DTIC ADA604588: Development and Qualification of S53 Ultrahigh-Strength Corrosion Resistant Steel for Cadmium Replacement

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by  Defense Technical Information Center

Development and qualification of S53 ultrahigh-
strength corrosion resistant steel
for cadmium replacement
JCAT
January 26, 2006 – San Diego, CA
Charlie Kuehmann
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1. REPORT DATE 3. DATES COVERED
26 JAN 2006 2. REPORT TYPE 00-00-2006 to 00-00-2006
4. TITLE AND SUBTITLE 5a. CONTRACT NUMBER
Development and qualification of S53 ultrahigh-strength corrosion
5b. GRANT NUMBER
resistant steel for cadmium replacement
5c. PROGRAM ELEMENT NUMBER
6. AUTHOR(S) 5d. PROJECT NUMBER
5e. TASK NUMBER
5f. WORK UNIT NUMBER
7. PERFORMING ORGANIZATION NAME(S) AND ADDRESS(ES) 8. PERFORMING ORGANIZATION
QuesTek Innovations LLC,1820 Ridge Avenue,Evanston,IL,60201 REPORT NUMBER
9. SPONSORING/MONITORING AGENCY NAME(S) AND ADDRESS(ES) 10. SPONSOR/MONITOR’S ACRONYM(S)
11. SPONSOR/MONITOR’S REPORT
NUMBER(S)
12. DISTRIBUTION/AVAILABILITY STATEMENT
Approved for public release; distribution unlimited
13. SUPPLEMENTARY NOTES
26th Replacement of Hard Chrome and Cadmium Plating Program Review Meeting, January 24-26, 2006,
San Diego, CA. Sponsored by SERDP/ESTCP.
14. ABSTRACT

15. SUBJECT TERMS
16. SECURITY CLASSIFICATION OF: 17. LIMITATION OF 18. NUMBER 19a. NAME OF
ABSTRACT OF PAGES RESPONSIBLE PERSON
a. REPORT b. ABSTRACT c. THIS PAGE Same as 28
unclassified unclassified unclassified Report (SAR)
Standard Form 298 (Rev. 8-98)
Prescribed by ANSI Std Z39-18
Drivers
Accidents by Aircraft System
Commercial Jet Transport Aircraft
1958-1993
Windows
10 Air Conditioning SCC failure
13
Autoflight
A 13
Electrical Power
i 15 Navigation
r 16 Engine Exhaust
c 21 Stabilizer
r 22 Doors
a 27 Fuel system
f 33 Nacelles/Pylons
t 37 Power Plant
Equip/Furnishings
39
Structures
S 40
Hydraulic Power
y 42 Flight Controls
s 49 Wings
t 85 Fuselage
e 100 Engine HE failure
m 185 Landing Gear
192
456
0 100 200 300 400 500
Occurences
Source: FLIGHT SAFETY FOUNDATION-FLIGHT SAFETY DIGEST-DECEMBER 1994 Benefits:
Issues:
•Dramatic reduction in LG cost (60%)
•Over $200 million spent in LG per year
•savings of $120 million per year
•80% corrosion related
•Significant reduction in SCC failures
•SCC failures
•Cadmium plating not required
•Cad plating used to protect current steel
•General corrosion mitigated
known carcinogen (Hill AFB ~ 2000 lbs/yr)
•80% of Steel Condemnations Avoided
Materials By Design®
Milestones and Plans
T
R
A
T T
R S
RT TA M Jan 05 - 1st production S53D
A S A
DecemSbEerR D19P 9S9 EED JSuTne 2S0E01R DP PHASE II Jdteuennmseiol e0n 3spt rr-oaSpte5es3r tAisec sa.le-up of March E2S0T03C P PROGR mqFueeabel it0tsy5 s.tepsetcsi.f ic2andtiohne aatdn asydh ips
o
T
June 02 - Series 6 designs Jan – 04 S53D
Nov 00 - Series 1 & 2
demonstrate mechanical manufacturing specification
designs demonstrate tensile
property goals released for production
properties in 300 lb heats.
Jan 01 - Series 3 designs
determine melt practice
e
specifications et
pl
Feb 06 – Forging m
o
Dec 05 – 1st component C
demonstration complete. m
completed. a
gr
7 o
00 Pr
Jan 2 TCP
S
y E
a
d
o
T
Nov 06 – 2nd component
Feb 06 – 3rd S53D heat June 06 – JTP testing
qualification complete.
complete. complete.
Materials By Design®
S53 System Flow-Block Diagram
PROCESSING STRUCTURE PROPERTIES
........
Matrix
Lath Martensite: Ms ~ 2000C
Ni : Cleavage Resistance (JUTS ~ 280 ksl
Co: SRO Recovery Resistance
c:Jvs~230ks
Cr: Corrosion Resistance p
E
~ Strengthening Dispersion AquiOUI Conoelon
Reelltance R
(Cr,Mo,V,Fe) C
2
c
Avoid Fe C, M C. M C , M ~15-5PH
3 6 7 3 23 6 F
0
· Passive Film Fonnatlon
Cr partitioning into oxide film R
Epp and icrit
M
I A
Mlcrosegregatlon
I
Cr. Mo. V FatlgueRee..._.ce N
I c
------- ~300M
Grain Refining Dispersion I
E
-......._. dlf
--------
Microvoid Nucleation Resistance
CcnToughn111
Ktc
~ 50 ksl~ln
Grain Boundary Chemistry
Cohesion Enhancement: B. Re
Impurity Gettering: La,Ce
Materials By Design®
INNOVATIONS LLC
S53 Processing Schematic
Temperature
1400
1300 fcc
1200
1100
Solution
Normalize
0 1000 Heal Treatment
0
~
::3 900
~
<l>
Q. 800
E
~ Anneal
700 ~·
C"l
600 0g .
1.t 2rnl
~·
Temper Temper
500 C"l
~
400
A 0 0.2 I 0.4 0.6 0.8 1.0
Carbon, wt.%
Room Temperature
Fine grain material with
predominantly MCgrain
stress free stock
refining carbides
Materials By Design®
INNOVATIONS LLC
ESTCP Program Objectives
• 3 Commercial scale heats
• Identify initial implementation components
• Qualification testing for AMS (S-basis) allowables
– Execution of Joint Test Protocol (JTP)
– Estimate MMPDS A & B-basis allowables by AIM
• Specifications for manufacturing process
– Alloy Production
– Forging
– Rough Machining
– Heat Treatment
– Finish Machining/Surface Preparation
• Cost/Benefit Analysis
• Future Implementation Plan
Materials By Design®
ESTCP Production Line-up
Primary VIM Homogenization
Bar Rolling
)
s
n
o
t
7
(
t
o
g
n
I
” JTP
4
2
~
Press Forge 4”RCS (~2000 lbs)
)
s ~ 8.5”RND (2500 lbs)
n
o
7 t 8”RND (~2000 lbs)
( Secondary VAR –24 in.
t
o
g
n
I
”
0
2
~ Bar Forging
)
s
n
o
t
5
2.
(
C
O
D
”
6
1
~ Demo Plan
Materials By Design®
Joint Test Protocol
JJTTPP
SS5533 vvaalliiddaattiioonn AAIIMM vvaalliiddaattiioonn
PPrroodduucciibbiilliittyy PPrrooppeerrttiieess PPeerrffoorrmmaannccee Heat treatments
Full scale billet Microstructure Fatigue Microstructure
Forging Tensile Salt fog corrosion Tensile -Ftu
Fatigue
Machining/grinding Hardness Galvanic corrosion
Axial @ 105cycles, R=-1
Repairability Fracture strength K Crevice corrosion Fracture
1c
CVN (-40F,RT), K
IC
Coating/stripping Charpy energy H embrittlement
Stress Corrosion
K 3.5%NaCl
ISCC
Fluid compatibility SCC
Tensile -Fty
NDI
Materials By Design®
S53A Scale-up Properties
350
S53A (300 pound heat)
S53A (3,000 pound heat)
300 285 285
250
225 225
200
150
100
63
59
50
16 15
0
YS [ksi] UTS [ksi] El. [%] RA [%]
Materials By Design®