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EPA DOE DoD Strategic Environmental Research and Development Program Improving Mission Readiness Through Environmental Research SERDP Program 1152 DACA72-00-C-003.

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Presentation on theme: "EPA DOE DoD Strategic Environmental Research and Development Program Improving Mission Readiness Through Environmental Research SERDP Program 1152 DACA72-00-C-003."— Presentation transcript:

1 EPA DOE DoD Strategic Environmental Research and Development Program Improving Mission Readiness Through Environmental Research SERDP Program 1152 DACA72-00-C-003 (9/26/02) 1 Electroformed Nanocrystalline Coatings An Advanced Alternative to Hard-Chrome Electroplating PP-1152 Dr. Maureen J. Psaila-Dombrowski, McDermott Technology, Inc. Douglas E. Lee, Babcock & Wilcox Canada Dr. Jonathan L. McCrea, Integran Technologies Dr. Uwe Erb, University of Toronto HCAT Meeting, Toronto, Ontario September 26, 2002

2 EPA DOE DoD Strategic Environmental Research and Development Program Improving Mission Readiness Through Environmental Research SERDP Program 1152 DACA72-00-C-003 (9/26/02) 2 Contents  Technical Objective  SERDP Program Overview  Background  Results Since Orlando Meeting  Summary

3 EPA DOE DoD Strategic Environmental Research and Development Program Improving Mission Readiness Through Environmental Research SERDP Program 1152 DACA72-00-C-003 (9/26/02) 3 Technical Objective  Develop an environmentally benign advanced nanocrystalline Co-based coating technology that:  Is compatible with conventional electroplating infrastructure  Will produce coatings that meet or exceed the overall performance of hard chrome (hardness, wear, fatigue, corrosion, and thermal stability)  Has costs similar to or less than life-cycle cost of existing hard chrome electroplating processes  Will be applied to non-line-of-sight surfaces

4 EPA DOE DoD Strategic Environmental Research and Development Program Improving Mission Readiness Through Environmental Research SERDP Program 1152 DACA72-00-C-003 (9/26/02) 4 Program Overview Three Phases  Phase ITechnology Viability Assessment  Completed  Phase IICoating Optimization  Completed  Phase IIIExtension to Complex ID Shapes  In Progress

5 EPA DOE DoD Strategic Environmental Research and Development Program Improving Mission Readiness Through Environmental Research SERDP Program 1152 DACA72-00-C-003 (9/26/02) 5 Program Plan

6 EPA DOE DoD Strategic Environmental Research and Development Program Improving Mission Readiness Through Environmental Research SERDP Program 1152 DACA72-00-C-003 (9/26/02) 6 Background  Synthesized Co-P, Co-Mo and Co-Fe nano alloys  Synthesized and Optimized Co-Fe,Co-Fe-P, Co-Fe-Zn and Co-Fe-Zn-P nano alloys  Optimized Co-P alloy  Cobalt chloride/ortho-phosphoric/phosphorous acid bath  Plating efficiency >90%  Grain size nm  As-deposited hardness 700 VHN  Deposition rate 2-8 mills/hr  Precipitation hardenable  Good salt spray results  High Taber wear results (CS 17)  Good pin-on-disk results

7 EPA DOE DoD Strategic Environmental Research and Development Program Improving Mission Readiness Through Environmental Research SERDP Program 1152 DACA72-00-C-003 (9/26/02) 7 Process Cost Initial Study Update

8 EPA DOE DoD Strategic Environmental Research and Development Program Improving Mission Readiness Through Environmental Research SERDP Program 1152 DACA72-00-C-003 (9/26/02) 8 Results  Process scale-up completed (2L to 50L)  Activation procedure developed for high carbon steel substrates  Adhesion tests performed as per ASTM B  Bend Test for Ductility performed as per ASTM B  Low Temperature Annealing Treatments Performed  191°C anneal shows little increase in hardness  250 ° C anneal (4 hr) increases hardness to ~800 VHN

9 EPA DOE DoD Strategic Environmental Research and Development Program Improving Mission Readiness Through Environmental Research SERDP Program 1152 DACA72-00-C-003 (9/26/02) 9 Adhesion Test  ASTM B  No peeling and/or flaking of the coating from the substrate under low magnification (4x) - 30% elongation (bending)

10 EPA DOE DoD Strategic Environmental Research and Development Program Improving Mission Readiness Through Environmental Research SERDP Program 1152 DACA72-00-C-003 (9/26/02) 10 Ductility

11 EPA DOE DoD Strategic Environmental Research and Development Program Improving Mission Readiness Through Environmental Research SERDP Program 1152 DACA72-00-C-003 (9/26/02) 11 Abrasive Wear (Taber)

12 EPA DOE DoD Strategic Environmental Research and Development Program Improving Mission Readiness Through Environmental Research SERDP Program 1152 DACA72-00-C-003 (9/26/02) 12 Sliding Wear  Experimental Set-up (Ball-on-Disk)  CSEM Tribometer  Static member - 6mm alumina (Al 2 O 3 ) Ball (1800VHN)  10 N Load  1000 meter total sliding distance  20 mm wear track diameter  10cm/s sliding velocity  Profile measured using stylus profilometer

13 EPA DOE DoD Strategic Environmental Research and Development Program Improving Mission Readiness Through Environmental Research SERDP Program 1152 DACA72-00-C-003 (9/26/02) 13 Sliding Wear Nano Co~10%P Nano Co~6%P Nano Co~4%P (HT) Nano Co~4%P Nano Co~2%P Nano Cobalt Nanocrystalline Samples Hard Chrome Tool Steel Mild Steel Standard Samples Wear Volume Loss (mm 3 /N/m) x Coefficient of Friction Hardness (VHN) Material

14 EPA DOE DoD Strategic Environmental Research and Development Program Improving Mission Readiness Through Environmental Research SERDP Program 1152 DACA72-00-C-003 (9/26/02) 14 Sliding Wear

15 EPA DOE DoD Strategic Environmental Research and Development Program Improving Mission Readiness Through Environmental Research SERDP Program 1152 DACA72-00-C-003 (9/26/02) 15 Fatigue Testing  4340 HCAT specimens acquired from Metcut  Plated by Integran and ground by Metcut  Testing underway at MTI.25”

16 EPA DOE DoD Strategic Environmental Research and Development Program Improving Mission Readiness Through Environmental Research SERDP Program 1152 DACA72-00-C-003 (9/26/02) 16 Fatigue Test Matrix

17 EPA DOE DoD Strategic Environmental Research and Development Program Improving Mission Readiness Through Environmental Research SERDP Program 1152 DACA72-00-C-003 (9/26/02) 17 H 2 Embrittlement  ASTM F-519 Type 1a Specimens acquired from Smith & Williston  Plated by Integran  Testing underway at MTI

18 EPA DOE DoD Strategic Environmental Research and Development Program Improving Mission Readiness Through Environmental Research SERDP Program 1152 DACA72-00-C-003 (9/26/02) 18 Initial H 2 Embrittlement Test Matrix

19 EPA DOE DoD Strategic Environmental Research and Development Program Improving Mission Readiness Through Environmental Research SERDP Program 1152 DACA72-00-C-003 (9/26/02) 19 Electrochemical Testing  Establish electrochemical behaviour CoEHC plate Ni 200Nano Co-2-3wt%P (4340) Nano CoNano Co-4-5wt%P (4340)  Linear polarization resistance scan (LPR)  Potentiodynamic scan (PDS) per ASTM G61  3.56 wt% NaCl, room temperature  Determine corrosion rate and potential for pitting  Testing in process at MTI

20 EPA DOE DoD Strategic Environmental Research and Development Program Improving Mission Readiness Through Environmental Research SERDP Program 1152 DACA72-00-C-003 (9/26/02) 20 NLS Application  Mockups designed and fabricated  Blind and through cylinders  Pins  External lugs  Anode design study in progress  Consumable Co electrode  Fixed graphite electrode Optical Micrograph - 13 mil Nano Co 2-3wt%P coating on 1” ID

21 EPA DOE DoD Strategic Environmental Research and Development Program Improving Mission Readiness Through Environmental Research SERDP Program 1152 DACA72-00-C-003 (9/26/02) 21 Process Data Summary

22 EPA DOE DoD Strategic Environmental Research and Development Program Improving Mission Readiness Through Environmental Research SERDP Program 1152 DACA72-00-C-003 (9/26/02) 22 Property Data Summary


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