Computational Design of Corrosion-resistant Gear Steel with Advanced Thermal Processing Navy SBIR FY2011.2 Sol No.: Navy SBIR FY2011.2 Topic No.: N112-107 Topic Title: Computational Design of Corrosion-resistant Gear Steel with Advanced Thermal Processing Proposal No.: N112-107-0607 Firm: QuesTek Innovations LLC 1820 Ridge Avenue Evanston, Illinois 60201-3621 Contact: James Wright Phone: (847) 425-8225 Web Site: www.questek.com Abstract: High performance gear and bearing materials are necessary to achieve long life and efficient operation of aerospace drive system turbine machinery operating in a marine environment. Current materials capable of providing fatigue and pitting resistance do not provide the desired corrosion resistance. For example, advanced stainless gear alloy Pyrowearr 675 has core mechanical properties similar to 9310, but it is difficult to surface-harden while limited due to suboptimal case carburized microstructure and insufficient corrosion resistance. Prior developments to optimize bearing alloy composition and processing have been primarily empirical, an approach that yields diminishing returns when analyzing these complex material systems. QuesTek Innovations LLC proposes to to computationally design and develop a stainless, case-hardened gear and bearing alloy. Property and processing requirements will be defined in collaboration with OEM drive system manufacturers and Navy technical experts. The rapid alloy design will leverage existing materials models and alloy microstructure and processing concepts at QuesTek. Technical feasibility will be demonstrated in the Phase I program with hardness and corrosion testing of solution nitrided sub-scale and laboratory scale prototypes. During the Phase II program, the manufacturing will be scaled up in collaboration with end-users and manufacturing partners to accelerate the technology adoption. Benefits: Successful completion of the program will result in a fully-developed, commercially available stainless gear and bearing alloy that will enable improved performance and durability of many commercial and military applications. Both military and commercial turbine engines will benefit from this technology by extending life and performance of mechanical systems while reducing unscheduled maintenance and repairs. This technology would be highly beneficial to any mechanical system required to operate in a corrosive environment. Non-aerospace applications may include improved medical devices, hand tools, and applications that may benefit from a unique combination of fatigue, wear, and corrosion resistance. Return