Abstract
It is known that with the inexpensive CAVSF process it is possible to reduce the average surface roughness of helicopter gear teeth from the conventional 16 micro-inches down to approximately 2 micro-inches.  The friction and the surface stress at the mating surfaces is remarkably decreased.  This result in an increase of the fatigue lifetime on the order of 300 to 400%, in reduced downtime, reduced component weight in new designs, higher energy efficiency and overall lower costs.

The CAVSF process was studied. Different effects such as the chemical reaction and erosion during the process were examined separately and in combination with each other.  The variation in the average material removal and the roughness during the process for different steels and alloys, as well as the change in chemistry of the solutions used during CAVSF were investigated.  Relations were drawn from the lowest possible roughness values to the microstructure of different carbon steels.  Different new treatment solutions for the CAVSF process were developed and in some cases the effectiveness of the process increased.

DISTRIBUTION STATEMENT A.  Approved for public release; distribution is
unlimited.  Research performed under Information Analysis Center
Contract No. FA4600-06-D-0003 U00002.