Exploratory Development of Functionally Graded Nano-Composite (FGNC) for Gear Applications Navy STTR FY2005 Sol No.: Navy STTR FY2005 Topic No.: N05-T006 Topic Title: Exploratory Development of Functionally Graded Nano-Composite (FGNC) for Gear Applications Proposal No.: N054-006-0359 Firm: QuesTek Innovations LLC 1820 Ridge Avenue Evanston, Illinois 60201-3621 Contact: James Wright Phone: (847) 328-5800 Web Site: www.questek.com Abstract: The proposed research would be a collaborative effort combining the gear testing expertise of Penn State's Gear Research Institute with the modeling and alloy design expertise of QuesTek Innovations. Engineers from the V22 manufacturer, Bell Helicopter, would be consulted to establish the desired property gradients in the designed alloy for improving the endurance of power transmissions built by Bell Helicopter. An increased strength of the core material will allow for increased power density compared to the existing gear alloys, and increased core toughness will provide improved damage tolerance. A new alloy will be designed to meet these criteria, and a 30 lb VIM/VAR prototype ingot will be produced. The core hardness, strength, and impact toughness of the prototype material will be measured. A preliminary carburization cycle will be developed during the phase I base and option programs using simulations. The contact fatigue resistance of a similar proprietary gear steel, C61, will be tested at Penn State to evaluate the rolling/sliding contact fatigue resistance of an alloy with an improved fatigue resistant microstructure during the phase I option program. Benefits: The primary anticipated benefit of this SBIR program is the demonstration of dramatic increases in main gearbox power densities within the Navy's Rotorcraft fleet. New materials to increase power load and reliability without increasing the size of these components would have a significant impact in the aerospace sector. QuesTek's Materials by Designr computational technology will be used to design an alloy composition and processing path customized for Navy rotocraft need. Optimized surface treatments, including high-temperature vacuum carburizing and shot peening, will be utilized to optimize the microstructure and therefore gear reliability. Once the benefits are demonstrated in this SBIR program for helicopter gears, the technology would be applicable for transfer to all gear markets including high-performance racing gears and other industrial applications. Return