SBIR-STTR Award

The objective of this work is to develop and demonstrate a novel surface engineering concept for protection of Aircraft Brake Pressure Plates. Carbon-made aircraft breaking system components experience increased service temperatures and, when swiped by the temp stick, chemically react with the crayon and, as a result, heavily oxidize and deteriorate. PVD-based technique is used in many industries to apply diffusion-type coatings engineering the material surface to comply with stringent operating conditions. This technique will be further investigated and developed to demonstrate its ability to generate protective diffusion coating in the surface of aircraft carbon brakes without changing their physical dimensions and with the goal to prevent rapid oxidation and subsequent failure of the pressure plates. It will provide elevated resistance to impacts from chemical reaction as well as wear from contaminants and deicing materials and ensure unaltered material characteristics of the carbon-carbon composite construction and longer time periods between maintenance cycles.

Keywords:
Aicraft, Carbon, Oxidation, Cracking, Wear, Protection.

Carbon fiber-based brakes are made out of so-called carbon-carbon composite material (CC) that consists of two components: weaved carbon cloth and solid carbon matrix. The limitations of oxidation protection systems for CC, especially in long duration, cyclic and/or reusable applications, have made an impact on continuous use of CC materials for aircraft brakes. During the exploitation they are exposed to very high heat, often above 1000° F, as well as many contaminants including aircraft and runaway chemicals. Temp sticks that are utilized to monitor the surface temperature of the brakes, catalyze high temperature oxidation reactions on the surface of the carbon brakes causing premature embritlement and subsequently, reducing brake life and increasing brake failures and often fires. The objective of this work is to continue investigate and develop oxidation resistant coatings and systems to reduce and possibly eliminate the CC surface oxidation via utilization of the Electro-magnetically enhanced Physical Vapor Deposition (EPVD™) technology. In Phase I, feasibility of the EPVD™ application was investigated. EPVD™ has proven its capability to produce a multitude of coatings unavailable in applications by any other coating systems; it demonstrated the advantage of zero environmental compliance burdens to the process. Phase II will pursue advanced development of the prototype coatings and coating systems applicable to surfaces of selected brake pressure plates. The coating systems designs will be optimized and integrated into a prototype to investigate and demonstrate consistent reproducibility of oxidation resistant coatings applicable to commercially manufactured CC systems.

Keywords:
OXIDATION, CHROMIUM, CARBON COMPOSITE, COATING SYS