Development of Cad Plating Replacement with Alkaline Zinc-Nickel Electroplating for Threaded Fasteners/Components

ABSTRACT: There is currently no repair process to restore aluminum landing gear cylinders inner dimensions. The magnetron sputtering System (MSS) process has the potential of restoring outer cylinders IDs dimensions. This technology is similar to ion vapor deposition (IVD) aluminum, and meets the same specification MIL-DTL-83488. ES3"s RODS Phase I testing results were very positive and indicated that 6061 aluminum alloy MSS coatings have a great potential for repairing the IDs of aluminum outer cylinders. The results for the 7075 aluminum MSS coatings were: 1) Similar hardness properties as the substrate alloy material. 2) Withstood high bending loads without spalling off. 3) Wear characteristics increased by almost 200% on the sputtered surface vs. the bare surface of the 7075 coupons. Phase II testing will demonstrate the feasibility of the sputtering method on both test cylinders and actual landing gear outer cylinders. Phase II feasibility testing shall be conducted on coupons consisting of 7000 series aluminum alloy to provide acceptable model of actual landing gear components in operations. Also, Field Service Evaluation of several landing gear outer cylinders will be conducted to certify the MSS process. After MSS process passes the testing and FSE a process specification will be developed for MSS. BENEFIT: Research conducted to develop magnetron sputtering (PVD) systems, which can restore IDs of worn or damaged land gear aluminum outer cylinders, focuses on military applications; however, benefits will be similar for all commercial & military landing gear that need IDs restored to original dimensions. ES3 expects the following benefits from magnetron sputtering systems restoring the Inner Dimension of landing gear outer cylinders based on both industry and in-house research: Outer cylinders with worn or damage IDs can be restored to serviceable condition Increased supportability of aluminum landing gear parts for USAF and commercial industry Reduction in ownership cost for the USAF and commercial industry Magnetron sputtering could be used to repair other aircraft parts