SBIR-STTR Award

New, patented highly advanced thermo-chemical processing (LINTERPROCESS) and heat-treatment (LINHEAT) technologies, presented in this proposal, were developed by SANOVA to address and solve metal and alloy performance issues described in this SBIR. Based on these innovative technologies, SANOVA will design treatment process which creates highly durable protective surface layers on components made from Pyrowear 675 alloy with superior corrosion resistance and other strong mechanical properties. Pyrowear 675 is one of the more promising relatively new materials being studied for use in bearing and gear manufacturing. But achieving adequate corrosion resistance on the surface of this alloy, while maintaining required mechanical properties and microstructure, proved to be a formidable challenge for traditional heat-treatment technologies. SANOVAs LINTERPROCESS and LINHEAT technologies have a distinct advantage over traditional furnace-based treatment processes due to combination of specially generated and applied highly effective active media and precise control of treatment parameters, and are able to produce desired mechanical performance, microstructure and compression stresses of Pyrowear 675 surface layer, while keeping chromium levels adequate to exhibit strong corrosion resistance. LINTERPROCESS and LINHEAT technologies are unique and offer important performance advantages and cost savings over traditional heat-treatment technologies. They produce highest-quality results in shortest treatment durations.

Benefit:
SANOVA is confident, that acceptance of this proposal will result in development of highly effective and easily commercialized custom treatment technology for creation of highly corrosion resistant protective layers on drive train bearing and gear components made Pyrowear 675 alloy. Strong mechanical properties and desired microstructure will be achieved, including high hardness, high residual stresses and small-size grains, while ensuring superior corrosion resistance by retaining necessary chromium content. There are significant and wide-spread potential military and commercial uses for this technology in commercial and military aviation, automotive, rail, medical devices and other industries. In addition, ease of implementation and significant cost-effectiveness of SANOVA technology will result in dramatic cost savings in components and manufacturing processes worldwide, as significant cost savings as compared to traditional furnace-based heat treatment technologies, are realized. SANOVAs LINTERPROCESS and LIHEAT technologies are simple, inexpensive, while highly effective. They are completely user and environment-friendly and require far less space, maintenance and down-time. Overall economic impact from wide acceptance of new SANOVA treatment technologies will be in $Bs. Specific advantages of SANOVA technologies that result in significant savings in efficiency and cost are listed in the body of the proposal.

Keywords:
high hardness., high hardness., Corrosion Resistance, high residual stresses, chromium content, gears and bearings, thermo-chemical processing, traditional heat treatment, Pyrowear 675 steel

Main goal of this project is achievement of increased corrosion resistance of steel Pyrowear 675 with application of SANOVAs new patented LINCARBOHEAT-675 technology. Custom active medium and preliminary treatment protocol of LINCARBOHEAT-675 technology with resistive heating were developed during successful Phase I implementation using SANOVAs retrofitted LINTERLAB-R1 laboratory equipment. Resulting preliminary technology yielded significant efficiencies, as compared to traditional furnace processes. High accuracy in concentration and supply into the working chamber of custom active medium, together with precise control of treatment temperatures and durations of all processing steps, enabled SANOVA considerably shorten production time and generate significant savings in space, energy consumption and other operating costs. But most importantly, highly effective microstructure on steel Pyrowear 675 was achieved for superior corrosion resistance. Even better results are anticipated in Phase I Option with utilization of SANOVAs recently deployed laboratory equipment LINTERLAB-i2 equipped with such capabilities as high-efficiency induction heating and scanning/rotation of specimen - crucial for inexpensive and rapid creation of effective treatment protocol for treatment of test specimens and small components in Phase II. Development, testing, and subsequent demonstration of initial treatment process on real OEM gas turbine bearing component will be performed on SANOVAs retrofitted production prototype equipment LINCARB-1 during Phase II.

Benefit:
Principal benefit of developing custom LINCARBOHEAT-675 technology is creation of highly corrosion-resistant surface layer, optimum microstructure and properties of carburized and subsequently heat-treated case and core of steel Pyrowear 675, which enables its effective use in manufacturing of improved gas turbine bearings and other components for reliable operation in harsh marine environment. There are significant and wide-spread potential uses for these technologies in commercial and military aviation, automotive, rail, medical devices and other industries. In addition, ease of implementation and significant cost-effectiveness of SANOVA technology will result in dramatic cost savings in components and manufacturing processes worldwide, as significant cost savings as compared to traditional furnace-based heat treatment technologies, are realized. SANOVAs processing technology is simple, inexpensive, while highly effective. They are completely user and environment-friendly and require far less space, labor, energy, materials, maintenance and down-time. Overall economic impact from wide acceptance of new SANOVA treatment technologies will be in $Bs.

Keywords:
carbon content and chromium content, protective surface layer, High hardness, carburizing and heat treatment, LINCARBOHEAT-675 and LINCARB and LINHEAT technologies, gas turbine engine bearing and gears, Pyrowear 675 steel alloy, Corrosion and wear resistance