CHROME REPLACEMENT ON HYDRAULIC ACTUATORS

UPDATE ON HVOF SEAL TESTING AND EXPERIENCE

PRESENTED BY:

SON HUYNH Senior Aerospace Application Engineer

Presentation Outline
Seal Testing and Experience on HVOF Coating Surface Finish Recommendations

High Pressure Material - Aerospace Case Study

APPLICATIONS 5000 psi Development Program MOTION Reciprocating with Dither
Turcon VL Seal Turcon Excluder DC

HARDWARE Rod (HVOF) < 5uin. Ra max. Housing (Bare Steel) 8uin. Ra max. LEAKAGE MEASURED Zero (insufficient to form a drop) SPECIFICATIONS Media Speed Stroke Length (in.) Pressure Temperature Range Phosphate Ester 3 to 4 Hz 4 Max. 0 to 5000 psi -65F to 275F

Commercial Aircraft - Aerospace Case Study

APPLICATIONS Outboard, Inboard Aileron and Elevator Actuators MOTION Reciprocating with high Hz dither
Turcon VL Seal Turcon Excluder DC

HARDWARE Rod (HVOF) 4uin. Ra max. Housing (Bare Steel) 8uin. Ra max. LEAKAGE MEASURED Zero (insufficient to form a drop) In service since early 2000. Performed to 30,000 Flight Hours. SPECIFICATIONS Media Speed Stroke Length (in.) Pressure Temperature Range

Phosphate Ester n/a 2.95 0 to 3000 psi -65F to 275F

Commercial Aircraft - Aerospace Case Study

APPLICATIONS Flight Controls MOTION Reciprocating with dither
Turcon VL Seal Turcon Excluder DC

HARDWARE Rod: HVOF apply Wc-Co-Cr Surface finish: per B+S recommendation LEAKAGE MEASURED 1 drop every 31,899 cycles

SPECIFICATIONS Media Speed Stroke Length (in.) Pressure Temperature Range

Phosphate Ester n/a .020 to 4 50 psi min 5000 psi max -65 to 275F

Basic Characteristics of Surface Texture

Lay

Typical Traversing Length Waviness Spacing

Roughness Average Ra Centerline valleys

Peaks

Waviness Height

Roughness Spacing

Roughness sampling Length or Cutoff

Surface Finish
PTFE

Elastomer

Influences: Sealing performance, wear and life time

Abrasion Dry Running

2 B Particles (2) are torn out of the soft surface (B) due to peaks of A 1 Hard particles (1) are removed from the surface due to wear, corrosion or system non-cleanliness. These particles become embedded into the soft surface (B) and cause scratches in the hard surface (A) the hard surface (A)

Improper Surface Preparation can lead to..

Premature seal wear/failure
Hardware damage scratching and scoring Excessive leakage System failure

Surface Finish Roughness: Ra

Ra = 1 L

L o

Z(x) dx

Roughness Average Ra the area between the roughness profile and its mean line, or the integral of the absolute value of the roughness profile height over the evaluation length

Ra is not enough to define a Dynamic Sealing Surface

Surface Finish Roughness: Rz

Rz1 Rz2 Rz3 Rz4 Rz5

sl
Lm = 5 x sl

Rz =

1 5 (Rz1+Rz2+Rz3+Rz4+Rz5)

Surface Finish Roughness: Rp, Rt

Rp

Rt

Lm

Surface Finish Bearing Ratio: Tp (Mr)

Material contact area: Tp (Mr)
L1 L2 L3 L4 L5 C

Definition: Material percentage at defined depth (C)

Lm

Tp =

L1+L2+L3+L4+L5 x 100 (%) Lm

Surface Finish Bearing Ratio

Simply expressed, at a given depth the profile is sliced (horizontally) and the material percentage is reported

Tp = 39%

Tp = 79%

Surface Finish Effects

High

Wear rate

Medium Leakage rate Aerospace std. Low 32 in Ra (0,8 m Ra) Seal friction 16 (0,4) 12 (0,3) 8 (0,2) 4 (0,1) 2 (0,05) 0 (0,0)

Surface Finish

Surface Finish Profile Comparison

Profiles Rt 1 1 1 1 1 1 1 Ra Mrc=.25 ABBOTT Curves 9 9 8 8 3 8 12 75% 15% 85% 20% 7% 25% 38%

Surface Finish Recommendations

Static, External Dynamic, Internal

Dynamic, External

Surface Finish Recommendations Static, Internal

The following is Busak+Shamban Aerospace surface finish recommendation for static seals on cylinder (bore) inside diameters (I.D.) and other static locations:
Measurement Ra Std. Recommendation 32 in maximum

The following is Busak+Shamban Aerospace surface finish recommendation for dynamic pistons seals on cylinder (bore) inside diameters (I.D.):
Measurement Ra Std. Recommendation 16 in

Surface Finish Recommendations Dynamic, External

The following Busak+Shamban Aerospace surface finish parameter recommendations for dynamic rod seals or dynamic external seals on HVOF applied coatings:

Measurement Ra Rp Rz (Rtm) Tp (Mr) Rsk

Std. Recommendation < 5in 8in maximum 40in maximum > 70% @ depth of p = 0.25 Rz relative to reference line = 5 % -0.1 to 3

Thank You For Your Attention

Contact Information: Son Huynh Phone: 260-748-5729 Email: son.huynh@busakshamban.com