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FINAL REPORT Alternative Copper-Beryllium Alloys Development

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FINAL REPORT Alternative Copper-Beryllium Alloys Development FINAL REPORT Alternative Copper-Beryllium Alloys Development SERDP Project WP-2138 MAY 2015 Ralph Jaffke Parviz Yavari Northrop Grumman Corporation Distribution Statement A This report was prepared under contract to the Department of Defense Strategic Environmental Research and Development Program (SERDP). The publication of this report does not indicate endorsement by the Department of Defense, nor should the contents be construed as reflecting the official policy or position of the Department of Defense. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise, does not necessarily constitute or imply its endorsement, recommendation, or favoring by the Department of Defense. WP-2138 Final Report V2 - PM Approved i 15-66289 Use or disclosure of data contained on this sheet is subject to the restriction on the title page of this proposal. Northrop Grumman Private/Proprietary Level I TABLE OF CONTENTS Page EXECUTIVE SUMMARY ..................................................................................... 1 1.0 OBJECTIVE ................................................................................................... 3 2.0 TECHNICAL APPROACH ........................................................................... 4 2.1 BACKGROUND ..................................................................................... 4 2.2 METHODS .............................................................................................. 6 2.3 MICROSTRUCTURAL CONCEPTS ..................................................... 9 2.4 PRELIMINARY ALLOY DESIGN AND PROCESS MODELING .......................................................................................... 10 2.4.1 Copper Based Alloy Designs (Ngcu-1a / Ngcu-1b / Cuprium) ...................10 2.4.1.1 Design of NGCu-1A Sn-Free .......................................................11 2.4.1.1.1 Final NGCu-1A Alloy and Process Selection ............. 16 2.4.1.2 Design of NGCu-1B Containing Sn .............................................17 2.4.1.2.1 Final NGCu-1B Alloy and Process Selection ............. 19 2.4.1.3 Design of Cuprium Containing Sn ...............................................20 2.4.1.3.1 Final Cuprium Alloy and Process Selection ............... 26 2.4.2 Cobalt Alloy Design ....................................................................................26 2.4.2.1 Design of NGCo-1A .....................................................................28 2.4.2.1.1 Final NGCo-1A Alloy and Process Selection ............. 31 2.4.2.2 Design of NGCo-2A .....................................................................31 2.4.2.2.1 Final NGCo-2A Alloy and Process Selection ............. 38 2.4.2.3 Design of NGCo-3A Alloy ...........................................................38 2.4.2.3.1 Final NGCo-3A Alloy and Process Selection ............. 47 2.4.2.4 Optimized Design of NGCo-3A ...................................................48 3.0 ALLOY CHARACTERIZATION AND DISCUSSION ............................. 56 3.1 CHARACTERIZATION TESTING PERFORMED AND RESULTS .............................................................................................. 57 3.1.1 Tension Test Results of Evaluation Materials .............................................58 3.1.2 Compression Test Results of Evaluation Materials ....................................62 3.1.3 Pin-on-Disk Wear Testing Results of Evaluation Materials .......................64 3.1.4 Reciprocating-Ball-on-Flat Test Results of Evaluation Materials ..............69 WP-2138 Final Report V2 - PM Approved ii 15-66289 Use or disclosure of data contained on this sheet is subject to the restriction on the title page of this proposal. Northrop Grumman Private/Proprietary Level I TABLE OF CONTENTS (Continued) Page 3.1.5 Alternative Alloys Testing Evaluation & Material Down- Selection ......................................................................................................73 3.1.6 Galling Test Results of Evaluation Materials ..............................................76 3.1.7 Fatigue Life Cycle Test Results of Evaluation Materials ............................81 4.0 ENHANCED BUSHING DEVELOPMENT EVALUATION ................... 83 4.1 FINITE ELEMENT SIMULATION TOOLS ....................................... 83 4.2 GENERAL PROPERTIES .................................................................... 84 4.3 PARAMETRIC CASE STUDIES ......................................................... 87 4.3.1 CASE 1: Increasing Load ............................................................................87 4.3.2 CASE 2: Shaft Rotational Velocity .............................................................88 4.3.3 CASE 3: Coefficient of Friction ..................................................................89 4.3.4 CASE 4: Shaft Boundary Conditions, Loading Conditions, and Tilt ...............................................................................................................92 4.3.5 CASE 5: Bushing Yield Stress ....................................................................94 4.3.6 CASE 6: Effect of Bushing/Shaft Tolerance ...............................................97 4.4 SUMMARY AND CONCLUSIONS OF MODELING EVALUATION ...................................................................................... 98 5.0 FULL SCALE ENVIRONMENTAL BUSHING TESTING...................... 99 5.1 BUSHING THRESHOLD TEST AND EVALUATION.................... 102 5.2 BUSHING ENDURANCE TEST AND EVALUATION ................... 112 6.0 ALTERNATIVE COPPER BERYLLIUM HEALTH RISK ASSESSMENT ............................................................................................ 120 7.0 CONCLUSIONS ........................................................................................... 120 REFERENCES: ................................................................................................... 123 APPENDIX A ....................................................................................................... 124 WP-2138 Final Report V2 - PM Approved iii 15-66289 Use or disclosure of data contained on this sheet is subject to the restriction on the title page of this proposal. Northrop Grumman Private/Proprietary Level I LIST OF FIGURES Page Figure 1. Overall Program Schedule .............................................................................................. 4 Figure 2. Flow Diagram for Design of Ferrium ............................................................................. 6 Figure 3. Example of a Wear Mechanism Map for Steel5 ............................................................. 8 Figure 4. Systems Design Chart for a Precipitation Strengthened Copper or Cobalt Alloy System ............................................................................................................................................ 9 Figure 5. Calculated Lattice Parameters for FCC Cu-X Binary Alloys (left) and L12 Precipitates (right) at 500°C ........................................................................................................ 11 Figure 6. Observation of the Presence or Absence of Cellular Growth in Different QuesTek Alloys and their Correlation with the Predicted Lattice Misfit .................................... 12 Figure 7. A Constrained Cu-Ni3Mn-Ni3Al Pseudoternary .......................................................... 13 Figure 8. Calculated Thermodynamic Equilibria Step Diagram for the NGCu-1A Design ........ 14 Figure 9. Calculated Solidification Curves for NGCu-1A Under Two Different Models........... 15 Figure 10. As-Cast and As-Homogenized Calculated Segregation Profiles, Illustrating that 975º C/48hrs Should be Sufficient to Eliminate Most of the Residual Micro-Segregation in the Alloy....................................................................................................................................... 15 Figure 11. NGCu-1A Round Stock Evaluation Material ............................................................. 17 Figure 12. Prior Published Work Demonstrating that a Cu-Ni-Mn-Sn-Al Alloy can be Successfully Hot-Worked at 850° C ............................................................................................ 18 Figure 13. Step Diagram of the NGCu-1B Design, and the Calculated Scheil Solidification Plot. The Final Solidification Temperature is Calculated to be 750° C....................................... 18 Figure 14. (a) NGCu-1B .............................................................................................................. 20 Figure 15. Images of Spray-Metal Forming Facility at Penn State’s Applied Research Lab ...... 22 Figure 16. As-Cast Micrographs from the SMF Cuprium Billet. Left: Etched Optical Micrograph Revealing the Fine Grained Structure, Right: SEM Micrograph Indicating the Presence of Very Fine (~1 Micrometer or Less) Grain Boundary Precipitates ........................... 23 Figure 17. Schematic Detailing the Production Path for the SMF Cuprium Alloy ..................... 23 Figure 18. Image of the As-Cast SMF Cuprium Billet ................................................................ 24 Figure 19: Optical Micrographs of Extruded SMF Cuprium at Different Magnifications .......... 25 Figure 20. Optical Micrograph of the Fully Tempered USMC B86 Alloy, Revealing the Absence of any Cellular Growth and the Presence of Annealing Twins ..................................... 27 Figure 21. The Re-Design Strategy to Obtain the Required Strength ........................................
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