HIP diffusion bonding for gear materials

Mechanical actuators used on aircraft flight control systems contain highly stressed gears which are made from low alloy steels; either through or surface hardened. Corrosion protection has traditionally been provided by cadmium plating. Conventional stainless steels, even when given surface treatments do not provide the necessary strength, wear and corrosion properties for such gears. HIP processing has been used on cobalt based alloy powders as a new approach to produce gears for mechanical and corrosion testing. The technology has been used both to consolidate the powder and HIP diffusion bond the alloy to conventional stainless steels. The microstructure and properties of the consolidated alloy are presented together with preliminary results from component testing. The diffusion bonding route has produced gears which have much better wear and corrosion resistance than conventional steel gears whilst retaining equivalent fatigue properties. The economics of the process are discussed together with the concept of using the HIP process to shape as well as consolidate the material.