DON26BZ01-NV002 TITLE: Integrated Metal Ceramic Matrix for High Strength Steels
COMPONENT TECHNOLOGY PRIORITY AREA(S): Advanced Materials;Sustainment
PROJECTED CMMC LEVEL REQUIREMENT: Level 2 (Self)
OBJECTIVE: Develop an integrated metal matrix for high strength steels.
DESCRIPTION: Landing gear components are limited to the use of high strength steels due to their harsh loading applications and various environmental conditions. Typically, high strength steels are used to survive the load requirements. The two technologies currently applied to most landing gear components are Hard Chrome and high velocity oxygen fuel (HVOF). Each has their disadvantages that affects landing gear components. A replacement for Hard Chrome and HVOF is required to improve the readiness and safety of landing gear components.
Hard Chrome’s main disadvantage is that it hides corrosion underneath the chrome plating which can lead to stress corrosion cracking in high strength steels. This failure mode would cause the complete loss of a landing gear system as the landing gear essentially snaps into pieces due to high stresses of landing. If corrosion is found before stress corrosion cracking occurs it still leads to the complete scrapping of landing gear components. This is due to Hard Chrome having no repair method. The only option for Hard Chrome is to replace, remove, and then reapply which takes days of machining and post machining. In addition to the machining, the application requires hazardous chemicals and produces waste that creates a health and safety risk to the fleet and its manufacturing personnel. Lastly, another risk with Hard Chrome is the dimensional limitations it provides. If too little or too much Hard Chrome is applied, the coating will immediately delaminate and damage landing gear and hydraulic components due to the foreign object debris (FOD) inside the system.
HVOF comes with its disadvantages as well. HVOF requires extremely low surface roughness on the pistons which have poor tribology. The poor tribology causes the hydraulics seals to perform dry and wear the seals away extremely quickly. Hydraulic fluid cannot stick to the walls of the piston due to the low surface roughness.
On top of the hydraulic disadvantages, the surface roughness requires precision post machining for long durations to survive the landing gear environments. In the fleet, the main issue seen with HVOF is spalling when the landing gear experiences high strains. When this occurs, the landing gear components must be removed and replaced.
This topic seeks an innovative solution that provides an integrated metal matrix for high strength steels that boosts the performance of and extends a component's survivability and improves a system's operational readiness and lifecycle costs. Current technology for titanium uses waveform energy. The process generates a targeted physical reaction within a substrate, activating the substrate at an atomic level for precise placement and gradient depth control of an integrated infusion. This infusion results in a matrix composite material that leverages the strengths of both components. The chemical bonding between a ceramic and the titanium alloy involves a combination of covalent and ionic characteristics — sharing and exchanging of electrons. This combination enhances the mechanical properties of the composite material, such as properties and porosity mitigation for corrosion protection, hardness for wear resistance, thermal stability, and overall durability, resulting in a metal-matrix suitable for various high-performance applications. Current technology can tailor characteristics such as hardness, electrical conductivity, thermal and oxidation, and mechanical strength. These meticulous adjustments enable the creation of the matrix with specific, desired functionalities, enhancing their performance in various applications to defeat corrosion, wear, erosion, thermal, and other challenges. For instance, a metal matrix composite gradient depth infusions of titanium nitride (TiN) achieved hardness ratings of 2800-3100HV (micro-Vickers). Currently, the process is limited to transition metals; however, there is a need to adapt and develop it for application to high strength steels. This innovative solution will provide the benefits of both Hard Chrome and HVOF while eliminating the current limitations of the respective coatings.
PHASE I: The Phase I Option focuses on identifying a potential coating by evaluating the compatibility of metal integration properties with the proposed high- strength steel. This includes determining whether a metal matrix can be successfully formed and sustained on the high strength steel surface. Attention will be given to identifying optimal surface characteristics—such as roughness, texture, patterning, and placement adjustments—to enhance oil retention and lubricity within landing gear components. Desired material properties and suitable tooling methods will be established to achieve the required metal integration. Sample coupons will be created as feasibility evidence for developing the coating process. This will be followed by analysis and characterization of the metal integration within high-strength steel substrates. Finally prototype plans will be developed to realize initial geometric characteristics for a titanium alloy component tailored to the project’s specifications.
PHASE II: Develop prototyped landing gear components with internal components using the developed integrated metal matrix. Perform landing gear qualification testing to ensure prototyped integrated metal matrix components can withstand landing gear environments.
Establish wear patterns, production process, and related properties.
PHASE III DUAL USE APPLICATIONS: Integrate the landing gear components into fleet aircraft.
Metal matrix composites are employed in advanced industries due to their high modulus and strength, favorable wear and corrosion resistance, and other good properties at elevated temperatures.
Aerospace: High-temperature components like exhaust nozzles, heat shields, and other components.
Engine components: Turbine disks, impellers, and other engine parts requiring high strength-to-weight ratios.
Structural components: Structures where lightweight and high strength are crucial.
Automotive: Engine parts like Piston rings, brake discs, and rotors benefit due to their high strength, wear resistance, and thermal conductivity.
Lightweight construction components to reduce vehicle weight, improving fuel efficiency.
Electronics: Thermal management heat sinks and electronic packaging to dissipate heat and improve device performance.
Industrial: Cutting tools due to their high strength and wear resistance. Wear-resistant parts in industrial machinery and tools where high wear resistance is needed.
REFERENCES:
KEYWORDS: Landing Gear; Coatings; Metal-matrix; Ceramics; High-Strength Steels; Hard Chrome
| 5/15/26 | Q. | 1. What is the size range of the end product landing gear components that need to be coated?
2. Is there a preferred processing method for the coating (ex. electrochemically deposited, vacuum coating, powder spraying)? 3. Is there a coating material that would be preferred (ex. SiC, SiN)? |
| A. | 1. No preferred method
2. No preferred material. 3. Material must meet/exceed hard chrome capabilities. |
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| 5/15/26 | Q. | 1. Would a surface-applied metal-ceramic matrix composite coating (e.g., deposited via cold spray) on high-strength steel, intended to replace hard chrome / HVOF and address corrosion, wear, and tribology requirements, be considered responsive to this topic, assuming Phase I effort focuses on material selection, coating architecture, and surface roughness optimization rather than bulk material integration?
2. What are the roughness requirements of the coatings and the materials in general? |
| A. | 1. Yes it would be responsive.
2. Chrome typically has a surface roughness of 16. HVOF typically has a surface roughness of 4. This is to preserve seal wear. No requirements, but typically would be within this range. |
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| 4/15/26 | Q. | Are duplex systems-such as nitriding combined with Diamond like Carbon (DLC)-that create a graded, integrated surface architecture on high-strength steels considered responsive to this topic? |
| A. | Yes. Duplex systems-such as nitriding combined with Diamond like Carbon (DLC)-that create a graded, integrated surface architecture on high-strength steels are considered responsive to this topic. | |
| 5/1/26 | Q. | Would anti-spallation methods including subsurface treatments, and/or coating thickness variations be compliant to this proposal request? |
| A. | Anti-spallation methods including subsurface treatments, and/or coating thickness variations would be compliant for this proposal if the hard chrome coating is being replaced by a new coating material.
If the proposal is a new surface treatment and a different coating thickness using the current hard chrome material, then it will not be considered. |
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| 5/1/26 | Q. | Would existing material post-processing techniques and treatments be considered responsive to this proposal request? |
| A. | If the existing post processing and techniques and treatment are applied to hard chrome, it would not be considered responsive to the proposal.
We are looking to replace the current hard chrome coating with a new material. |
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| 04/27/2026 | Q. | Is the focus solely on coatings? Or would developing an integrated metal matrix process (such as a 3D printed high strength steel with dispersed ceramics) be in scope for this topic? |
| A. | The focus for this SBIR is to find an alternative to current high strength steel coatings. A new process can be considered but would still require coating high strength steel components/cylinders during the effort. | |
| 04/22/2026 | Q. | Would an externally deposited but metallurgically bonded metal-ceramic surface system for high-strength steel be considered responsive, provided it achieves the desired integrated surface behavior, gradient functional properties, and hard chrome/HVOF replacement performance for landing gear applications? |
| A. | Yes an externally deposited metal-ceramic matrix will be considered for this topic provided it achieves the same performance capabilities as hard chrome. | |
| 4/19/2026 | Q. | 1. Does the topic anticipate coating of interior diameter (ID) bore surfaces of the outer cylinder/strut in addition to the exterior diameter (OD) piston surface, or is the Phase I scope limited to OD piston surfaces only?
2. What high-strength steel alloy is anticipated as the primary substrate for Phase I coupon testing - 300M, 4340M, or Aermet 100? |
| A. | 1. Phase I scope limited to OD piston surfaces only.
2. Aerement 100 or Aero 100 |
** TOPIC NOTICE ** |
The Navy Topic above is an "unofficial" copy from the Navy Topics in the DoW FY-26 Release 1 SBIR BAA. Please see the official DoW Topic website at www.dodsbirsttr.mil/submissions/solicitation-documents/active-solicitations for any updates. The DoW issued its Navy FY-26 Release 1 SBIR Topics pre-release on April 13, 2026 which opens to receive proposals on May 6, 2026, and closes June 3, 2026 (12:00pm ET). Direct Contact with Topic Authors: During the pre-release period (April 13, through May 5, 2026) proposing firms have an opportunity to directly contact the Technical Point of Contact (TPOC) to ask technical questions about the specific BAA topic. The TPOC contact information is listed in each topic description. Once DoW begins accepting proposals on May 6, 2026 no further direct contact between proposers and topic authors is allowed unless the Topic Author is responding to a question submitted during the Pre-release period. DoD On-line Q&A System: After the pre-release period, until May 20, 2026, at 12:00 PM ET, proposers may submit written questions through the DoW On-line Topic Q&A at https://www.dodsbirsttr.mil/submissions/login/ by logging in and following instructions. In the Topic Q&A system, the questioner and respondent remain anonymous but all questions and answers are posted for general viewing. DoW Topics Search Tool: Visit the DoW Topic Search Tool at www.dodsbirsttr.mil/topics-app/ to find topics by keyword across all DoW Components participating in this BAA.
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