USA flag logo/image

An Official Website of the United States Government

Fretting Wear Elimination in Gear Box Housings

Award Information

Agency:
Department of Defense
Branch:
Air Force
Award ID:
Program Year/Program:
2009 / SBIR
Agency Tracking Number:
F051-129-1595a
Solicitation Year:
2005
Solicitation Topic Code:
AF05-129
Solicitation Number:
2005.1
Small Business Information
IBC Materials & Technologies
902 Hendricks Drive Lebanon, IN -
View profile »
Woman-Owned: No
Minority-Owned: No
HUBZone-Owned: No
 
Phase 2
Fiscal Year: 2009
Title: Fretting Wear Elimination in Gear Box Housings
Agency / Branch: DOD / USAF
Contract: FA8501-09-C-0010
Award Amount: $1,577,116.00
 

Abstract:

A new high-performance anti-wear coating is being developed under an SBIR program with the Air Force Research Laboratorys Materials Directorate for the Joint Strike Fighter. This coating is based on the Micro-Plasma Oxidation process, which is a high-voltage electrochemical process of oxidation which creates micro discharges on the surface of the part immersed in an electrolyte. This results in the creation of a nanostructured ceramic coating of a dense, ductile oxide layer. The oxide layer improves mechanical, wear, thermal, dielectric and corrosion properties of the surface. Test results under the Phase I SBIR program have shown a 10X improvement in wear life over the baseline. IBC Materials will apply the Micro-Plasma Oxidation process to repair worn-out missile launcher rails in combination with Friction Stir Weld and Cold Spray build-up processes to restore the missile rails to specified dimensions. IBC will also adapt and optimize a wear-protective coating based on the Micro-Plasma Oxidation process to improve the wear life of the rail. A localized coating fixture will be developed to allow coating of the missile rail outside of the bath and to avoid the need to mask the part. BENEFIT: The forward hanger and missile rail for the AIM-9X missile system are currently experiencing a large amount of fretting and galling wear due to excess vibration & play of the system. As a result several hundred missile rail units are scrapped each year due to excessive wear, costing the Air Force millions of dollars in parts and labor. A repair method to build the materials back to specified dimensions, as well as an improved protective coating, will restore the rails to full service life and possibly extend the life of the missile rails. This will result in a large labor and cost savings for the U.S. Air Force and U.S. Navy AIM-9X programs. These repair methods can also be applied to other DoD missile systems, as well as gearboxes, landing gear, pumps, and hydraulic equipment.

Principal Investigator:

Solomon Berman
President
(765) 482-9802
solomon@in-motion.net

Business Contact:

Jason Reynolds
Operations Manager
(765) 482-9802
ibcadmin@in-motion.net
Small Business Information at Submission:

IBC Materials & Technologies
902 Hendricks Drive Lebanon, IN -

EIN/Tax ID: 200082734
DUNS: N/A
Number of Employees:
Woman-Owned: No
Minority-Owned: No
HUBZone-Owned: No