N112-107 TITLE: Advanced Bearing and Gear Steel Materials and Thermal Processing

TECHNOLOGY AREAS: Materials/Processes

ACQUISITION PROGRAM: F-35, Joint Strike Fighter

RESTRICTION ON PERFORMANCE BY FOREIGN CITIZENS (i.e., those holding non-U.S. Passports):  This topic is "ITAR Restricted."  The information and materials provided pursuant to or resulting from this topic are restricted under the International Traffic in Arms Regulations (ITAR), 22 CFR Parts 120 - 130, which control the export of defense-related material and services, including the export of sensitive technical data.  Foreign Citizens may perform work under an award resulting from this topic only if they hold the "Permanent Resident Card", or are designated as "Protected Individuals" as defined by 8 U.S.C. 1324b(a)(3). If a proposal for this topic contains participation by a foreign citizen who is not in one of the above two categories, the proposal will be rejected.

OBJECTIVE: Develop innovative materials, thermal processes, or a combination of both to improve the mechanical properties and corrosion resistance of carburizing grades of bearing and gear steels.

DESCRIPTION: Advanced case carburized bearing and gear steels have been shown to offer significant improvements in bearing performance, providing increased benefits to turbine machinery operating in a marine environment. However, conventional carburizing techniques have had limited success in meeting all required properties necessary for bearing and gear performance, particularly low pitting and corrosion resistance. Postprocessing techniques and coatings likewise have had limited success in improving the corrosion resistance of carburized bearings and gears. New bearing and gear steels, possibly optimized for alternate thermal processes such as plasma nitriding, may lead to a new generation of lighter weight, corrosion-resistant transmission components.

An innovative approach is needed to develop new steel materials and/or thermal processes that can lead to improved fatigue, pitting, and corrosion properties for high-temperature turbine engine applications in a marine environment. Such new bearing and gear materials in combination with new thermal processes have the potential to yield lighter weight and/or higher performance components for military gas turbine engines. Reduced machining and thermal processing costs may be an added benefit. Coordination with a major turbine engine manufacturer is strongly encouraged.

PHASE I: Determine the feasibility of developing an innovative material or thermal processing technology--or a combination of both--that will provide enhanced mechanical and corrosion properties compared to carburized 9310 or Pyrowear 675.

PHASE II: Develop and test the material or thermal process developed in Phase I and demonstrate a production-ready system that is capable of processing full-scale turbine engine bearings and gears.

PHASE III: Working with an engine manufacturer, transition the technology to produce optimized, full-scale turbine engine bearings and gears that provide enhanced mechanical and corrosion properties.

PRIVATE SECTOR COMMERCIAL POTENTIAL/DUAL-USE APPLICATIONS: This technology would benefit both commercial and military turbine engines by extending the useful life and performance of bearings and gears while reducing unscheduled maintenance and repairs.

REFERENCES:
1. Menthe, E., Rie, K-T, Schultze, J. W., & Simson, S. (1994). Structure and properties of plasma-nitrided stainless steel. Surface and Coatings Technology (Switzerland), 74(1-3), 412-416.

2. Pfaffenberger, E. E., & Tarantini, P. (1993, June). High temperature corrosion resistant bearing steel development. Paper presented at the AIAA/SAE/ASME/ASEE 29th Joint Propulsion Conference, Monterey, CA.

3. Menthe, E., Bulak, A., Olfe, J., Zimmerman, A., & Rie, K.-T. (2000). Improvement of the mechanical properties of austenitic stainless steel after plasma nitriding, Surface and Coatings Technology, 133/134(2000), 259-263.

4. Larisch, B., Brusky, U., & Spies, H.-J. (1999). Plasma nitriding of stainless steels at low temperatures. Surface and Coatings Technology (Switzerland), 116-119, 205-211.

KEYWORDS: corrosion resistant steels; bearings; gears; steel thermal processing; carburizing; turbine engine

** TOPIC AUTHOR (TPOC) **

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