1

Kamatics Hydro Pintle Bearing Presentation

Kamatics CorporationPO Box 3Bloomfield CT. 06002(860) 243-9704www.kamatics.com

Revised 12/3/11

This document includes technical data as defined by ITAR 120.10 and is subject to export licensing requirements of the U.S. Department of State – prior written authorization is required for export or re-export

Kaman Corporation

Kaman IndustrialTechnologies

Distribution

Aerostructures Precision Products Helicopters Kaman SpecialtyBearings

Aerospace

KAMANCORPORATION

Kamatics

RWG Frankenjura

K-MAX

SH-2

Structural andIntegration

Subcontracting

Missile and Bomb Fuzing

Memory and Instrumentation

Major Structural Subcontracting -

Jacksonville

Kaman Corporation

Kaman Composites

Wichita, KS

Brookhouse, U.K.

Middletown & Orlando Brookhouse, U.K. & Wichita

Kamatics Seattle Office

Kamatics First Application in 19651st application in 1965 on the Servo Flap Bearing on the Kaman SH2 Helicopter

Original Bearings corroding, swelling and seizing in the marine and high humidity environment

Kaman engineering solves the problem using Carbon/Ceramic sphericals.

Kamatics is incorporated. KAron bearings developed shortly afterwards to solve bearing problems on aerospace, marine, nuclear and industrial applications

KAron Self Lubricating SystemsKAron is a homogeneous combination of a self adhering base polyester resin, Teflon and other fillers to enhance the liner performance under different load, temperature and coefficient of friction requirements. The KAron can be bonded to a wide variety of materials.

The base polyester resin is the main load carrying portion of the liner

The Teflon is the main ingredient for controlling the coefficient of friction

The proprietary fillers enhance the load and temperature capabilities

The higher the percentage resin the greater the load capacity

Teflon

Increasing the TFE content lowers the friction but also reduces the load capacity

Polyester Resin

Other Fillers

Specific fillers are used enhance specific characteristics of the liner

Adhesive

Friction

KAron BX

Ingredient &processimprovements

KAron Characteristics• Self-Lubricating (No maintenance required)• Homogenous - uniform wear rates & friction• 100% Bond, Non Peelable• Excellent fluid compatibility• Excellent abrasion resistance• Machinable (.005 to .040 depending on the substrate and operating loads)

• High Load Plus Excellent Anti Fretting properties • Does not swell or lose its hardness in fluids• Excellent wear rates • Grit resistance. The tight tolerances prevents large particles from entering system.• KAron hardness of RC90 M Scale limits embedability of fine particles • Thin KAron on Cu/Ni/Sn (Toughmet) or bronze alloys increases load capacity

KAron Bushing Advantages Specific liners for wide variety of applications. 100% Bond, Non peelable. Able to withstand

installation damage. KAron has a high load capacity so the reduced load area is not an issue

KAron is harder than most TFE liners, limited embedability means better wear resistance in a gritty environment.

Machineability, advantages with final installation. Ability to apply thin liner on Cu/Ni/Sn (Toughmet) or bronze alloys

The Journal Bearing Construction:

Oversize Blank, Bearing Surfaces Roughened and Cleaned KAron Applied Oversized and Cured 100% Bond Achieved Final Machining of KAron and Blank Optional Final Machining by Customer Oversize OD Available for Repairs

9

Machinable Liner Advantage

• It is Feasible for Back-to-Back Bushing Installations to be Machined After Assembly (Fabric Bearings Cannot be Machined)

• The Desired Running Clearance of .0005 - .002 is Feasible if the Bushings are Machined After Assembly

• Consider for Multiple Lug Installations for Size and Concentricity Control

Before Machining After Machining

KAron LinerSphericals

The injection of the liner into the cavity between the outer race and ball offers many advantages.

• There is no radial swaging pressure which eliminates the issues of over/under pressure possible when swaging the straight outer race over a spherical surface

• With the injection process the KAron bonds to the outer race and conforms to the ball leading to near perfect conformity

• The injection process enables the use of a cathedral cavity which in addition to the adhesion strength of the KAron creates both a bonded surface and a mechanical lock

• The final result is a free moving spherical with minimal clearances right off the production line

KRP Track Roller Advantages No Lubrication Stainless Steel construction Independent radial and axial load capacity Higher load capacity, load is distributed over 40% of

he bearing vs. line or ball contact Higher friction due to sliding vs. rolling but remains

constant for the life of the bearing. (Important to discuss with customer.)

KAron liner on OD of inner race and thrust surfaces

The Track Roller Bearing Construction:

No lubrication Uniform coefficient of friction Seals Independent radial and axial capacity Stainless steel construction Unique self-aligning feature reduces loads on the

track, prevents skidding

Self Aligning Roller

Cam Follower

Track Roller

Standard and Self Aligning Track RollersThe KAron liner system replaces the ball or needles in track rollers and ball bearings.

The Kamatics design is a sliding system versus a rolling system. While higher than a needle or ball bearing it remains constant for the life of the bearing

The Kamatics designs offers greater load carrying ability, an independent radial and axial capability and high misalignment capability

Unique DesignsSide Load Bumpers incorporated in the track roller

Self Aligning feature for track deflections.Operates Smoothly on Uneven or “Wavy”Tracks. Maintains Full Contact on Track

Eccentric Rollers for easier rigging and adjustments

Combination track slider

Large track rollers (36 inch diameter)

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KAron SpecialsCustomer Coated Components

Pre-KAron BlankExtra material on surfaces adjacent to Karon lined

KAron Coated BlankSurfaces adjacent to liner locations coatedto simplify process Finished Machined Part

KAron

15

10,00067

20,000138

30,000207

40,000276

50,000345

60,000414

10038

20093

300149

400204

500260

600316

700371

KAron BHigh Loads

3 Feet per Min..91 Meter per Min.

.10 COF KAron V

High Loads10 Feet per Min.

3.04 Meters per Min..075 COF

T87/T87SHigh TemperatureHigh Frequency50 Feet Per Min.

15.24 Meters per Min..10 COF

KAron VSLow Friction

Flight Control Applications10 Feet per M in.

3.04 M eters per M in.COF .04

Selected Kamatics Liner Systems

Temperature F - C

0

Dyn

amic

Loa

d PS

I- M

pa

The graphs shown indicate the pressure limits for the respective operating temperatures and are for re ference purposes only. Contact Kamatics for assistance in determining the proper liner taking into consideration the pressure , temperature and duty cycle .

16

0.01.02.03.04.05.06.07.08.09.10.11.12.13.14.15.16.17.18.19.20

2 4 6 8 10 12 14 16 18 20

KAron B

KAron V

KAron VS

0

Coefficient of FrictionKAron B, V and VS

Bushings and Sphericals

Coe

ffici

ent o

f Fri

ctio

nA

mbi

ent T

empe

ratu

re

Pressure KSI

The coefficient of friction data is a summury of many tests conducted by Kamatics and our customers. Variables such as contamination and temperature can effect the friction for a given application. Please contact Kamatics for more detailed information For track rollers a more appropiate measurement is the "force to roll" versus the coefficient of friction. Please contact Kamatics for more detailed information.

Range of Friction for a Greased M/M Bearing

-John Day Dynamic Run-Friction Factor During Blade Closing

0

0.02

0.04

0.06

0.08

0.1

0.12

0.14

0 2 4 6 8 10 12 14 16

Blade Angle (Deg)

Fric

tion

Fact

or

JD U8 (11/19/2008) JD U9 (11/19/2008) JD U16 (11/19/2008)JD U8 (03/19/1980) JD U9 (03/26/1980) JD U16 (03/27/1980)

KAron V Bushings

Existing Bronze Bushings

Kaplan Turbine Hub

Friction Comparison

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Dirty Contaminated EnvironmentOperational Experience and Successful Testing

Kamatics Testing: Silted Water

Helicopters Controls: Fine Sand Landing Craft: Salt Water/Sand

Pintle Test: Brackish/Rust Filled Water

AS81820AS81934 BMS3-39

High LoadSlow Speed Good Anti FrettingFriction .10

Aircraft Flaps/SlatsLanding gear Highly loaded LinkagesJet engine controls

Dynamic Operating Pressures to 50,000 psi (345 MPa).Velocities to 3 fpm (1 M/min.)Temp: –100° to 400° F(-73° to >205°C)

MachineableDensity: 1.51 gm/ccRockwell M 95Thickness Range .005 - .060”(.127 – 1.5 mm)

KAron B

Typical ApplicationsCharacteristicsPhysical PropertiesLiner

Aircraft Track Rollers.Marine ApplicationsHydro TurbinesNavigation GatesMotor SportsIndustrial

Dynamic Pressures: 40,000 psi (276 MPa)Velocities: 0 fpm (3 M/min.)Temp: –100° to 300° F (-73° to 150°C)Thickness: .005 to .040”(0.127 to 1.5 mm)COF: +68°F (20°C) 0.03 to 0.08COF: -65°F (-54°C) 0.1 to 0.18

KAron V

Qualified to AS8943High Loads

Moderate Speeds25% Lower Friction

than KAron B

Typical ApplicationsCharacteristicsLiner

Flight ControlsAileronsRuddersElevatorsSpoilersFlaps/SlatsTrack RollersSphericalsLanding GearSteering SystemsHelicopterSwashplate/Gimbal

Dynamic: Pressures to 15,000 psi (103 MPa)Velocities: to 10 fpm (3 M/min.)Excellent low temperature frictionTemp Range –100° to 300° F (-73° to 150°C)Thickness Range .005 - .040”(0.127– 1.5 mm)COF +68°F (20°C) – 0.02 to 0.05COF -65°F (-54°C) – 0.08 to 0.15

KAron VS

EN4538/4539/4540Low Friction @ Low Temp

Lowest Friction of the KAron Liner Systems

Typical ApplicationsCharacteristicsLiner

Hydrofoil Test 30 Years Ago

KAron V Bearings Selected for: Inboard & Outboard Trunnion Forward and Aft Flap Steering Actuators Lower & Upper Kingposts Door hinge bearings Forward Retract Actuator Base

Forward and Aft Flap bushings

0

0.001

0.002

0.003

0.004

0.005

0.006

KR8 Spherical Test Bearings

AS81820 Oscillation Test Max Allowable Wear .0045

0

0.001

0.002

0.003

0.004

0.005

0.006

Mil H5606 @

160F

TT S 735 @110F

Skydrol500 @160F

Mil L7808 @

160F

Mil A8243 @

160F

AS81820 Fluid Test Max Allowable Wear .006

Bearing: KR8 CNGB: Bore (.5) Ball (440C), Outer race (17.4) KAron B

Oscillation Load Test Fluid Compatibility Test+/- 25 Degrees (100 Degrees total) 24 Hour Soak 10,400 lbs. (Approx. 35,000 PSI) +/- 25 Degrees 20 CPM 7,800 lbs. (Approx. 25,000 PSI) Ambient Temperature 20 CPM25,000 Cycles 25,000 Cycles

KAron B AS81820 Qualification Testing KAron BX Now Qualified to AS81820 Type A

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Customer High Performance KAron B Bushing Test

SAE AS 81934 Requirements:35,000 PSI ( 241Mpa)+/- 25 Degrees (100 Degrees total)25,000 CyclesDry/Aircraft FluidsDeicing fluid (Reduced load)

New High Performance Requirements:50,000 PSI (345 Mpa)+/- 25 Degrees (100 Degrees total)25,000 CyclesDry/Aircraft Fluids Deicing fluid (Reduced load)

.0005(.0127)

.001(.0254)

.0015(.0381)

.002(.0508)

.0025(.0635)

.003(.0762)

.0035(.0889)

.004(.0106)

.0045(.1143)

.0009(.02286)

.0006(.01524)

.00065(.01651)

.00093(.023622)

.001(.0354) .00063

(.016002)

.0011(.02794).00065

(.01651)

.005(.127)

DryLD Hyd

Fluid

TT-S-735

Mil-L-78

08Mil-H

-5606

Mil-A-82

43

Grease

Water

.0015 inch (.0381 mm) Maximum Wear per High Performance Specification

.0045 inch (.1143 mm) Maximum Wear per SAE AS 81934

Wea

r in

Inch

es (m

m) @

25,

000

Cyc

les

Bushing Dimensions:KAron B.8750 Bore.375 Length17.4 Substrate

Contamination

High Load - Slow Oscillations

The New Bearing Standard

• Increased Loads

• Reduced Allowable wear

• Contaminated Environment

KAron B Results

Low Uniform Wear Rates Under all Conditions

Added Benefits

• Low Friction

• Machineable Liner

• Injection Molded Sphericals

• Excellent Anti Fretting Properties

KAron BX The First of the Next Generation Kamatics LinersQualified to AS81820 Type A High Performance Specification

SummaryImproved ProcessingImproved Wear RatesImproved FrictionImproved Performance

25,000100,000

1,000,000

0100,000200,000300,000400,000500,000600,000700,000800,000900,000

1,000,000

Cyc

les

AS-81820 AS-81820Type A

Karon BX

Performance Standard

Liner Performance Comparison

Karon BX –40X Baseline Performance

New high performance specification

100,000 cycles @ 35,000 PSI (4 x current 81820 requirements)

Kamatics ran additional testing to one million cycles (Dry) Extended contamination testing planned.

40% reduction in friction.

The X processing is now being applied to all the Kamatics liner systems. Similar results are expected.

KAron BXFriction Performance

Hydro Turbine Linkages

Less than .001 Wear Auto lubricated and still severe damage

KAron vs. Greased Bronze At Grand Coulee DamInspected after 10 years of operation

Long periods of static vibrations followed by movement

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Composite Bearings

MIL-B-85560 is a specification for plain and flanged sleeve bearings with a composite substrate and a self-lubricating liner.

Qualification Requirements:

• 40,000 psi (276 MPa) static load

• 20,000 psi (138 MPa) dynamic load

• -65°F (-54°C) to 250°F (121°C) service temperature

• Compatibility with aerospace fluids and marine environments

Qualified to AS 85560

Flap/Slat Side Load PadsSpoiler EdgesLeading/Trailing Edge RibsEngine Cowls/FairingsClevis Link/Beam ProtectionDoor SlidesTurbine Wicket Washers

Thermoset resin matrix with synthetic fibersLaminate construction for strength and durabilityDynamic Operating Pressures to 20,000 psi (138 MPa)Temp Range –100° to 250° F (-73° to 120°C)Wear Strip Thickness .020” (0.5 mm) to .060”(1.5 mm)Plate Thickness .120” (3.0 mm)

P54Composite MatrixSheets/Pads/Strips

Aerospace ApprovedWear/Anti-FrettingImpact Resistant

Protects Expensive Mating Surfaces

Typical ApplicationsCharacteristicsLiner

Navigational Locks•Miter Gate Pintles•Sector Gate Pintles

KAron PintleFeatures

•KAron coated pucks can be replaced and/or repaired

•Clearance between Karon-coatedpucks, installation surface, and themating surface provides path fordebris to exit the load zone

•Copper Nickel Tin substrate provides fail-safe protection

• Can incorporate wear sensing capability

KAron Pintles Puck Sensors

KAron Pintle Mating Materials

Mating pintle component should be constructed from high-hardness corrosion resistance material, such as stainless steel with a hardness of Rc 40 or higher and a mating surface finish of Ra 16 or better.

KAron PintleConfigurations

Pintle (Male Component) Mounted Puck Design

Gudgeon/Pintle Bushing (Female Component) Mounted Puck Design

Pucks of different (cylindrical) ODsizes can be employed to maximizethe effective coated surface area.

Karon V

Puck Substrate: ToughMet

Mating pintle component should be constructed from high-hardness corrosion resistance material, such as stainless steel with a hardness of Rc 40 or higher and a mating surface finish of Ra 16 or better.

Base Substrate: Stainless Steel

Miter Gate Pintle Bearing: MaterialsDalles Lock and Dam, Oregon – Installed 2011

Puck Substrate: Aluminum-nickel-bronze alloy

Karon V

Base Substrate: Aluminum-nickel-bronze alloy

Sector Gate Pintle Bearing West Closure Complex, New Orleans – Installed 2011

KAron Pintle Bearing Pressure Calculation

Kamatics evaluated the bearing pressures that could be present under certain puck-to-pintle base contact conditions. The given pintle load for the Sector Gate was 1,353 kip. The pressure was calculated for the 3 contact conditions shown below (red Karon puck surfaces are loaded surfaces). The static limit load capacity of the Karon V liner system was 55,000 psi.

Bearing Area: 400.92 sq. in.Bearing Pressure: 3,372 psi

Bearing Area: 330.09 sq. in.Bearing Pressure: 4,095 psi

Bearing Area: 259.27 sq. in.Bearing Pressure: 5,214 psi

Condition 1: Condition 2: Condition 3:

• Powertech/Panama Canal Pintle Test

• 200,000 Cycles, Brackish Rusted Water

• KAron Pucks and Low Friction KAron VS Have excellent Results

• Minimal Wear with no damage to the pintle ball

• KAron Puck Design Reduces Costs

12388 - 88th AvenueSurrey, British ColumbiaCanada V3W 7R7

SCALE MODEL TESTING OF KAMATICSNAVIGATION LOCK SELF-LUBRICATING KARONV PINTLE AND KARON VS BUSHING.PDF

Full report available upon request;

KAron Pintle Test

Sector Gate Pintle Bearing West Closure Complex, New Orleans

Miter Gate Pintle Bearing: Dalles Lock and Dam, Oregon

KAron PintlesApplications

Sector Gate Pintle Bearing West Closure Complex, New Orleans – Installed Early 2011

Sector Gate Pintle Bearing West Closure Complex, New Orleans – Installed Early 2011

Miter Gate Pintle Bearing: Dalles Lock and Dam, Oregon – Installed Early 2011

Miter Gate Pintle Bearing: Dalles Lock and Dam, Oregon – Installed Early 2011

Self-Lube Selection Process

Customer Design Considerations

A better Surface finish and hardness improves bearing performance for all types of liner systems

The Basics

Bearing/Housing Envelope, Drawings

Pin Size/Mating Surface (Finish/Hardness)

Life Requirements/Existing Issues

Loads

• Maximum Static (Radial/Axial)

• Maximum and Normal Dynamic

• Vibration or Shock Loads

Movement

• Angle of Oscillation

• Speed (Cycles per Minute/RPM)

• Angle of Misalignment (Sphericals)

Other

• Temperature Range

• Contamination (Type/Frequency)