HARD CHROME PLATING ALTERNATIVES

1. HARD CHROME PLATING ALTERNATIVES HARD CHROME PLATING ALTERNATIVES Mary Gilman Boeing C-17 Pollution Prevention Project Manager Boeing Hard Chromium Natural Work Group Leader

2. HARD CHROME PLATING ALTERNATIVES BOEING HARD CHROMIUM NATURAL WORK GROUP • Hold quarterly telecon and net meetings. • Bring together chromium plating experts at various locations. • Identify environmentally compliant, safe alternatives. • Disseminate information and data. • Share and leverage results and lessons learned. • Document cost savings across programs. • Monitor in-house evaluation and implementation programs.

3. HARD CHROME PLATING ALTERNATIVES BOEING HARD CHROMIUM NATURAL WORK GROUP (cont) • Renton Evaluation Programs • Thermal spray coatings on various substrates, high strength steel for landing gear -- Gary Erickson • Diamond-like-carbon coating -- Dennis Dull • Wet chemical methods -- Mike Ware • St. LouisEvaluation Program • Corrosion resistance of thermal spray coatings -- Steve Gaydos • Mesa Evaluation Program • Sputtering down gun barrels -- Tony Piazza • Long BeachEvaluation Programs • Commercial working with FAA to use Seattle testing results and documentation -- Tom Posten • C-17 planning coupon fatigue testing, landing gear durability testing and hydraulic actuator component testing -- Mary Gilman

4. HARD CHROME PLATING ALTERNATIVES C-17 POLLUTION PREVENTION PROGRAM • Objective is reduction or elimination of hazardous materials from C-17 weapon system • Evaluate and implement non-hazardous materials as replacements • Completed over 60 projects to date since March 1995 • Work recognized by the U.S. Air Force, regional regulatory agencies, and within Boeing Company • Awarded 1997 Pollution Prevention Continuous Improvement Award by Region IX U.S. Environmental Protection Agency (EPA) • Awarded 1997 and 2000 Air Force Material Command Single Manager Pollution Prevention Awards

5. HARD CHROME PLATING ALTERNATIVES HAZARDS of CHROMIUM • Chrome plating applied by suppliers and depots. • Plating bath contains mostly hexavalent chromium (CrVI) carcinogenic and hazardous to health and environment. • Compliance regulated by OSHA Standard, NESHAP, TRI and reduction targeted as EPA and C-17 COC. • Federal EPA plans an 89% reduction on limit for wastewater. • State and local to follow • Federal OSHA plans a 50-100 fold reduction in PEL permissible exposure limit. • CAL OSHA already reduced to 0.5 ppm. • Increasing costs of worker protection and surveillance, environmental compliance and waste disposal.

6. HARD CHROME PLATING ALTERNATIVES ANTICIPATED BENEFITS of HVOF ALTERNATIVE • Application materials and spray process are non-hazardous to environment and worker. • Improved performance in fatigue, wear, porosity and corrosion properties. • Improved durability and life extension in field repair and overhaul procedures. • Not susceptible to hydrogen embrittlement, requires no embrittlement relief bake. • Labor costs are lower for HVOF, but operating costs are higher. • Long term costs of HVOF will drop given market competition and environmental factors.

7. COMPLETED -- C-17 EVALUATION EFFORT Identify specifications and requirements. Identify and review landing gear production and support documentation. Search literature and survey industry for alternatives. Compare alternative technologies and identify most promising candidates for successful implementation. Characterize parts and recommend alternatives based on size, complexity, and internal surfaces. Conduct supplier and program cost and schedule impact analysis. Perform Environmental, Health & Safety Analysis. HARD CHROME PLATING ALTERNATIVES

8. CURRENT -- C-17 ANALYSIS EFFORT Perform Life Cycle Cost analysis on landing gear. Environmental and worker safety impact Development of material and process change Material and labor for production and overhaul Reliability, maintainability and availability Equipment procurement, maintenance and operation Revision of production and support documentation Deliver Risk Assessment Analysis report. Summary of environmental, performance, documentation, cost and schedule impacts. HARD CHROME PLATING ALTERNATIVES

9. PLAN -- C-17 FATIGUE COUPON TESTING Prepare specimens for fatigue testing Develop test plan Fabricate NC310 HSS (310 KSI) specimens Apply Type 17 WC/CoCr HVOF thermal coating Perform fatigue testing Perform testing for smooth fatigue, tensile and bond-tensile Verify HVOF coating performs as well as chrome plating Perform inspections before and after testing Magnetic particle, dye penetrant, and ultrasonic HARD CHROME PLATING ALTERNATIVES

10. PLAN -- HYDRAULIC ACTUATOR TESTING Develop test plan to evaluate hydraulic actuators Identify functional and performance requirements Identify test equipment and procedures Focus on piston rod/gland interfaces and interactions Not address piston head to cylinder bore interactions Select coating and seal material, finish, and geometry Evaluate compatibility with hydraulic fluids Select combination for maximum wear resistance and life of components, mating parts and seals HARD CHROME PLATING ALTERNATIVES

11. PLAN -- C-17 LANDING GEAR TESTING Prepare parts for durability testing Develop test plan and select parts to test Purchase 300M high strength steel (280 KSI) landing gear pins and bolts Apply Type 17 WC/CoCr HVOF thermal spray coating Perform durability rig testing Complete extension program to six lifetimes Perform inspections for delamination or failure of HVOF coating Verify HVOF coating performs as well as chrome plating HARD CHROME PLATING ALTERNATIVES

12. OTHER C-17 LANDING GEAR ISSUES Some problems on main landing gear components Post shelf wear and wheel axles Base material 300M high strength steel Finished with hard chrome plating Plating surfaces with some wear, galling, chipping, burning, or corrosion pitting Good candidate components to evaluate HVOF as alternatives Expect HVOF hard coatings to improve wear performance and extend life of components HARD CHROME PLATING ALTERNATIVES