TECHNOLOGY AREAS: Air Platform, Materials/Processes, Weapons

ACQUISITION PROGRAM: F-35, Joint Strike Fighter; ACAT I

OBJECTIVE: Develop innovative approaches for reducing the weight and improving the safety and reliability of high performance hydraulic actuators used in Navy aircraft.

DESCRIPTION: High performance hydraulic actuators are being used in new Navy fixed wing and rotary wing aircraft. Although they have been performing satisfactorily in most cases, there have been reported incidences where the actuators have been compromised or have failed. Some of these failures have been catastrophic. Also, due to unique Navy requirements, high performance hydraulic actuators are being specified in an array of access and subsystem door applications. Since most of these actuator components are fabricated from weight inefficient steels, the resulting weight penalty is significant. In addition premature failure of these components has occurred due to fatigue and wear. It is therefore desirable to develop innovative approaches that would provide for weight reduction and reliability enhancement of the actuator components.

PHASE I: Investigate innovative approaches for weight reduction and improved reliability of hydraulic actuators. Conceptually demonstrate the feasibility of the approach.

PHASE II: Utilizing the approach developed under Phase I, fully develop the prototype design and produce limited quantities of prototype actuators for component testing. Develop a manufacturing plan to produce the actuator components and provide projections of weight, cost, and maintainability.

PHASE III: Demonstrate producibility of the actuator in a production environment. Perform component qualification and certification for Navy applications

PRIVATE SECTOR COMMERCIAL POTENTIAL/DUAL-USE APPLICATIONS: Commercial aircraft and the automotive industry are two areas that can benefit from low cost, durable, lightweight high performance hydraulic actuators.

REFERENCES:
1. "Lightweight Hydraulic System Development and Flight Test," SAE Technical Paper No. 801189.

2. "Lightweight Hydraulic System Technology – 800 psi Update," SAE Technical Paper No. 851910.

3. Frazier, W. E., "Corrosion-Resistant Alloys for Naval Aviation," Advanced Materials and Processes, Mar. 2007, page 21.

KEYWORDS: Material Systems; High Pressure; Actuator; Material Selection; Manufacturing Processes; Subsystem.

** TOPIC AUTHOR (TPOC) **

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