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Development of Hydraulic Actuator Repair and Overhaul Procedures for Oklahoma Air Logistics

The Oklahoma City Air Logistics Center's Avionics and Accessories Division is advancing hydraulic actuator repair and overhaul procedures across multiple weapon systems. Currently, in Phase 1, 124 Air Force Technical Orders have been reviewed, reaching 100% completion, alongside 729 engineering drawings (60.4% complete). Phase 2 focuses on material and flight testing, involving 87 distinct flight control actuator part numbers. Key evaluations include coatings and seal performance, with Delta-qualification anticipated for several candidate items. The project aims to finalize and implement solutions based on comprehensive testing.

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Development of Hydraulic Actuator Repair and Overhaul Procedures for Oklahoma Air Logistics

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  1. Program established to assist Oklahoma City Air Logistics Center Airborne Accessories Directorate Avionics and Accessories Division (OC-ALC/LII) in development and implementation of replacement repair and overhaul procedures for hydraulic actuators across multiple weapon systems.

  2. Phase 1 - TO and Drawing Review, Database Development, Test Requirement Development • 124 Air Force Technical Orders Reviewed • 100% complete • 729 Engineering Drawings Reviewed • 60.4% complete • 276 Chrome plated parts and 195 potentially chrome plated parts have been identified.

  3. Phase 2 - Material, Rig, and Flight Testing • Flight Control Actuators • 87 distinct part numbers • Revised estimate: 8-10 will require delta-qualification • Candidate items selected

  4. Phase 2 - Material, Rig, and Flight Testing • Utility Actuators • 73 distinct part numbers • Revised estimate: 10 will require delta-qualification • 1 candidate items selected • Snubbers • 12 distinct part numbers • Estimate 3 will require delta-qualification

  5. Phase 2 - Material, Rig, and Flight Testing • C-130 Rudder Booster Assembly • Rudder booster actuator manufactured by Kaiser Fluid Technologies. • Qualified by Lockheed Martin. • Delta-Qualification will be performed by Kaiser Fluid Technologies.

  6. Phase 2 - Material, Rig, and Flight Testing • C-130 Rudder Booster Assembly • 4 chrome plated surfaces. • Piston rod • 3 sections, with piston heads separating them • Piston head (2 piston heads on the unit) • Not part of the piston rod • Trunnion OD • Mates with an aluminum-bronze bushing • Trunnion ID • Not wearing part

  7. Phase 2 - Material, Rig, and Flight Testing, rod coating surface finish and seal selection • Existing seals are elastomeric T-seals contacting chrome plated rod • Various testing to date shows: • Elastomeric seals do not wear as well against ground HVOF coated surfaces as they do against chrome. • Elastomeric seals do not wear as well as teflon capped seals against HFOV coated surfaces. • Additional Greene Tweed testing indicates that superfinishing of the coated rod surfaces reduces elastomeric seal life during endurance tests.

  8. Phase 2 - Material, Rig, and Flight Testing, rod coating surface finish and seal selection • Options under consideration: • Electroplated Chrome with AGT seals (baseline) • HVOF WC-CoCr with AGT seals • HVOF WC-CoCr with new Greene Tweed seals • HVOF WC-CoCr with new Shamban seals

  9. Phase 2 - Material, Rig, and Flight Testing • C-130 Rudder Booster Assembly • HVOF coatings superfinished - Ra: 2-4 • Chrome ground - Ra: 8-16

  10. Phase 3 - Data Evaluation • Results of Testing will be evaluated and a solution finalized.

  11. Phase 4 - Implementation • The solution developed during evaluation will be implemented.

  12. Lessons learned • Some parts may NOT be suitable for HVOF. Other coatings may be required coatings. • Piston heads • Trunnion ID

  13. Lessons learned • There is more to this than HVOF. • Surface finishing • Application process • Seal choices

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