Objective: The objective of this project is to replace cadmium (Cd)-plated high-strength steel in Leading Edge Flap Actuator Systems (LEFAS) and Wing Fold Actuator Systems (WFAS) with Ferrium S53 high-strength corrosion-resistant steel. In addition to the environmental hazards of Cd plating, these systems are prone to plating damage during assembly and therefore experience corrosion and corrosion-induced cracking. This project will focus on qualifying S53 components for insertion into the F-35 LEFAS and WFAS through full-scale rig testing by the production suppliers. Technology Description: S53 was developed by computational metallurgy under Strategic Environmental Research and Development Program (SERDP) project WP-1224 by QuesTek Innovations LLC and is currently being qualified under Environmental Security Technology Certification Program (ESTCP) project WP-0304 by Landing Gear Engineering at Hill Air Force Base. The material was developed specifically for landing gear and is mechanically equivalent to 300M high-strength steel but with stainless steel qualities. The ultimate strength is 280 ksi with corrosion resistance approaching 15-5 PH stainless steel. It is much stronger than any stainless steel available today. As of December 2005, three production 10,000-lb heats of S53 have been made, and S-basis allowables will be developed before project initiation. In principle, S53 is a valid replacement material for the major components of the rotary-geared actuators (RGA) used in LEFAS and WFAS units. By evaluating RGA-related performance and qualifying the material for use in RGA components, S53 will be ready for insertion into F-35 aircraft during low-rate initial production (LRIP). Once this is accomplished, S53 can be qualified and inserted into existing weapons systems such as the F-18 and F-22. Expected Benefits: S53 corrosion-resistant high-strength steel can be directly substituted for the existing Cd-plated HP 9-4-30 steel in rotary-geared actuators, either by using its full strength or by modifying the heat treat to reduce the ultimate strength and increase toughness. Even if S53 requires an additional coating to meet lubricity, wear, or salt fog requirements, it can be expected to perform much better than the existing materials and save weight by eliminating bushings. An initial estimate projects maintenance repair operation savings of approximately $4 million per year in parts and the elimination of 500,000 square inches of Cd plating in the F-35 fleet. (Anticipated Project Completion - 2010) Principal Investigator:
Mr. Michael Schow
417 SCMS/GUEB
6040 Gum Lane
Hill Air Force Base, UT 84056
Telephone: (801) 777-2092
Fax: (801) 777-9395
E-mail: Michael.Schow@HILL.af.mil
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