Lightweight High Performance Titanium Sliding Contact Bearing

The invention relates to lightweight high performance bearings for use in aircraft in which titanium coated with chromium oxide is employed as one of the members used in sliding contact with a copper second member.

Prior art sliding contact bearings in aircraft have presented excessive weight and poor overall performance problems. Sliding bearings used in landing gear, for example, are relatively large and take a substantial load. Weight reduction in such bearings can only be achieved by substituting lower density or more efficient materials, that is, smaller bearing envelopes.

Many of the present bearings are made of steel and are very heavy compared with titanium, for example. Titanium is a very desirable metal because of its lightweight but it had not been used successfully in metal-to-metal sliding surface contact due to severe galling problems. In the prior art no coatings or lubricants had been developed to solve this metal-to-metal bearing problem.

Chromium oxide coating has been used on titanium spherical bearings with a Teflon coated race in hydrofoil applications and in the wing pivot bearing on an F-14 airplane. Although chromium oxide is known to be brittle, it has been found to be satisfactory as a coating and used in a Teflon race because the lubrication is permanent and in situations where there are no significant shock loads which would tend to chip the brittle chromium oxide. That is, there is no risk of losing lubrication with a Teflon race but in situations where a bearing could become grease starved or subject to shock loads, it was considered that chromium oxide would not be a satisfactory coating for titanium or other metals when used against a metal race, including copper or copper alloys. Landing gear trunnion bearings on a large airplane obviously take significant shock loads and, therefore, it was considered that chromium oxide would be too brittle to be used as a coating on a titanium bearing, the titanium being considered primarily as a weight saving material in contrast to the steel bearings being used.

A search of the patent literature discloses the use of titanium bearings. For example, U.S. Pat. No. 3,724,919 teaches the use of a titanium allow for a low friction, seawater-lubricated bearing in conjunction with a high density polyethylene race, but did not suggest the use of chromium oxide as a coating for titanium.

U.S. Pat. Nos. 4,309,474; 4,043,623 and British Pat. No. 1,023,007 teach the use of chromium oxide as a surface coating for bearing surfaces but titanium was not one of the alloys included in these patents.

The following patents disclose subject matter of general interest:

U.S. Pat. No. 2,934,480 Slomin,

U.S. Pat. No. 3,143,383 Bamberger et al,

U.S. Pat. No. 3,297,552 Gisser et al,

U.S. Pat. No. 3,418,028 Watson et al,

U.S. Pat. No. 3,391,287 Vogt,

No. 541,580 Great Britain.

The invention is the combination of a sliding contact bearing and race in which the bearing or race may be made of titanium or a titanium alloy coated with plasma-sprayed chromium oxide, Cr.sub.2 O.sub.3, and in which the other member may be made of copper or a copper alloy. In the combination the chromium oxide on the titanium slides against the copper surface generally in the form of a journal bearing arrangement.

Bearings, according to the invention, are typically ring-shaped and comprised of a titanium alloy and having an outer circumferential bearing surface coated with chromium oxide. The race is also generally ring-shaped and is substantially comprised of copper or a copper alloy. The race has an inner generally circumferential surface complementary to the coated surface of the bearing and the bearing is fitted within the race so that the complementary surfaces are positioned for relative sliding-rotation so that the chromium oxide makes bearing contact with the inner circumferential copper, the copper and chromium oxide being lubricated. The bearing and complementary surface in the race may be cylindrical or may be spherical.

It has been found that the use of bearings, according to the invention, in a main landing gear forward trunnion support structure in a large aircraft permits about a 40% weight savings in comparison with steel bearings.

Further advantages of the invention may be brought out in the following part of the specification wherein small details have been described for the competence of the disclosure without intending to limit the scope of the invention which is set forth in the appended claims.

Referring to the accompanying drawings which are for illustrative purposes:

FIG. 1 is a cutaway pictorial view of a spherical bearing and race according to the invention;

FIG. 2 is an exploded view of the bearing and race shown in FIG. 1;

FIG. 3 is a fragmentary view of a plasma-sprayed chromium oxide coating on a titanium alloy spherical bearing, as shown in FIG. 2, magnified 500 times;

FIG. 4 is a cutaway view of a cylindrical bearing and race according to the invention;

FIG. 5 is a cross-sectional view of a cylindrical bearing and race in which the race is made of titanium and has its inner circumferential surface coated with chromium oxide and the bearing is made of copper; and

FIG. 6 is a cross-sectional view of a spherical bearing in which the race is made of titanium and has its inner circumferential surface coated with chromium oxide and the bearing is made of a copper alloy.

Referring again to the drawings, there are shown in FIGS. 1 and 2 cutaway views of slotted-entry, spherical sliding ball bearings 10 and complementary races 12. The bearings 10 are ring-shaped and are made of titanium or of a titanium alloy. They have an outer circumferential surface 14 coated with chromium oxide 16. As shown in Fig. 1, the bearing is fitted within the race 12 which has an inner circumferential surface 18, complementary to the circumferential surface 16 on the bearing.

The outer surface 20 of the race is generally cylindrical and has an annular groove 22 through which extend a plurality of grease passages 24, the passages terminating inwardly in an inner circumferential groove 26 for supplying a continuous coating of grease to the interior of the race at 32 and to the outer circumferential surface of the bearing at 30. The race 12 is made of copper or a copper alloy.

For insertion of the bearing into the race on one side 34 of the race, there are diametrically-spaced slots or grooves 36 and 38, formed so as to be wider than the bearing along its center line, the slots having their outer bottoms 40 and 42 spaced diametrically apart so that distance between them at the race side 34 is greater than the largest diameter of the spherical circumference of the bearing. The slots decrease in depth as they extend inwardly into the race along the direction of its centerline and terminate at the groove 24 so that the distance of the groove 24 is greater from the side 34 than the groove 24 is for the opposite side of the race. Thus, to insert the bearing into the slot, it is positioned so that it can be moved into the slots, that is, with a plane through the bearing and perpendicular to its centerline, positioned perpendicular to a plane perpendicular to the centerline of the race. After the bearing is thus moved inwardly into the race, until it is stopped by the circumferential surface of the bearing spaced away from the slots, the bearing may be then rotated in the race 90.degree., and it is then held within the bearing by the smaller diameter edges along the opposite flat sides of the race. Inner circumferential surface 40 of the bearing is adapted to be fitted on a journal for rotation therewith or relative thereto.

In FIG. 3 there is a fragmentary cross-sectional view of a bearing 10 made of titanium or a titanium alloy on which a coating of chromium oxide 14 has been plasma-sprayed and which is shown to be mechanically bonded to the titanium. The view is magnified 500 times and the dark spots in the chromium oxide are small holes.

The bearing may be titanium or any common titanium base alloy in which the titanium weight is at least 70%. Well-known titanium alloys such as the following have been used, according to the invention, the amounts being shown by weight:

about 85% Ti, about 10% V, about 2% Fe, and about 3% Al;

about 90% Ti, about 6% Al, and about 4% V; and

about 86% Ti, about 6% Al, about 6% V, and about 2% Sn.

In the race pure copper or any copper base alloy in which the copper weight is at least 80% can be used. In addition, the race can be made of aluminum bronze containing by weight:

about 91% Cu, about 7% Al, and about 2% Fe;

aluminum nickel bronze containing by weight about 81% to 88% Cu, about 9% to 15% Al, and about 4% Ni; and

beryllium-copper containing by weight about 98% Cu, about 2% Be, and traces of Fe and Ni.

In FIG. 4 a cylindrical race 50 made of copper or a copper alloy has a cylindrical journal bearing 52 made of titanium or a titanium alloy 54 and has a plasma-sprayed chromium oxide coating 56. The cylindrical coating 56 is adapted to be slidably engaged in the inner cylindrical surface 58 of the race, the bearing having an inner cylindrical surface 60 adapted to fitted on a journal. The inner surface of the race and the outer surface of the bearing are grease lubricated by any conventional manner, as shown in FIGS. 1 and 2.

In FIG. 5 an inner cylindrical bearing 64 is made of copper or a copper alloy, and an outer race 66 is made of titanium or a titanium alloy and has its inner cylindrical surface plasma-sprayed with chromium oxide to form a coating 68 for slidable and rotational contact with the bearing 64.

In FIG. 6 still another embodiment of the invention is shown in which a copper or copper alloy bearing 70 has an outer spherical circumferential surface 72 in sliding bearing contact with a complementary internal spherical surface 74 formed of a coating of chromium oxide plasma-sprayed on an inner spherical surface 76 of a titanium or titanium alloy race 78.

The alternate embodiments in FIGS. 5 and 6 are grease lubricated between the bearing and race and the copper and titanium alloys may be the same as those described with respect to FIGS. 1 and 2.

One inch diameter bore, high-strength Ti alloy spherical balls, namely, 85Ti-10V-2Fe-3Al (numbers indicate percentages by weight), were fabricated and installed in slotted-entry Be-Cu races, as seen in FIGS. 1 and 2. These bearings were tested in dynamic cyclic wear tests and fatigue tests to simulate the jarring action or shock loading a bearing may experience. Chromium plated stainless steel spherical balls, of the same shape as shown in FIGS. 1 and 2, were tested in the same type of Be-Cu races, which are a more or less standard aircraft bearing combination.

Under severe conditions, that is, grease-starved condition or ingestion of contaminated grease, the chromium oxide on the Ti balls, according to the invention, were much superior to the stainless steel bearings, as indicated in Table 1 below.

An outstanding result occurred in a test where the bearing was lubricated at the start of a dynamic cyclic wear test with no additional grease added through the duration of the test of 100,000 cycles. A cycle generally consists of a plus and minus 20.degree. oscillation at various bearing stresses starting with 6 ksi., which are typical service conditions for a forward trunnion bearing on a landing gear of a large commercial airplane. The torque had reached a maximum and was decreasing at the conclusion of the test. This data, and examination of the bearing, indicating that the bearing was still functional after 100,000 cycles.

The dynamic cyclic wear tests were conducted at 15 cycles/minute with a plus and minus 20.degree. oscillation, as stated. The required grease lubrication cycles were established by monitoring the torque and temperature of the bearings during initial testings. Tests were performed using clean and contaminated MIL-G-23827 grease.

The tension-compression fatigue tests assess the ability of brittle coatings to withstand some of the jarring action that may be encountered by spherical bearings. The test loads started with those experienced by typical trunnion support bearings and then were raised to higher stresses.

Four titanium bearings, according to the invention, plasma-sprayed with chromium oxide coating and four 15-5 PH steel bearings, chromium plated, were tested. The test results are shown in Table I.

Bearing No. 1 was tested to 100,000 cycles at 6 ksi. bearing stress with no wear on the spherical ball and minimal wear on the race (periodic lubrication was performed every 900 cycles). The torque decreased over 50% from the start to the end of the test, indicating that no seizing was occurring. Bearing No. 2 was tested to 1720 cycles under the same conditions as above. The bearing stress was then increased 50% to 9 ksi. The testing result after 100,000 cycles was the same as for number 1, that is, no wear on the ball and minimal wear on the race. The torque this time decreased from 2925 to 1027 in.-lb. from the beginning to the end of the test.

The number I chromium-plated 15-5 PH steel bearing was tested at 9 ksi. with the same results. It started out with a lower torque value, 2002 in.-lb., but after 100,000 cycles had the same torque value as the titanium number 2 with chromium oxide coating. In comparing the chromium oxide coated titanium bearing, number 2, with the number I steel bearing, there was no wear on the former and there was minimal wear on its race but on the chromium plated steel bearing there was copper pick-up on the chromium plating.

In order to examine the effect of contaminants on the chromium oxide coating, the number 3 titanium bearing was subjected to the same test conditions, as above, at 6 ksi. with contamination introduced to simulate particles ingestion possible in actual service conditions. The bearing was lubricated normally every 900 cycles, but on every fourth lubrication cycle it was lubricated with grease containing 10% by volume of road dust per MIL-E-5272. In addition there was a constant drip of deicing fluid per MIL-A-8243 diluted with 50% water. The result for the number 3 bearing was the same as for the number 1 and 2 without contaminant, no wear on the ball, except that the final torque after the test was about 488 in.-lb. The steel bearings II and III were tested to 100,000 cycles in the same manner. They had somewhat higher torque at the end, 735 and 754 in.-lb. The chromium plate on the steel balls was torn in spots, and extensive wear of the races was observed.

The above titanium bearings with the plasma-sprayed chromium oxide coating were rotated to load the opposite ball and race surfaces. In the Table they are marked 1*, 2*, and 3*. Bearing test No. 1* was the same as for No. 1 to verify the excellent results from the previous contamination test. The results were the same as for the first test but the torque values were lower as shown on the Table. The bearing stress for No. 2* was increased to 13 ksi., the maximum allowable for grease lubricated bearings. The bearing was lubricated with clean grease every 900 cycles. The temperature build-up resulting from the friction between the ball and race with this loading was sufficient to discolor the outer race. After 100,000 cycles no noticeable wear was observed on the ball. In the test of No. 3* the loading was dropped back to 6 ksi., but the ball was only lubricated at the start of the test. No significant wear was observed on the ball after 100,000 cycles but minor pitting of the coating had occurred.

The chromium plated stainless steel bearings did not perform as well as the plasma-sprayed chromium oxide titanium balls under the more severe test conditions. Two contaminated grease tests, bearings II and III, survived 100,000 cycles but the chromium plating was worn off in areas. The chromium plating was also worn through extensively on test bearing No. IV which was only lubricated at the start of the test comparable to titanium bearing No. 3*. The test was stopped after about 80,000 cycles as the high torque was wearing out the drive sockets of the test machine. The maximum torque was about 86% higher than the flame-sprayed chromium oxide for the comparable test for No. 3*.

The durability of the brittle ceramic chromium oxide coating was a matter of concern before testing. One titanium ball, No. 4, was subjected to tension-compression fatigue tests to observe its behavior under this jarring action. The starting point stress cycle was +5 to -1 ksi., which is the maximum stress that the candidate trunnion bearing would experience. All testing was done at 30 H.sub.Z using sine-wave loading. The bearings were inspected after 150,000 cycles of test and showed no visible damage. Then the loads were incrementally increased by 50% and tested another 150,000 cycles. Testing was terminated at +20 ksi. to -4 ksi. with no damage. After that, the No. 4 ball was dynamic cyclic wear tested at the same condition as the No. 1 to 100,000 cycles. There was no wear found on the titanium balls.

In FIG. 3 the plasma-sprayed chromium oxide is on an 85Ti-10V-2Fe-3Al alloy ball. The thickness of the coating is about 120-170 microns. No evidence of oxygen diffusion in the base metal was found. The tests are compiled in Table I below.

The plasma-sprayed chromium oxide coating on titanium provided a very good wear resistance. The testing results obtained were as good as or better than those obtained from chromium-plated 15-5 PH spherical bearings. The plasma-sprayed chromium oxide bearings were superior to the chromium plated 15-5 PH bearings in the contamination test and the test where the bearing was lubricated only at the start of the test. No damage was evident on the titanium bearing, but the chromium plate was worn through in areas on the steel ball.

A fatigue test made after those shown in Table I of a titanium bearing, according to the invention, on a main landing gear forward trunnion support structure on a large airplane demonstrated the viability of using titanium spherical bearings with a plasma-sprayed chromium oxide coating in air frame applications. Use of titanium in place of steel would permit about a 40% weight savings.

The invention and its attendant advantages will be understood from the foregoing description and it will be apparent that various changes made be made in the form, construction, and arrangements of the parts of the invention without departing from the spirit and scope thereof or sacrificing its material advantages, the arrangements hereinbefore described being merely by way of example. We do not wish to be restricted to the specific forms shown or uses mentioned except as defined in the accompanying claims.