Curtiss-Wright Surface Technologies
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1 Surface Technologies Division Curtiss-Wright Surface Technologies Metal Improvement Company, LLC Jochen P. Fuhr 1 October 20, 2015 Proprietary Curtiss-Wright
2 CWST - Services Application of appropriate surface technologies to enhance the performance of materials Controlled Shot Peening Analytical Services Shot Peen Forming Parylene Coating Laser Peening Isotropic Finishing Component Coating & Repair Thermal Spray Engineered Coatings 2 October 20, 2015 Proprietary Curtiss-Wright
3 CWST International Business Units Over 75 Business Units Worldwide 3 October 20, 2015 Proprietary Curtiss-Wright
4 CWST International Facilities Bangalore, India 4 October 20, 2015 Proprietary Curtiss-Wright
5 CWST International Facilities Bangalore, India Markets Aerospace, Oil & Gas, Power Generation and Automotive Quality Certificates AS9100 Rev C ; Nadcap Production facilities Sqft facilities Controlled shot peening process Major Customer AIRBUS, BOEING, BOSCH, CESA, GE, SAAB, SIEMENS, UTAS, TRIVENI TURBINES, Contact Information Manjunath.MV Business Unit Manager manjunath.mv@cwst.com 5 October 20, 2015 Proprietary Curtiss-Wright
6 Shot Peening - Industries Aerospace Automotive Power Gen. Gen. Industrial Oil & Gas Gears & Springs Airframe Automotive Steam & Gas Diverse Oil & Gas Gears Engine Wind Welding Springs Forming Hydro Medical C.A.S.E. On-site PEENTEX Dual Peening 6 October 20, 2015 Proprietary Curtiss-Wright
7 Shot Peening - Theory Metal Fatigue/Failure Mechanism Fatigue/failures are typically caused by: Bending Load Torsional Load Axial Load Contact Failure (Pitting, Fretting, Galling, Spalling) Corrosion Failure (SCC, Intergr. Corr., Corr. Fatigue) Thermal Load & Heat Effects (e.g. Welding, Grinding) Cavitation/Erosion (Wear) 7 October 20, 2015 Proprietary Curtiss-Wright
8 Shot Peening - Theory Fatigue Strength - MPa Fatigue Strength vs. Residual Stress (here: AISI 4340/1.6565/ 40NiCrMo6) Ref -9, 7th Edition Peak Residual Stress MPa 8 October 20, 2015 Proprietary Curtiss-Wright
9 Shot Peening - Theory How it works! s 0 smax s0 low magnitude tensile stress 9 October 20, 2015 Proprietary Curtiss-Wright
10 Shot Peening - Theory Resultant Distribution of Stress in a Shot Peened Beam with external Load applied Tension 0 Compression Applied Load Residual Stress Resultant Stress 10 October 20, 2015 Proprietary Curtiss-Wright
11 Shot Peening - Theory Fatigue Strength & Fatigue Life Normal Grinding and Shot Peening Fine Grinding Normal Grinding Improvement of S/N Curves by Grinding and Shot Peening on Automotive Gears 11 October 20, 2015 Proprietary Curtiss-Wright
12 Shot Peening - Theory Fatigue Life Improvements Shot Peening to Overcome Notch Sensitivity (High Stress) Radii 12 October 20, 2015 Proprietary Curtiss-Wright
13 Shot Peening - Theory Controlling the Process Media Intensity Coverage Equipment 13 October 20, 2015 Proprietary Curtiss-Wright
![Shot Peening - Reliability Relative tooth root bending fatigue [%] Controlling the](/docs-images/72/67143651/images/14-0.jpg "Process Average fatigue improvement by shot peening app. 40% (standard deviation app. 3%!")
14 Shot Peening - Reliability Relative tooth root bending fatigue [%] Controlling the Process Average fatigue improvement by shot peening app. 40% (standard deviation app. 3%!!) SAME gear design (m 5) SAME manufacturing SAME pre-treatment SAME Shot Peening SAME Fatigue Testing different ZF internal & external shot peening locations Controlled Shot Peening provides Consistent & Reliable Improvements! Source: Alfred Sollich, Kugelstrahlen erhöht die Schwingfestigkeit von Verzahnung, März October 20, 2015 Proprietary Curtiss-Wright
15 Shot Peening - Specifications Controlling the Process Specifications SAE AMS2430 (Aerospace) SAE J2441 (Automotive/Industrial) 15 October 20, 2015 Proprietary Curtiss-Wright
16 Shot Peening - Gears Applications Gears Pitting Tooth root bending fatigue 16 October 20, 2015 Proprietary Curtiss-Wright
17 Shot Peening - Gears Effects of Shot Peening on gears: + Close surface residual compressive stresses ses(x) + Reduction of retained Austenite + Strain hardening (dislocation density) + Compensating the detrimental effect of the oxidation layer (carburisation process) -/+ Surface roughness Increase of Fatigue Strength 17 October 20, 2015 Proprietary Curtiss-Wright
18 Residual Stress (MPa) Shot Peening - Gears With Shot Peening Without Shot Peening Depth - micron 0 degrees 90 degrees Residual Stress - As Carburised Material 20MnCr5-8 Module Gear 18 October 20, 2015 Proprietary Curtiss-Wright
19 Shot Peening - Gears As ground Pressured air s/p Wheel s/p No failure 19 October 20, 2015 Proprietary Curtiss-Wright
20 Shot Peening - Gears As ground Shot peened No failure 20 October 20, 2015 Proprietary Curtiss-Wright
21 Shot Peening - Gears 21 October 20, 2015 Proprietary Curtiss-Wright
22 Shot Peening Gears (Trucks and Off-Road Machines) 22 October 20, 2015 Proprietary Curtiss-Wright
23 Dual Peening Process Effect of Dual Peen Process Metal Improvement Company Shot Peening Applications 9th Edition 23 October 20, 2015 Proprietary Curtiss-Wright
24 Dual Peening Process Planetary Gears Material ZF7B Dual Shot Peening (2 different shot 2 different intensities) Tooth root grounded + dual shot peening Blasted (cleaned) + dual shot peening Tooth root grounded + single shot peening Dual shot peening Single shot peening No shot peening Source: Relative Fatigue Strength [%] Alfred Sollich, Kugelstrahlen erhöht die Schwingfestigkeit von Verzahnung, März October 20, 2015 Proprietary Curtiss-Wright
25 Shot Peening + Isotropic Finishing Applications C.A.S.E. Isotropic Super Finishing As Ground Shot Peened Superfinished Material: EN36 Case Carburised (58-60Rc) CASE: Shot Peening + Superfinishing 25 October 20, 2015 Proprietary Curtiss-Wright
26 Shot Peening Gears/Pitting Macro-Pitting/Micro-Pitting 26 October 20, 2015 Proprietary Curtiss-Wright
27 Shot Peening Gears/Pitting Superimposed forces and material stresses at the contact areas of gear flanks 27 October 20, 2015 Proprietary Curtiss-Wright
28 Shot Peening Gears/Pitting Effect of Shot Peening ONLY! As ground Shot peened No failure 28 October 20, 2015 Proprietary Curtiss-Wright
29 Shot Peening Gears/Pitting C.A.S.E. Chemical Assisted Surface Engineering Improving Flank Failures Shot Peen + Superfinish (CASE) Macro Pitting - Surface/Contact Fatigue Micro Pitting Surface Roughness Relate Creates an Isotropic Surface Finishing Proportionally removes surface asperities Lubricant retentative surface 29 October 20, 2015 Proprietary Curtiss-Wright
30 Shot Peening Gears/Pitting C.A.S.E. Chemical Assisted Surface Engineering Before CASE After CASE Benefits - Lower Roughness values - No sharp points to break lubricant film - Retain valleys for lubricant film integrity - Removal of point to point contact - Both Macro and Micro pitting resistance is improved 30 October 20, 2015 Proprietary Curtiss-Wright
31 Shot Peening Gears/Pitting Comparison: No treatment / C.A.S.E. / ISF only SP + ISF ISF only 31 October 20, 2015 Proprietary Curtiss-Wright
32 Shot Peening Gears/Pitting C.A.S.E. Chemical Assisted Surface Engineering 32 October 20, 2015 Proprietary Curtiss-Wright
33 Shot Peening Gears/Pitting Application: Automotive/Motorsport Machining state Ra [µm] * As ground 0.45 Shot Peened 0.60 C.A.S.E *Sample values 33 October 20, 2015 Proprietary Curtiss-Wright
34 Shot Peening Gears/Pitting Application: Industrial Machining state Ra [µm] * As ground 0.50 Shot Peened n/a C.A.S.E * Sample values 34 October 20, 2015 Proprietary Curtiss-Wright
![state Ra [µm] * As](/docs-images/72/67143651/images/35-3.jpg "ground 0.")
35 Shot Peening Gears/Pitting Application: Wind Energy Machining state Ra [µm] * As ground 0.46 Shot Peened n/a C.A.S.E * Sample values 35 October 20, 2015 Proprietary Curtiss-Wright
36 Shot Peening Gears/Pitting C.A.S.E. Benefits Surface reduction to mirror like finishes Reduced manufacturing times and production costs Finishes suitable for microbiological cleansing and sterilisation Optimum surface roughness and stress characteristics Reduced contact/surface fatigue Increased lubrication retention and heat transfer Good rounding ability to sharp edges for ease of handling and assembly Reduced power loss Reduction in lubricant temperature (minus 10-20C) Reduced transmission noise 36 October 20, 2015 Proprietary Curtiss-Wright
37 Shot-/Laser Peening - Summary Summary CWST Services for/against: o o Metal Fatigue Bending Fatigue Torsional Fatigue Axial Fatigue Fretting Fatigue Contact Fatigue (Pitting) Corrosion Fatigue Shot Peen Forming e.g. Aircraft Components Correction of Distortion 37 October 20, 2015 Proprietary Curtiss-Wright o o Corrosion Stress Corrosion Cracking Sulfide Stress Cracking Intergranular corrosion Corrosion Fatigue Further Applications Work Hardening Surface Texturizing (PEENTEX) Chrome Plating/Thermal Spray Welding Galling CASE (SP + Superfinishing)
38 CWST - Information Further information: This and much more information available as PDF download from our Web Site 38 October 20, 2015 Proprietary Curtiss-Wright
39 Metal Improvement Company Westerhaar Wickede - Germany jochen.fuhr@cwst.com 39 October 20, 2015 Proprietary Curtiss-Wright
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