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.: N054-006-0209 Firm: Advanced Powder Solutions 10010 Cucklebur Houston, Texas 77095 Contact: Dean Baker Phone: (661) 373-1729 Abstract: Recent attempts at improvements in V-22 gear life have focused on coatings over existing gear materials (for ex. DLC on Pyrowear 0053, or others), unfortunately for various reasons (interface failure, high contact stress, thermal expansion mismatch, etc.) these materials have never made an impact on the V-22 program or made it into Textron-Bell Helicopter's materials insertion programs. Currently, V-22 gears are made of low-carbon, low-alloyed steel that are manufactured, machined and then carburized (case hardened) at the gear surface to achieve a tempered martensitic case structure with the appropriate surface hardness, while maintaining the internal hardness, strength and toughness required for the gear performance. Recent advances in metal matrix composite fabrication now allow for the creation of functionally graded nano-composites with similar properties and performance. The increae in performance will provide increased powder density, reduced life cycle cost, operate at higher temperatures, decrease V-22 vehicle weight by reducing gear weight and the oil reserve required. The Advanced Powder Solution's team of experts in this area- will provide a significant effort in finding suitable replacements to provide the desired increase in power density. Benefits: Lower cost gears and components. Increased performance and reduced cost in operation for DoD and commercial components. Return