European Union REACh Legislature
As the Sunset date of September 2024 for the REACh imposed ban on hexavalent chromium in the EU quickly approaches, will your business be ready when the lights turn off?
Adapting to market changes is crucial for the long-term success and sustainability of any business. Adaptable companies can respond quickly to market trends, emerging technologies, and changing customer preferences. This agility provides a competitive advantage over less flexible competitors, allowing for a faster capture of opportunities and mitigation of threats.
Is your business aware of the approved chrome plating alternatives within the markets you serve? Is your business Proactive or Reactive when it comes to transitioning away from chrome plating? Businesses that adapt effectively to market changes are better positioned to capture new market segments and expand their market share.
HVAF Knowledge
Here are a number of advantages for HVAF versus traditional chrome plating:
- Corrosion Resistance: Hybrid HVAF coatings typically provide excellent corrosion resistance. The thermal spray process used in HVAF can deposit a variety of materials that are inherently more corrosion-resistant than chrome plating.
- Density and Porosity: HVAF coatings tend to have lower porosity and higher density compared to chrome plating. This can result in a more uniform and durable coating that is less prone to corrosion and wear.
- Bond Strength: HVAF coatings often exhibit strong bonds with the substrate material. The high kinetic energy of the sprayed particles during the HVAF process can contribute to a more robust bond, enhancing the coating’s adhesion.
- Coating Uniformity: HVAF coatings can be applied more uniformly across complex shapes and surfaces. This is particularly advantageous when coating intricate or irregularly shaped components.
- Environmentally Friendly: Chrome plating involves the use of toxic hexavalent chromium, which can have environmental and health risks. HVAF coatings, on the other hand, can be applied using a variety of materials that are more environmentally friendly.
- Reduced Health and Safety Risks: The HVAF process typically involves fewer hazardous materials compared to chrome plating, making it a safer option for both workers and the environment.
- Thicker Coatings: HVAF coatings can be applied in thicker layers than chrome plating, providing enhanced protection against wear and corrosion.
- Cost-Effectiveness: HVAF coating processes can be more cost-effective than chrome plating, considering factors such as material costs, process efficiency, and environmental compliance.
Boeing 737 Brake Sleeve HVAF Processing Video
In our continuous effort to educate and inform industries on HVAF coating technology, we are sharing another video https://youtu.be/DJWh9RTSVwo showing a Boeing B737 Brake Sleeve coated with our AH-06 Hybrid torch depositing a WC-10Co4Cr coating at a spray rate of 62 lbs/hr (28kg/hr). The total coating time to apply a 0.0066” (168µm) thickness was an impressive 78 seconds. Traditional chrome plating processing time would be approximately 10 hours depending on the size of the rectifier.
We will let you do the math on how many of these B737 brake sleeves can be coated with our Hybrid HVAF coating technology in that same 10-hour period that it takes for chrome plating.
Why Hybrid HVAF instead of Chrome Plating?
Simple answer Cost! Hybrid HVAF coating is a highly efficient, cost-effective alternative to chrome plating. As the old adage goes “Time is Money”, Hybrid HVAF can process parts at an extremely high rate. Hybrid HVAF torches can deposit thermal spray powders at a rate of 72lbs/hr (33kg) depending on the torch you’re using. The typical processing time for Chrome plating is between 8-10 hours tank time followed by another 10-hours of baking in the oven.
Conclusion
Adaptability is a key driver of resilience and success in today’s dynamic business environment. Businesses that embrace change, continually assess market conditions are better positioned to thrive and remain relevant over the long term.
The availability of alternative technologies to replace the use of hexavalent chrome plating in the Aerospace & Defence industry as well as numerous other industries definitely exists. Thermal spray technology has been proven to be the leading alternative technology and recent advancements have proven its ability to displace hexavalent chrome plating on all outer and inner diameter surfaces.
Continued pressure from the EU REACh mandate has required air-framers, engine manufacturers, and landing gear manufacturers to identify, test and approve alternative environmental friendly technologies to replace harmful hexavalent chrome plating applied to their aircraft components.
Chrome Plating Processing vs Hybrid HVAF Coating
The Aerospace industry is moving away from traditional chrome plating. I frequently get asked, “Can Hybrid HVAF process hundreds of thousands of parts that are currently chrome plated”. The answer is a YES, Hybrid HVAF can achieve very high spray rates therefore, a significant amount of coating material can be applied in a relatively short period.
With faster coating application, production throughput is increased. This is particularly advantageous in the aerospace industry where large quantities of components need to be coated within a given timeframe.
The efficiency gained from high spray rates translate into time and cost savings. Less time spent on coating processes means lower labor costs and reduced energy consumption. Additionally, the overall cost per coated unit will decrease as a result of these time efficiencies.
Numbers Tell the True Story
Our video shows a Boeing B777 Pin sprayed with our AH-06 Hybrid torch depositing a WC-10Co4Cr coating at a spray rate of 62 lbs/hr (28kg/hr). The total coating time to apply a 0.0066” (165µm) thickness was 2.28 minutes. Another key point is that a traditional chrome plating processing time would be approximately 600 minutes. Consequently our AH-06 torch can easily spray 150 pins or more depending on your booth setup.
Finally, the high spray rates of Hybrid HVAF contribute to increased productivity by enabling rapid and efficient coating application. Reduced processing times, enhancing production throughput, and minimizing downtime are key factors. These benefits make Hybrid HVAF extremely valuable when coating performance and efficiency are critical.
Introduction
The thermal spray process has been a game-changer in various industries, offering a versatile and efficient means of applying protective coatings to a wide range of substrates. One of the strategies that have gained significant attention of late is the ability to apply thicker layers of coatings per pass.
One of the most apparent benefits of applying thicker coatings per pass is the significant reduction in application time. With thicker layers, more coating material is deposited in a single application cycle. This translates to fewer passes required to achieve the desired coating thickness. Thicker coatings per pass dramatically reduces the overall processing time, which not only enhances efficiency but also lowers labor and energy costs.
Years of Testing
Since we started working with our landing gear OEM partners 7-years ago on the approval of our HVAF Hybrid coating technology, we’ve invested a lot of time spraying and testing multiple coating thickness per pass scenarios. The testing results demonstrated that our coatings effectively met all the landing gear OEM specification requirements for coatings sprayed at up to 0.0018” per pass.
AERO-HVAF’s AH-06 Torch
Watch our video below that demonstrates our AH-06 Hybrid HVAF torch coating a landing gear pin at a spray rate of 55lbs/hr. (25kg) 5-passes @ 0.0017”/pass. Total processing time to obtain an 0.0087” thickness took 3.09 minutes. In comparison a HVOF (hydrogen based) torch spraying at the maximum spray rate of 5lbs/hr. (2.27kg) 36-passes @ 0.00024”/pass would take 38 minutes. The production gain is quite obvious and in favour of our HVAF coating technology, wouldn’t you agree!
Landing Gear Pin HVAF Hybrid WC-10Co4Cr Coating Video
Numbers Always Tell the True Story!
Thick layers of coating per pass is a strategy that holds immense potential for enhancing efficiency, performance, and cost-effectiveness. It reduces processing time, minimizes heat exposure, and results in more uniform coatings with improved bond strength. Additionally, it contributes to sustainability efforts by reducing waste and resource consumption.
Fatigue testing is essential for landing gear components to guarantee their safety, reliability, compliance with regulations, and optimal design. It plays a critical role in the overall safety and performance of the aircraft, making it a fundamental aspect of the aerospace industry.
Standard landing gear OEM fatigue bars have a diameter of 3/8” (9.5mm). The small diameter coated fatigues go through multiple high and low strain fatigue testing to ensure the viability and endurance of the applied coating. It’s important to note that there is no universal standard for the size of fatigue bars. The majority of landing gear OEMs choose to use a 3/8” (9.5mm) diameter fatigue bar, which is representative of their smallest diameter components.
As seen in the video our AH-06 torch can effectively spray Fatigue bars at a spray rate up to 62lbs/hr (28kgs). Considering the high spray rate of our Hybrid HVAF torch, fatigue testing must be performed on multiple spray rates of 11, 22, 33, 44, 55 & 62lbs/hr. (5, 10, 15, 20, 25 & 28kg/hr.).
Fatigue testing is crucial for landing gear components for several reasons:
- Safety: Landing gear components are subjected to repetitive loading and unloading cycles during every flight. The stresses and strains imposed on these components can lead to the development of cracks over time. Fatigue testing helps ensure that these components can withstand the stresses they will encounter throughout their operational life without failing, which is critical for the safety of aircraft and passengers.
- Reliability: Landing gear components must operate reliably under various conditions, including different aircraft weights, landing speeds, and runway conditions. Fatigue testing helps identify potential weaknesses in the design or materials used in these components, ensuring that they meet the reliability requirements necessary for commercial aviation.
- Compliance with regulations: Aviation authorities such as the Federal Aviation Administration (FAA) and the European Union Aviation Safety Agency (EASA) have strict regulations and certification requirements for aircraft and their components. Fatigue testing is often a mandatory part of the certification process to demonstrate that landing gear components meet these regulatory standards.
- Predicting service life: By subjecting landing gear components to fatigue testing, engineers can estimate the expected service life of these components more accurately. This information is valuable for airlines and maintenance crews to plan maintenance schedules and replacement intervals, minimizing the risk of unexpected failures.
- Design optimization: Fatigue testing provides valuable data on how landing gear components behave under repeated stress cycles. Engineers can use this data to refine the design of these components, optimizing their shape, materials, and manufacturing processes to enhance their fatigue resistance and overall performance.
- Cost savings: Identifying and addressing fatigue-related issues during the design and testing phase is generally more cost-effective than dealing with failures and maintenance problems once an aircraft is in service. Fatigue testing helps identify potential problems early, reducing the risk of costly downtime and repairs.
- Performance under extreme conditions: Landing gear components must perform reliably not only under typical operating conditions but also under extreme conditions, such as emergency landings or hard landings. Fatigue testing helps assess how landing gear components behave under these adverse scenarios, ensuring their robustness and safety.
In summary, fatigue testing is essential for landing gear components to guarantee their safety, reliability, compliance with regulations, and optimal design. It plays a critical role in the overall safety and performance of aircraft, making it a fundamental aspect of the aerospace industry.
Introduction
In today’s rapidly advancing industrial landscape, the demand for machinery and components that offer exceptional durability and performance is higher than ever before. Whether in the oil and gas industry, aerospace, or manufacturing, the inner bores of components play a critical role in the overall functionality of various systems. To meet the demands of these industries, carbide coating of inner bores has emerged as a powerful solution, especially when paired with High-Velocity Air Fuel (HVAF) coating technology. In this blog, we will explore the benefits and applications of carbide coating for inner bores, while delving into the advantages that HVAF technology brings to the table.
Carbide Coating for Inner Bores
Carbide coatings are a class of materials known for their exceptional hardness, wear resistance, and corrosion resistance. They are composed of carbide particles, typically tungsten carbide (WC) or chromium carbide (Cr3C2), embedded in a metallic matrix, such as nickel or cobalt. These coatings are applied using various methods, including thermal spray technologies, chemical vapor deposition (CVD), and physical vapor deposition (PVD).
HVAF Coating Technology
High-Velocity Air Fuel (HVAF) is a thermal spray coating technology that has gained recognition for its ability to produce high-quality, dense coatings with excellent adhesion. HVAF involves the combustion of fuel gas (typically propane or propylene) with compressed air, producing a high-velocity, high-temperature gas stream. This gas stream accelerates powdered coating material, such as carbide particles, to supersonic speeds before impacting the substrate. The result is a dense and well-bonded coating with minimal oxidation and porosity.
Benefits of HVAF Technology for Carbide Coating of Inner Bores:
High Density and Bond Strength: HVAF technology produces coatings with exceptional density and bond strength, ensuring that the carbide coating adheres securely to the inner bore surface.
Low Porosity: The supersonic particle velocities in HVAF minimize porosity in the coating, resulting in a smoother and more corrosion-resistant surface.
Minimal Oxidation: HVAF operates at lower temperatures compared to other thermal spray methods such as High Velocity Oxygen Fuel (HVOF), reducing the risk of oxidation and ensuring the integrity of the carbide coating.
Precise Control: HVAF allows for precise control over coating thickness and composition, ensuring that the desired properties are achieved.
Applications of Carbide Coating with HVAF in Inner Bores
The combination of carbide coatings and HVAF technology finds applications across a wide range of industries:
Aerospace: HVAF-coated carbide inner bores are used in aircraft landing gears and engines, where they provide superior corrosion and wear resistance coupled with dimensional stability.
Oil and Gas: Carbide-coated inner bores in drilling tools, pumps, and valves offer exceptional wear resistance in abrasive and corrosive drilling environments.
Manufacturing: Inner bores of industrial machinery components, such as hydraulic cylinders and bearings, benefit from carbide coatings for extended service life.
Automotive: Carbide-coated inner bores in engine components enhance durability and performance.
When it comes to inner bores, carbide coatings offer several advantages:
Improved Wear Resistance: Inner bores are often subjected to abrasive wear due to the movement of fluids, gases, or particles. Carbide coatings significantly enhance the wear resistance of these surfaces, extending the component’s lifespan.
Corrosion Protection: Many industrial applications involve exposure to corrosive environments. Carbide coatings act as a barrier against corrosion, preventing degradation of the component’s inner surfaces.
Reduced Friction: The low coefficient of friction of carbide coatings reduces energy consumption and minimizes heat generation, resulting in improved efficiency.
Tolerance Maintenance: Carbide coatings can be applied with precise thickness control, ensuring that tight tolerances are maintained within inner bores.
Conclusion
Carbide coating of inner bores using HVAF technology is a game-changer in various industries where wear resistance, corrosion protection, and overall component longevity are paramount. The marriage of carbide’s exceptional properties with HVAF’s precision and quality results in high-performance inner bore coatings that stand up to the harshest environments. As industries evolve, these advanced coating solutions will play an increasingly crucial role in ensuring the reliability and efficiency of critical components.
