KSC Engineering Directorate

Materials Science Division

Development of HVOF
Superfinishing Spec

Development of Grinding Spec for

High Strength Steel and Cr Plate

Jon L. Devereaux
ASETS Defense ’11 NASA – KSC
New Orleans, LA February 10, 2011
 KSC Engineering Directorate High Strength Steel & Cr Grinding Spec
Materials Science Division

• Development of High Strength Steel & Chrome Plating 
Grinding Specification
• Draft AMEC – 08AA 
• Low Stress Grinding of High Strength Steel Parts Heat 
Treated to 180 KSI or Over, and Low Stress Grinding of 
Chrome Plating Applied to High Strength Steel Parts 
Heat Treated to 180 KSI or Over
• This Grinding Specification provides an option or an 
alternative to MIL‐STD‐866 which is no longer active for 
new design
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 KSC Engineering Directorate High Strength Steel & Cr Grinding Spec
Materials Science Division

• Barkhausen Noise or “Rollscan” Inspection  

• Barkhausen noise detects changes in magnetic domains 
within the material when subjected to an alternating 
magnetic field, applied by a probe at the surface.

• This technique is very sensitive to localized changes in 
microstructure/hardness and residual stress gradients. 

• Barkhausen Noise Inspection (BNI) procedure is covered in 
Aerospace Recommended Practice ‐ ARP 4462, LGPS 3001 
(for Goodrich) and BAC 5653 (for Boeing parts).

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 KSC Engineering Directorate High Strength Steel & Cr Grinding Spec
Materials Science Division

• The BNI (Barkhausen requirement), for first article 
inspection may force some facilities to request 
assistance (although ARP 4462 published in 1991). 
• Possibly there should be periodic workshops offered 
on this subject (BNI) for both demonstration and 
discussion of experiences and approaches. 
• For example, at the various conferences or meetings 
where grinding of high strength steel components or 
grinding of chrome plating on HSS is of interest

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 KSC Engineering Directorate High Strength Steel & Cr Grinding Spec
Materials Science Division

Alloys Strengthening  Tempering  Grind burn detection

Phase Temperature
Quench & Temper Epsilon Carbide  200 to 500°F Nital etch; reveals 
(Fe2C) dissolved epsilon carbide 
(4340, 9310, 300M, etc.) region or austenitized 
region; fresh martensite
Precipitation Hardening  M2C (M: V, Mo,  875 to 1150°F Barkhausen; corrosion 
& PH SS Cr) resistance of high‐alloy 
Eta [Ni3(Ti,Al)] and stainless steels either 
(Ferrium S53,  take too long or will not 
AerMet 100,  respond to nital etch (in 
Ferrium M54, MLX‐17,  the case of stainless 
Custom 465, S240,       steels, passivation is 
PH 13‐8Mo, 17‐4PH,   usually completed in 50% 
15‐5PH, etc.) nitric acid); Barkhuasen is 
a form of magnetic 
inspection
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 KSC Engineering Directorate High Strength Steel & Cr Grinding Spec
Materials Science Division

• Quenched and tempered, low alloy, high strength (i.e. 
180 KSI UTS and above), martensitic steels (e.g. 4130, 
4330V, 4340, 9310, 300M, etc…)  are more susceptible 
to grinding burn.
• Grinding wheel speed should be limited to 4,000  SFPM.
• Some precipitation hardening alloys (e.g. Ferrium S53, 
AerMet 100/310/340, Custom 455/465, MLX‐17, and 
others, including the majority of PH stainless grades    
PH 13‐8Mo, 17‐4PH, 15‐5PH, etc.) may achieve high 
integrity ground surfaces using higher wheel speeds 
(e.g. 6,500 SFPM).
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 KSC Engineering Directorate High Strength Steel & Cr Grinding Spec
Materials Science Division

Low Stress Grinding Specification     
for Steel & Chrome Plating        
Published in August 2010              
as  AMS 2453

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 KSC Engineering Directorate HVOF Superfinishing Spec
Materials Science Division

• Development of HVOF Superfinishing Specification

• The NASA Technical Standards Program (NTSP) is

sponsored by the Office of the Chief Engineer
(OCE).

• The primary mission is the enhancement of

NASA's engineering capabilities by providing
technical standards required to meet the needs of
the Agency.

• The NTSP provides these standards to the Agency

by doing the following:
– supporting the development of non-Government
Voluntary Consensus Standard (VCS) Industry
Standards 8
 KSC Engineering Directorate HVOF Superfinishing Spec
Materials Science Division

• NASA is currently operating under CR for FY-11

• Technical Standards Budget supporting the

development of non-Government VCS Industry
Standards
– FY-10 SLIM
– FY-11 NONE

• ESTCP is providing support to attend SAE Technical 
Committee Meetings for completion of the 
Superfinishing Document and Publication as an 
AMS  – Aerospace Material Specification.
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 KSC Engineering Directorate HVOF Superfinishing Spec
Materials Science Division

• Development of HVOF Superfinishing Specification
• Draft AMEC – 07AC 
• To be published as AMS Specification
• Superfinishing of HVOF Applied Tungsten Carbide 
Thermal Spray Coatings
• Oscillating Stone Method
• Tape or Abrasive Film Method
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KSC Engineering Directorate HVOF Superfinishing Spec
Materials Science Division

• Oscillating Stone Method

– Type and grit sizes of abrasives to be used
– Cutting fluids/coolants
– Workpiece surface speeds
– Contact pressure for stones
– Traverse rates
– Stone oscillation rates
– Polishing with diamond paste

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KSC Engineering Directorate HVOF Superfinishing Spec
Materials Science Division

• Tape or Abrasive Film Method

– Microfinishing Film
– Lapping Film
– Type and grit sizes of abrasives to be used
– Cutting Fluids/Coolants
– Workpiece surface speeds
– Film index rates
– Contact pressure for film superfinishing
– Traverse rates
– Film oscillation frequency

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 KSC Engineering Directorate HVOF Superfinishing Spec
Materials Science Division

• Requirements for surface finish parameters after

superfinishing

• April 24-25, 2006 SAE A-5 Landing Gear Meeting in

Sacramento, CA

• To discuss inconsistensies in surface finish

parameters used to characterize a surface finish

• Need for more standardized parameters and

terminology to characterize the required surface
finish depending on the application

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 KSC Engineering Directorate HVOF Superfinishing Spec
Materials Science Division

• ARP 5935 (published 2007) Use of HVOF Thermal

Spray Coatings for Hard Chrome Replacement in
Landing Gear Applications

– Type 1 are surfaces that require seals/hydraulic fluid/sliding

member
– Examples include Landing Gear Strut and Actuator Piston
Barrels
– To maximize seal life, Superfinishing is required
– Recommended surface finish parameters include:
– Ra 4 µinch or better
– Rz 40 µinch max (avg. peak-to-valley)
– Rp 8 µinch max (mean line to highest peak)
– Rmr 70 to 90% @ Co = 5% and C1 = 0.25Rz
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 KSC Engineering Directorate HVOF Superfinishing Spec
Materials Science Division

• Use of HVOF Thermal Spray Coatings for Hard

Chrome Replacement in Other Applications
• Hydraulic Actuator Piston Rods

– Applications with seals/hydraulic fluid/sliding member

– Hydraulic Actuator Piston Rods
– To maximize seal life, Superfinishing is required
– Recommended surface finish parameters may include:
– Ra 4 µinch or better
– Rz 40 µinch max (avg. peak-to-valley)
– Rp 8 µinch max (mean line to highest peak)
– Rmr 70 to 95% @ Co = 5% and C1 = 0.25Rz

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 KSC Engineering Directorate HVOF Superfinishing Spec
Materials Science Division

Superfinishing Specification has been approved by SAE’s 
AMEC – Aerospace Metals Engineering Committee
Completed 28‐Day ballot to SAE Committee B         
(Finishes & Processes) October 25, 2010
Comment Resolution currently in progress
9 Technical Comments
18 Editorial Comments
All but 1 Technical Comment has been resolved

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 KSC Engineering Directorate HVOF Superfinishing Spec
Materials Science Division

Document being prepared for 14‐Day Affirmation ballot 
to Committee B with Info to AMEC
To affirm T‐Changes from 28‐Day ballot
SAE AMS Metals Division Spring Meeting to be held 
March 27 – 31 in Clearwater, FL
Committee B to vote on unresolved T‐Comment
Check for Pullouts & Microcracking after completion of 
Superfinishing Process
AMEC found it to be non‐persuasive
AMS 2449 Grinding Spec for HVOF applied Tungsten 
Carbide coatings calls out Fluorescent Penetrant 
Inspection and 40X Magnification visual after grinding 17
 KSC Engineering Directorate HVOF Superfinishing Spec
Materials Science Division

Title Changed To:  Superfinishing of HVOF Applied               
Tungsten Carbide Coatings

Title changed to be less restrictive  ‐
“applied to High Strength Steels” deleted from title to 
alloy for superfinishing of coatings applied to Titanium

Reference source handbook and website link added to 
Section 8 for additional information on surface finish 
parameters, terms, & sketches

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KSC Engineering Directorate
Materials Science Division

Questions ? ? ?

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KSC Engineering Directorate HVOF Superfinishing Spec
Materials Science Division

Backup Slides

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 KSC Engineering Directorate HVOF Superfinishing Spec
Materials Science Division

• Bearing Ratio or Material Ratio

• Rmr 70 to 90% @ Co = 5% and C1 = 0.25Rz

• The ratio of material to air in a horizontal slice through the surface
profile expressed as a percentage.

• The zero percent or reference line for the bearing ratio is located
at the top of the highest peak within the evaluated profile.

• The bearing ratio may be measured at different depths (e.g. C1,

C2, C3) through the profile and varies with slice depth.

• To avoid dependence of the bearing (or material) ratio on a single

peak, a reference line is selected to shift the reference line below
the highest profile peak.

• The reference line is specified as a bearing (material) ratio

percentage.
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 KSC Engineering Directorate HVOF Superfinishing Spec
Materials Science Division

• Specifying a five percent reference line indicates that the

top five percent of the profile is not included in the bearing
ratio calculation.

• A reference line of Cref = 5% (also referred to as Co= 5%)

is commonly used for applications covered by this
specification.

• A slice depth of C1= 0.25Rz is commonly used as the slice

depth at which to measure bearing ratio for applications
covered by this specification.

• Other slice depths commonly used include 6, 8, & 10 µinch

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