Manufacturing Process Development for Dust and Rain Erosion Resistant Coated Metallic Clads for Helicopter Rotors
Final rept. 5 Apr 1976-30 Jun 1980
SOLAR TURBINES INTERNATIONAL SAN DIEGO CA
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Manufacturing processes for creating erosion resistant coatings on metallic rotor blade leading edges were optimized as a follow-on to a coating development program sponsored by AMMRC Contract DAAG74-C-0054. Solide coated, titanum rotor nose caps were produced in sections up to 30 inches long. Commercially pure A75 and alloyed Ti-6Al-4V titanium was used. Newly developed graphite coating mandrels made possible simultaneous coating and creep forming of titanium sheet material to accurate airfoil contours. Sand and rain erosion tests were performed along wth tensile, impact, salt spray and adhesive bonding tests. Costs per part for production quantities were estimated. Solide coated test specimens of titanium and SAE 430 stainless steel were provided to three major helicopter manufacturers for test and evaluation Hughes, Sikorsky and Bell. Their conclusions were that Solide coatings are excellent in rain erosion resistance and low angle sand erosion resistance but do not meet minimum survival requirements when subjected to sand erosion by large particles greater than 100 micrometer impinging at high angles greater than 45 degrees.
- Fabrication Metallurgy