algorithm used to produce the final plies. Our software is benchmarked against the manual process with a list of successfully cut materials using a low cost fabric cutter with a steel drag blade. Our system provides up to 60% improvement in ply fabrication times for lower strength materials (e.g. fiberglass) and comparable times for high strength materials (e.g. carbon fiber).
Vongchanh, Leng, Szarski, Martin
DATC spells progress for defense prototyping19AUTP02_032/1/2019
A public-private partnership between the U.S. Army's TARDEC and SAE International is making it easier for suppliers to engage the government on military ground-vehicle technology projects. A slogging bureaucracy, miles of “red tape” and a sea of acronyms are just some of the hurdles that keep many suppliers from working with the U.S. defense industry on ground-vehicle projects. For years the government, led by the U.S. Army Tank-Automotive Research, Development and Engineering Center (TARDEC), sought to develop a streamlined procurement process. Their aim was to speed the adoption of private-sector innovations, particularly for prototype development, while expanding access for smaller, non-traditional military suppliers. A breakthrough came in 2016, when TARDEC partnered with SAE International's Industry Technologies Consortia affiliate to form the nonprofit Defense Automotive Technologies Consortium; DATC currently has 190 members-70% of which are non-traditionals. The consortium serves as a gateway between the government and the auto industry for OTA Prototype projects (OTAs, or Other Transaction Agreements, run for seven years, during which up to $700 million in projects can be awarded).
Brooke, Lindsay
Aluminum Extrusions Help Ski Maker Achieve Olympic-Sized GoalsTBMG-336902/1/2019
Minalex Corp. Whitehouse Station, NJ
Thinking Ahead Thermally: A Guide to Thermal Management Considerations for Medical Devices, Part 2TBMG-335711/1/2019
As the medical device and engineering industry grows, there is also demand for better devices and equipment. Trends such as smaller and more powerful electronics, as well as increased focus on improved customer experience, affect the medical device industry as much as any other. Medical devices, though, also need to be portable, and their costs must be judiciously managed. Above all, reliability is crucial.
Effects of Surface Preparation on Medical Silicone Adhesive PerformanceTBMG-3345312/1/2018
Medical device manufacturers often use silicone adhesives to bond parts together when assembling products such as catheters, pacemakers, cochlear implants, aesthetic implants, and gastric balloons. In addition to evaluating the different types of adhesive formulations, device manufacturers also need to critically assess several other factors in the adhesion process, including the substrates to be bonded, their surface energy, and even the overall device manufacturing process. Without addressing these factors early in the design process, medical device manufacturers risk costly delays and potential device manufacturing issues.
Does Your Coating System Require Climate Control? What to Look For and What to ExpectTBMG-3342212/1/2018
There is one aspect of the paint and coatings finishing business virtually guaranteed to give the budget director heart failure: climate control. There's no way around it – climate control systems are expensive.
COVER - ENGINE ACCESSORY DRIVE, SQUARE, 127.28 BC, METRIC AMS4424 (UNS M11630) OR AMS4484MA3454B (Current)9/17/2018
E-25 General Standards for Aerospace and Propulsion Systems
Development of friction coefficient controller for E-coat (KTL)2018-36-02009/3/2018
Global competitiveness increase in the past decades has been a crucial factor for the technological advance and industrial automotive development. Possibility of reducing costs, concentrate knowledge and increase in manufacturing efficiency has lead to development of global automotive platforms. In this scenario, the supply chain needs for adaptations that allow evolution at the same fastness imposed by original equipment manufacturer (OEM). Such demands reflect directly on the fasters market requiring lighter and stronger products. Stronger products are obtained by increasing corrosion resistance and lowering friction coefficient, in order to increase the clamp load and, consequently, reduce the weight without reducing performance. However, increasing corrosion resistance causes, generally, an increase in friction coefficient and, consequently, a decrease in clamp load. To minimize such effects, the surface coating industry has been developing, over the years, friction controllers that provide a higher corrosion resistance and better control of friction coefficient. Currently, there are products that exceed 1.000 hours of resistance to salt spray (salt spray tests according to ASTM B-117) and have friction coefficient from 0.08 to 0.12 (tests performed according to ISO 16047). However, these surface treatments are not commonly applicable due to higher costs. This impact is even more significant when we deal with larger, and hence heavier, parts such as U-bolt. An alternative to these surface treatments would be E-coat (KTL). Generally, fasters coated with KTL show high corrosion resistance, friction coefficient and friction deviation that makes their application technically unfeasible. Due to this characteristic, the KTL fasteners usually specify in the thread the phosphate and oiled coating. That is, even with fastener body presenting high corrosion resistance, the thread has low corrosion resistance in order to meet the friction coefficient specification. The present work aimed to develop a friction controller solution for fasteners coated with KTL that meets 480 hours of salt spray resistance (minimum zinc flake specification), including the thread, and present a friction coefficient of 0.08 to 0.16 (phosphate and oiled reference).
Egêa, Renan Barranqueiro, Primolini, Alexandre, Maia, Bruno Inácio da
3D-Printed Active Materials for RobotsTBMG-328389/1/2018
The Army uses robots that are structurally rigid, making them impractical when performing military operations in highly congested and contested urban environments where covert maneuvering is critical for gaining military superiority. Stealthy maneuvering requires high structural flexibility and distributive control to sneak into confined or restricted spaces, operate for extended periods, and emulate biological morphologies and adaptability.
Plating, Brush, Zinc-Nickel Low Hydrogen EmbrittlementAMS2451/9C (Current)8/2/2018
This specification covers the requirements for brush plating of zinc-nickel by electrodeposition.
AMS B Finishes Processes and Fluids Committee
Titanium Alloy, Bars, Wire, Forgings, and Rings 6.0Al - 4.0V Annealed, Heat TreatableAMS4967M (Historical)6/12/2018
This specification covers a titanium alloy in the form of bars, wire, forgings, flash welded rings up through 4.000 inches (101.60 mm) in diameter or least distance between parallel sides and stock of any size for forging, heading, or flash welded rings (see 8.6).
AMS G Titanium and Refractory Metals Committee
Application of Ultra High Speed Laser Cladding Technology for Functional Coatings DepositionF-0074-2018-128075/14/2018
ABSTRACT The technology of high speed laser deposition is a development of the method of applying functional coatings using a laser beam. It is characterized by high surfacing speeds, allowing high cooling rates, little mixing with the substrate, which leads to a high purity of the padding material and an increase in the properties of the applied layer compared to conventional laser welding. This paper presents a description of the technology of high speed laser deposition in an application for the aviation industry. The prepared stand for the implementation of the process and its verification on the aircraft landing gear component, modified as part of the AMpHOra project, has been presented. The project was carried out as part of the PZL Mielec consortium and with the scientific partner of the Wrocław University of Technology. The results presented in the article show that the coatings obtained by this technology can be competitive with hard chromium electrolytic coatings.
Dworak, Adam, Koruba, Piotr, Sienicki, Jaroslaw, Jurewicz, Piotr
Gear and Bearing Tribology Contact Simulation for Advanced Propulsion and Drive SystemsF-0074-2018-128585/14/2018
ABSTRACT The development of a Wedeven Associates Machine (WAMmp) for micro-pitting utilizes an advanced gearbox design and other support components to apply high loads and precision surface velocities while measuring traction under incipient sliding conditions. It is intended to evaluate oil and material pairs for specific performance characteristics related to high cycle fatigue and micropitting. Testing and modeling from WAMmp data creates the opportunity to predict the performance of bearing/gear materials, surface processing, and lubricants during the component design phase. Wedeven Associates, Inc. (WAI) has developed surface finishing processes to axially hone test articles to represent gear tooth finishing. The development of this method provides a meaningful tool for evaluation of new technologies and for predictive modeling for advanced gearbox and drive system designs.
Wedeven, Lavern, Fetty, Jason, Kratz, Steve, Wedeven, Graham, Homan, Robert, Kratz, Douglas
Two-Component Molding Can Solve Medical Design Challenges and Reduce CostsTBMG-289255/1/2018
Device manufacturers count on their supply chain partners for answers. What can be adjusted, how can we add value, and what methods can be used to streamline manufacturing processes, reduce SKUs, and improve part quality? One way is by moving from single-component molding to two-component molding.
Technique for Chemically Combining Soft MaterialsTBMG-287234/1/2018
Every complex human tool has contained multiple materials wedged, tied, screwed, glued, or soldered together. But the next generation of tools, from autonomous squishy robots to flexible wearables, will be soft. Combining multiple soft materials into a complex machine requires entirely new methods. Current methods are limited, relying on glues or surface treatments that can restrict the manufacturing process.
Superalloy Surface Treatment for Improved Performance of Power TurbinesTBMG-283302/1/2018
To produce power more efficiently and cleanly, the next generation of power turbines will have to operate at extreme temperatures and pressures. Currently, single-crystal, nickel-based superalloys are used in such extreme environments. MCrAlY coatings (where M = Co, Ni, or Co/Ni) are widely applied to first- and second-stage turbine blades and nozzle guide vanes, where they may be used as corrosion-resistant overlays or as bond coats for use with thermal barrier coatings.
Bioinspired Surface Treatments for Improved Decontamination: Commercial Products17AERP12_0612/1/2017
Investigation seeks to determine which coatings shed fluids most effectively. Naval Research Laboratory, Washington DC In January 2015, the Center for Bio/Molecular Science and Engineering at the Naval Research Laboratory (NRL) began an effort to evaluate and develop top-coat type treatments suitable for application to painted surfaces that would reduce retention of chemical threat agents following standard decontamination approaches. Four commercially available surface treatments were evaluated: NANOskin Hydro Express, Rust-Oleum® NeverWet®, Eagle One Superior NanoWax™, and Rust-Oleum® Wipe New. Aluminum coupons were painted with a polyurethane-based system following the directions for those products. Deposition of the surface treatments onto painted surfaces was completed as advised by manufacturer directions. NANOskin Hydro Express was shaken and sprayed onto a clean, cool surface. The product was spread evenly on the surface and allowed to dry. Eagle One Superior NanoWax™ was similarly applied by spraying and wiping. Rust-Oleum® NeverWet® was applied by simply spraying onto the surface and allowing to dry. Rust-Oleum® Wipe New was applied by wiping it onto the surface with the preloaded microfiber towel provided.
From Research to Diagnostics: Plasma Treatments Improve Quality, FunctionTBMG-2797412/1/2017
Each year, billions of multi-well plates, pipettes, bottles, flasks, vials, Eppendorf tubes, culture plates, and other polymer items are manufactured for use in research, drug discovery, and diagnostic testing.
Aerospace & Defense Technology: December 201717AERP1212/1/2017
High-Reliability Capacitors When the Mission Just Can't Fail WIAMan High-Tech Test Lab Focuses on Saving Soldiers' Lives Improving the Surface Finish of Additive Manufactured Parts A new chemical immersion treatment could revolutionise the aerospace industry Using Thermoplastic Composites for Aerospace Applications Identifying and Isolating Signals Using Radio Frequency Photonics Bioinspired Surface Treatments for Improved Decontamination: Commercial Products Investigation seeks to determine which coatings shed fluids most effectively. Mechanical Characterization and Finite Element Implementation of the Soft Materials Used in a Novel Anthropometric Test Device for Simulating Underbody Blast Loading Understanding the mechanical behavior of components made from eight soft polymer materials is necessary to ensure the predictive capability of WIAMan FE models. Processing and Characterization of Lightweight Syntactic Materials Hollow spheres encapsulated in a metal matrix, syntactic metal foam offer significant potential as lightweight energy-absorbing materials. High Temperature Graphene-Peek Adhesive Compounding graphene into polymers has the potential to improve various material properties, even at very low concentrations. Stress Corrosion-Cracking and Corrosion Fatigue Impact of IZ-C17+ Zinc-Nickel on 4340 Steel New protective material could replace cadmium and aluminum coatings on critical components.
Bioinspired Surface Treatments for Improved Decontamination: Commercial ProductsTBMG-2795512/1/2017
In January 2015, the Center for Bio/Molecular Science and Engineering at the Naval Research Laboratory (NRL) began an effort to evaluate and develop top-coat type treatments suitable for application to painted surfaces that would reduce retention of chemical threat agents following standard decontamination approaches. Four commercially available surface treatments were evaluated: NANOskin Hydro Express, Rust-Oleum® NeverWet®, Eagle One Superior NanoWax™, and Rust-Oleum® Wipe New.
Electrochemically Enhanced Mechanical Polishing of OpticsTBMG-2801412/1/2017
NASA’s Marshall Space Flight Center astrophysicists are developing better instruments to measure high-energy X-rays zipping about space when viewed from above the Earth’s atmosphere. Scientists at MSFC adapted a novel method for material removal and super-polishing to the mandrel fabrication of an advanced X-ray telescope.
Chemical Check Analysis Limits Wrought Low-Alloy and Carbon SteelsAMS2259F (Historical)10/25/2017
This specification defines limits of variation for determining acceptability of the composition of wrought low-alloy and carbon steel parts and material acquired from a producer.
AMS E Carbon and Low Alloy Steels Committee
Effect of Metallurgy on the Formation of Tribofilms and Wear Prevention2017-01-235710/8/2017
Different mechanical components in a vehicle can be made from different steel alloys with various surface treatments or coatings. Lubricant technology is needed to prevent wear and control friction on all of these different surfaces. Phosphorus compounds are the key additives that are used to control wear and they do this by forming tribofilms on surfaces. It has been shown that different operating conditions (pressures and sliding conditions) can influence the formation of tribofilms formed by different anti-wear additives. The effect of surface metallurgy and morphology on tribofilm formation is described in this paper. Our results show that additive technology can form proper tribofilms on various surfaces and the right combination of additives can be found for current and future surfaces.
Devlin, Mark, Guevremont, Jeffrey, Hewette, Chip, Ingram, Marc, Pollard, Grant, Wyatt, William
A Novel Fixturing Solution for Handling Complex-Shaped Components2017-01-20829/19/2017
Many components used in the aerospace industry are complex-shaped, without symmetric axes and parallel surfaces. Fabricating and repairing these components often require fixturing system to support manufacturing processes such as drilling, surface finishing, inspections and assembly. Currently available fixturing systems can be divided into dedicated and flexible fixtures. Among these, the flexible fixtures are suitable for rapidly changing fabricating processes and handling several complex-shaped components using same fixturing system. Background research suggested that the pin type fixturing system is the predominant design used in such applications to fix complex-shaped components. In pin type fixturing systems, force is applied to a single point of contact. This increases the pressure applied to the work piece and possibility of damaging these components. Further, conventional pins use rigid designs, which cannot adapt to the shape of the work piece. This reduces the applicable clamping force and the increases the possibility of slipping. This paper describes a fixturing system to address these problems by developing a distributed force fixing method with conformance to complex shapes. Proposed fixturing system uses jamming granular materials with negative pressure. A flexible rubber container fill with granular material is attached to the tip of a modified pin. When the container touches the work piece it conforms to the shape of the work piece. Then the rubber container vacuumed, which rigidifies the container and fix the shape, through granular jamming. Series of experiments were carried out to decide the best suited granular material in terms of highest holding force with best adaptability to a complex surface. Experiments were carried out using eight different low cost locally sourced materials. According to the experimental results proposed system successfully provide required holding forces to manipulate complex shaped components.
Jayaweera, Nirosh, Kulasekera, Asitha, Maduranga, Posindu, Kasun, Thilina, Seekkuarachchi, Prabodh, Sampath, Janaka
The Next Generation HI-LOK and HI-LITE System2017-01-20869/19/2017
The fast growth of air traffic and the need for lighter and more fuel efficient aircraft is driving the ramp-up of important new aircraft programs. These increases in production rates are driving manufacturers to seek out robust and reliable installation systems. They must also adapt to the unique requirements of composite materials that now have an increasingly important place in the aerospace industry. Moreover, environmental constraints continue to evolve and drive new regulations, such as REACH (Registration, Evaluation, Authorization and Restriction of Chemicals) in Europe. As an example, this regulation is leading to the adoption of non-chromate surface treatments and paints for most applications. The legacy generation of fasteners does not comply with all of these new requirements. Clearance fit installation and the lower coefficient of friction of composite structures increases the resultant installation torque on the pin recess, at levels the traditional hexagonal recess cannot safely withstand. A new range of technologies had to be developed while ensuring continuity in performance, tools and assembly methods. The solution was integrated within a proven and well-known structural aerospace fastener family, namely the HI-LOK and HI-LITE systems. The traditional hexagonal recess has been replaced by the ASTER recess, whose design is optimized for usage on the threaded end of fasteners. The ASTER recess helps achieve higher torque resistance for both installation and removal of the fasteners. This insures that the recess will not be damaged during installation and provides robust installation conditions. To address environmental and health concerns, the non-chromate HI-KOTE 1NC aluminum-pigmented coating replaces legacy coatings without compromising performance. These combined technologies form a complete, mature range of fasteners and tools that may be used as a direct drop-in replacement in any composite, metallic or hybrid structure, eliminating the need for joint redesign.
Lo, Justin
Gear Repair for Helicopters and Wind Turbines via Isotropic SuperfinishingF-0073-2017-121405/9/2017
ABSTRACT The wind turbine, aerospace, and helicopter gear industries recognize the importance of surface finish and surface texture for maximizing component and system performance. Optimizing surface finish and surface texture has been shown to reduce failure rates and increase operating safety margins. Isotropic superfinishing in the form of chemically accelerated vibratory finishing has been utilized to increase the performance of new wind turbine, aerospace, and helicopter gears for many years. The wind turbine gearbox industry has also used isotropic superfinishing as a method of repairing damaged gears for over a decade. The aerospace and helicopter gear industries have only minimally employed this technology as a repair technique. As the aerospace and helicopter industries scrap many gears due to only minor surface damage, further consideration of isotropic superfinishing as a repair tool is warranted. This paper will summarize the technical capabilities, recent advancements, and economic benefits of using isotropic superfinishing to repair wind turbine, aerospace, and helicopter gears. With this information, the aerospace and helicopter gear industries will be better positioned to evaluate isotropic superfinishing's potential to recover otherwise scrap gears and thereby reduce sustainment costs.
Cline, Vincent, Michaud, Justin, Winkelmann, Lane
Fatigue Life Prediction of Induction Hardened Case Depth Specimens Made From 38MnVS6 Micro Alloyed Steel2017-01-03573/28/2017
The application of induction hardening treatment plays a vital role for enhancing fatigue life of various automotive components. This will incorporate compressive residual stresses in the component at significant extent. In this paper, wide range of experiments have been carried out on Rotating Bending Fatigue (RBF) specimens made from 38MnVS6 micro alloyed steel with induction hardening up to three different case depths. The set of specimens are fatigue tested at fully reverse loading condition using rotating bending fatigue testing machine. Based on this study a surface treatment factor is evaluated. This surface treatment factor is used as an input for evaluating precise fatigue life of the specimen using FEA packages. The fatigue life evaluated using FEA is showing good agreement with the results obtained through tests on the actual specimens.
Lomate, Dattaprasad, Tewari, Asim, Date, Prashant, Ukhande, Manoj R, Shegavi, Girish M, Singh, Raj Kumar Prasad
Durability Improvement of Engine Valves and Interfacing Systems2016-32-002011/8/2016
Development of small air cooled motorcycles is ever challenging due to combination of customer expectation, regulatory requirements and cost factors. Achieving higher performance, emission standards means higher engine and parts operating temperature. Under these changes meeting durability targets at reasonable cost needs good understanding of material, surface treatment and tribological aspects. In this paper some of the surface and process improvements done to reduce wear in engine valves and interface systems is discussed in detail. Design of engine valves shall ensure meeting thermal, mechanical strength requirements, wear and durability targets. Surface treatments, coating, surface finish and also use of special materials in tip, valve stem, seat ensures higher durability; low wear in valve and interfacing parts. During new engine development process verification tests, wear observed in valve stem- guide, valve tip- screw interface. Effect of various design parameters are studied through a simulation tests. Results of different trials are shown. Various solutions are evaluated based on performance and cost.
Thiruvallur Loganathan, Balasubramanian, Narasimhan, Srivenkata Subramani, Varadha Iyengar, Lakshminarasimhan, Sandur, Ajith Kumar, Vediappan, Sudhagar
Flexible and Low-Cost Robotic System for Drilling Material Stacks2016-01-20919/27/2016
The aim of this paper is to present a robust and low-cost automatic system for drilling aluminum stacks, as well as an integral methodology for the design of tool trajectories and the control of the drilling process itself. The proposed system employs a high accuracy robotic arm, a commercial spindle head and a specially developed SCADA, which enables it to load tool trajectories designed by using any software application. Furthermore, this SCADA is useful to monitor the main parameters of the drilling process for anticipating problems related to the unexpected tool wear or for a quick response in case of tool collision. A special jig for positioning the stack to be drilled is designed to increase the robot accessibility. In this work, tests are performed for optimizing the cutting parameters of the robotic system in order to maximize the accuracy and the surface finishing of the holes. This analysis is carried out for different tool diameters and taking into account several machining strategies. Finally, a real aeronautical subassembly provided by TIER 1 supplier AERNNOVA is drilled by using the robotic system. The promising results are discussed.
Cano, Raul, Ibanez de Garayo, Oscar, Castillo, Miguel Angel, Marin, Ricardo, Ascorbe, Hector, de los Santos, Jose Ramon
Advanced Finishes for Brake Components and Other Castings2016-01-19519/18/2016
Caused by a number of beneficial properties inherently from the zinc-nickel material, this electrodeposited alloy is used more and more for cathodically protecting layers on ferrous components like cast iron brake calipers. Direct plating from acidic solutions is the state-of-the-art solution for zinc-nickel surface finishing of these components. To contribute to the continuous improvement of the final component and reduce the finishing cost, areas for improvement have been scrutinized in a current finishing system. Areas for improvement have been identified in the uniformity of the nickel distribution within different current densities and in the handling and economy of the metallic zinc anodes used for zinc metal replenishment. While today’s acidic zinc-nickel electrolytes suit and usually exceed the requirements for an alloy containing 10-15% nickel, nickel incorporation may drop just below 12% incorporation rate in areas which are plated at high current densities. Formation of white corrosion products is observed in those areas earlier than in areas bearing higher (>12%) nickel. Development on the zinc-nickel plating electrolyte’s additive system has resulted in a significantly more uniform plated deposit with improved resistance against white corrosion. Previous disadvantages in the plating system including rising metal concentrations, anode passivation and insufficient zinc metal utilization will be overcome using the new membrane anode system. This separates the zinc metal anode from the plating bath. The electrolyte can then be operated at constant metal concentrations, constant anode voltages, with no need to remove anodes in idle periods, without any anode reactivation and significantly better anode metal utilization. These developments provide important contributions for improved operating efficiencies through higher productivity and improved material economy. The significant effect of these developments on higher and more consistent quality of the plated layers finally also contributes to the overall reliability of cast iron brake systems.
Dingwerth, Björn
Toughened Uni-piece Fibrous Reinforced Oxidation-Resistant Composite (TUFROC)TBMG-253539/1/2016
The Toughened Uni-piece Fibrous Reinforced Oxidation-Resistant Composite (TUFROC) allows for much more affordable and sustainable operations involving Space Launch Services and other systems that utilize Earth re-entry vehicles. TUFROC has an exposed surface design and appropriate materials combination that will allow a space vehicle to survive both the mechanical stresses during launch and the extreme heating and stress of re-entry. It provides a thermal protection tile attachment system that is suitable for not only spacecraft applications, but also could be used where there are extreme heating environments [up to 3100 °F for 5 to 10 minutes and 3600 °F, and possibly higher, for very short time intervals (one-minute or less)].
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