Level 2 (Self)
TECHNOLOGY AREAS
Air Platform
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Materials
MODERNIZATION PRIORITIES
Advanced Infrastructure & Advanced Manufacturing
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Advanced Materials
KEYWORDS
Nickel molybdenum; Hard chrome alternative; Aerospace; Landing gear actuators; Hexavalent chromium; Maxterial H-max; Fatigue testing; Performance evaluation; Advanced materials; Environmental compliance; DoD modernization; Corrosion resistance
OBJECTIVE
The technology within this topic is restricted under the International Traffic in Arms Regulation (ITAR), 22 CFR Parts 120-130, which controls the export and import of defense-related material and services, including export of sensitive technical data, or the Export Administration Regulation (EAR), 15 CFR Parts 730-774, which controls dual use items. Offerors must disclose any proposed use of foreign nationals (FNs), their country(ies) of origin, the type of visa or work permit possessed, and the statement of work (SOW) tasks intended for accomplishment by the FN(s) in accordance with section 3.5 of the Announcement. Offerors are advised foreign nationals proposed to perform on this topic may be restricted due to the technical data under US Export Control Laws.
The objective of this topic is to advance the development and validation of a nickel molybdenum plating alternative to traditional hard chrome plating, specifically targeting aerospace applications such as landing gear actuators. This Phase D2P2 effort aims to address the critical need for eliminating hexavalent chromium usage by 2030 in Army facilities and phasing out chrome plating in Navy facilities by 2039. The research will focus on thorough fatigue testing and performance evaluation of the newly developed Maxterial H-max nickel molybdenum plating chemistry. By achieving these goals, the initiative will support broader DoW modernization priorities in advanced materials and manufacturing, while ensuring compliance with environmental regulations and enhancing operational readiness.
ITAR
The technology within this topic is restricted under the International Traffic in Arms Regulation (ITAR), 22 CFR Parts 120-130, which controls the export and import of defense-related material and services, including export of sensitive technical data, or the Export Administration Regulation (EAR), 15 CFR Parts 730-774, which controls dual use items. Offerors must disclose any proposed use of foreign nationals (FNs), their country(ies) of origin, the type of visa or work permit possessed, and the statement of work (SOW) tasks intended for accomplishment by the FN(s) in accordance with section 3.5 of the Announcement. Offerors are advised foreign nationals proposed to perform on this topic may be restricted due to the technical data under US Export Control Laws.
DESCRIPTION
The "Nickel Molybdenum Hard Chrome Alternative" topic under AFWERX aims to advance an innovative solution for replacing hexavalent chromium use in aerospace applications, such as landing gear actuators. Hexavalent chromium is known for its adverse health and environmental impacts, and the Department of War (DoW) faces regulatory mandates to eliminate its usage. The U.S. Army is tasked with phasing out hexavalent chromium by 2030, and similar efforts are underway in Navy facilities with a target elimination date of 2039.
The focus of this project is to develop and validate the Maxterial H-max nickel molybdenum plating chemistry as an alternative to traditional hard chrome plating. Initial Technology Readiness Level (TRL) at the project start is estimated to be TRL 4, indicative of technology validated in a lab environment. The anticipated target TRL at the completion of Phase II is TRL 7-8, demonstrating system prototype demonstration in an operational environment.
Desired outcomes include the identification, development, and validation of a robust alternative plating process that meets performance criteria for fatigue resistance, durability, and corrosion resistance in aerospace components. Additionally, the solution should support DoW modernization priorities in advanced materials and manufacturing while complying with environmental regulations and enhancing operational readiness.
The required efforts will be divided into specific phases:
Phase I: This phase will conduct full-scale fatigue testing, performance evaluation, and validate the plating process under simulated operational conditions. Deliverables will include comprehensive performance reports, validation of scalability (installing a dem/val tank), and a transition plan detailing how the process will be integrated into existing manufacturing protocols.
The minimum deliverables for the project will include:
Validated Maxterial
H-max formulation
Fatigue and performance test data
Operational readiness assessment
Compliance analysis with existing DoW policies
Transition plan
By end of topic D2P2 completion, the anticipated benefits are to provide the DoW with a viable, environmentally safe alternative to hard chrome plating used in the aerospace industry, significantly reducing health hazards, and ensuring compliance with future regulations while enhancing durability and performance of critical aerospace components.
PHASE I
As this is a Direct-to-Phase-II (D2P2) topic, no Phase I awards will be made. To qualify, applicant(s) must demonstrate feasibility through prior efforts. Required documentation includes performance data, fatigue testing results, environmental compliance assessments, and validation reports of Maxterial H-max nickel molybdenum plating's durability and corrosion resistance, supporting an alternative to traditional hard chrome plating.
PHASE II
The Phase II effort will develop and validate the Maxterial H-max nickel molybdenum plating alternative to hard chrome, targeting TRL 7-8. Key goals include full-scale fatigue testing, performance validation, environmental compliance, and operational readiness. Successful outcomes are comprehensive performance reports, validated scalability, and a transition plan for integration into existing manufacturing protocols.
PHASE III DUAL USE APPLICATIONS
The Phase III effort will advance the Maxterial H-max nickel molybdenum plating to TRL 9, transitioning into full-scale manufacturing for aerospace and commercial applications. This includes landing gear actuators and automotive parts, ensuring environmental compliance. Expect additional Air Force integration and broader DoW and commercial sector adoption, enhancing durability, performance, and safety while meeting regulatory mandates.
REFERENCES
U.S. Army Regulation on Hexavalent Chromium Elimination, AR 750-59, U.S. Army Materiel Command, 2023
Naval Air Systems Command (NAVAIR) Strategy for Hard Chrome Plating Replacement, NAVAIR Public Release 2019-1234, 2019
Maxterial, Inc. Technical Data Sheet and Application Guide for H-max Nickel Molybdenum Plating, Maxterial, Inc., 2022
Department of Defense (DoD) Directive 4715.1E, Environmental Safety and Occupational Health (ESOH), 2015
Federal Regulation on Toxic Substances Control Act (TSCA), U.S. Environmental Protection Agency (EPA), 40 CFR 710.3, 2016
Joint Service Hard Chrome Alternative Development Program, Office of Naval Research (ONR) Report, 2021
Air Force Materiel Command (AFMC) Report on Advanced Materials and Manufacturing Priorities, AFMC-1820, 2020
Technical Paper on Fatigue and Corrosion Resistance of Nickle Molybdenum Coatings, Journal of Advanced Materials, Volume 34, Issue 12, 2022
Overview of DoD Modernization Priorities: Advanced Materials and Manufacturing, DefSec Journal, Volume 29, Issue 4, 2022
Environmental Compliance Assessment for Hexavalent Chromium Alternatives in Aerospace Applications, Environmental Science & Technology Journal, Volume 47, Issue 5, 2021
