LIFESAVING SYSTEMS CORP. 

220 ELSBERRY RD. • APOLLO BEACH, FL 33572 '' 

PHONE 813/645-2748 • FAX 813/645-2768 

www.lifesavingsystems.com 

February 11, 2010 

US Department of Transportation 

Docket Operations, M-30 

West Building Ground Floor, Room W12-140 

1200 New Jersey Avenue, SE. 

Washington, DC 20590 

Ref: Airworthiness Directive, Docket No. FAA-2009-1148 

Attn: Mark R. Schilling, Acting Manager - Rotorcraft Directorate 

Gary Roach, Aviation Safety Engineer - Rotorcraft Directorate 

Dear Sirs: 

The purpose of this letter is a formal request by Lifesaving Systems Corp. (LSC), manufacturer of the 

D-LOK Hoist Hook, to have the FAA rescind the above referenced AD on the following grounds: 

1. Information cited in support of the AD is erroneous and without basis. The AD claims "Testing shows 

that the affected hooks could fail at 200 lifts." This is false. There is no test data supporting this 

claim. There is real world physical testing performed by both LSC and Goodrich providing verifiable 

counter evidence to such claim. To date no defects, other than minor surface discontinuities (which 

have been classified as cosmetic in nature only), have been reported. 

2. The argument presented by both FAA and EASA as basis for the AD is an "unapproved change in 

manufacturing process from forged material to cast material that have different physical properties." 

LSC presents the counter claim that the physical properties of the cast part, having been subjected to 

Hot Isostatic Pressure Densification (HIP'D), are endued with physical properties similar and near 

identical to the wrought form. The metal alloy and all subsequent processing are identical. Any minor 

difference in obtaining the same end form by one or the other method is more than compensated for 

by the safety factors inherent in the D-LOK's robust design and by the 25% increase in cross-section 

at the point of greatest stress implemented in the cast & HIP'D hooks. All physical testing confirms 

the cast & HIP'D hook to be of superior strength to the original forged part. 

3. AD makes the claim that the parts cost to replace the hook is $3000 per hoist. This information is not 

correct. LSC has provided all customers with a replacement hook at no charge on exchange. Thus, 

with exception of labor, the effective parts cost for replacement is $0 reflecting a total cost to U.S. 

operators of only $7,280. Significantly less than the amount $280,280 reported in the AD. 

4. LSC, as manufacturer of the D-LOK Hoist Hook, was not consulted prior to FAA's release of the AD, 

and as such not permitted the opportunity to provide supporting engineering analysis. LSC had brief 

telephone discussion with FAA representative in July of 2009. At which time the implied FAA concern 

was of minimal nature. However, 7 months later and 6 months after release of the EASA AD, the 

FAA claims there is no time for comment/verification of facts due to safety priority. As well, the 

majority of affected hooks have already been replaced prior to release of the FAA AD. 

To summarize, the cause and issuance of the AD is without basis, and appears to be a direct result of a 

knee-jerk and unjust reaction within and by industry that has not considered the full engineering analysis 

of the entire manufacturing process and intended application. LSC makes the claim that the transition to 

the cast manufacturing process, subsequently followed by the Hot Isostatic Pressure Densification, 

results in a finished product with properties near identical to the wrought form. Further, within the 

intended application of hoist systems having a 600 lbs working load limit, the inherent safety factor of the 

robust D-LOK design more than compensates for any minor difference in material properties between 

cast with HIP densification and forged processes. The severity of any safety concern in reference to the 

affected hooks is thus nil. 
To substantiate the above claim LSC provides the following information: 

1. Counter to industry statements the hooks were manufactured in a controlled process. Hooks were 

cast, solution heat treat, and homogenization heat treat in accordance with SAE AMS-5355. Final 

precipitation heat treat is in accordance with SAE AMS-2759/3C. All vendors in relation to supply of 

the cast hooks of the affected lots have ISO accreditation, NADCAP accreditation, or other aviation 

source approval. 

2. All hooks underwent Hot Isostatic Pressure Densification which eliminates internal voids, removes 

casting porosity (increasing fatigue strength) and brings part density to near forge characteristics. 

The process endues overall integrity similar to wrought forms (reference "Hot Isostatic Processing of 

Cast Steels - Exhibit A). The HIP'D process has been utilized within aerospace and power industries 

for many years. Technology advancement and costs reductions enable the HIP'D process to be 

applied to a greater range of products and industries that were previously restricted access due to 

high costs. Successful implementation of HIP'D processes has produced both cast and powdered 

metal parts across a broad spectrum of alloys with near wrought properties, while retaining the 

manufacturing and complex design benefits of the cast/pm process. 

3. All affected hooks received multiple visual inspections and each hook was proof load tested to 

4000 lbs by Lifesaving Systems prior to release. 

4. During the transition to the cast & HIP'D manufacturing process, LSC took the opportunity to improve 

the geometry of the hook body and increase the material cross-section of the hook at its point of 

greatest stress or maximum bending moment. The noted cross-section of the hook was increased by 

approximately 25% compared to the previous forged design. See attached drawing (Exhibit B) for 

comparison. This change in cross-section results in an approximate increase of 20% in tensile 

strength over that of the forged hook in pull tests performed by LSC. 

5. For all intents and purposes, and with the exception of the manufacturing process (cast & HIP'D vs. 

forged) the affected hooks are identical in material (17-4 PH stainless steel) and function to the prior 

forged design. On this basis and due to the fact that the parts were cast in accordance with 

aerospace standards and further subjected to the Hot Isostatic Pressure Densification process which 

imparts characteristics and integrity similar to wrought forms, LSC's analysis is primarily by 

similarity/improvement over the current approved part. All structural testing by LSC shows the cast & 

HIP'D design to be stronger than the previous forged design. All other considerations concerning 

corrosion, temperature, environment, etc. are related to material properties of which the base metal 

and general design are unchanged. 

6. To date no defects, other than minor surface discontinuities (which have been classified as cosmetic 

in nature only), have been reported in respect to the affected hooks. Any reference as to testing 

and/or simulation showing failure is false or without real world correlation. Physical testing performed 

by both LSC and Goodrich Hoist and Winch proves as such. The following tests have been 

performed and can be verified. 

a. LSC Test Report dated 30 November 2007 (Exhibit C). A pre-production sample of the cast 

hook body was pulled to 8,000 lbs without permanent deformation and then to 10,000 lbs 

(limit of LSC test fixture) without failure. 

b. LSC Test Report dated 16 January 2008 (Exhibit D). A cast hook body was cycled 100 times 

at 3100 lbs and subsequently pulled to 9,400 lbs without failure. 

c. Goodrich successfully completed a fatigue test consisting of 1.02 million cycles at limit load 

(2,100 lbs) of an affected hook (lot 1108) without failure. Then subsequently subjected the 

same hook to an ultimate load of 11,100 lbs without fracture. 

d. Goodrich successfully completed a second fatigue test with a gross flaw purposely introduced 

consisting of a .170" diameter hole drilled through the cross-section of an affected hook at its 

point of greatest stress (see attached drawing, Exhibit E). The hook with induced flaw was 

subjected to 100,000+ cycles at limit load (2,100 lbs) prior to failure. It should be noted that 
FEA/Simulation software predicted failure at 2 cycles. This test highlights two points. First, 

even with the grossly induced flaw the hoist hook is of such a robust design with overengineered safety factors, that the potential for failure with even severe defect is minimal to 

nil in real world use. Second it proves to illustrate the poor correlation of simulation analysis 

to physical actuality that leaves all simulation analysis suspect. 

7. An overall analysis of the end-use application and safety factors inherent in the design of the affected 

hooks is also warranted. The cast & HIP'D hooks are installed on hoist systems rated at 600 lbs. Per 

FAA's most stringent requirements (Human External Cargo) the limit load for the intended application 

is established as (3.5)*(600) = 2,100 lbs, with an ultimate load of (1.5)*(limit load) = 3,150 lbs. All 

testing to date clearly shows that the affected hoist hooks exceed the limit load requirements prior to 

deformation by an additional safety factor of 3.8 (8000 lbs/2100 lbs), and ultimate load is exceeded by 

an additional safety factor of 3.5+ (11,100 lbs/3150 lbs). It should also be noted that CFR Part 

29.621 requires casting factors not less than 1.25 for critical parts. The affected hooks exceed this 

requirement by 280%. 

In conclusion, there has been misinformation released within industry concerning LSC and the 

D-LOK hoist hook. This misinformation is without merit and should not be included in the basis of an FAA 

AD/Ruling. Inclusion of unfounded statements regarding non-existent test data leads the company to 

question the purpose of making such comments. These statements, whether or not of purposeful intent, 

have the effect of defaming the subject manufacturer and undermine the legitimacy of the FAA serving as 

a Government Authority. Further, LSC was not presented with the opportunity to provide supporting 

evidence prior to issuance of the AD. The above claims and supporting evidence issued by LSC serve to 

illustrate that the affected hooks have been manufactured in a controlled process and the design and 

manufacture more than satisfy the safety requirements of the intended application. Although LSC 

recognizes FAA's legitimate concern to ensure the safety of all aviation operators and public, the safety 

concern and severity in reference to the affected hooks as listed in the AD has been extended well 

beyond reason. 

It is therefore requested that the FAA rescind the current AD. Any and all unsupported and false 

statements should be removed and it is again questioned why FAA would release false statements. 

It is LSC's recommendation that the FAA thoroughly evaluate LSC's claim as to the cast & HIP'D parts 

having near wrought physical properties. Thus permitting analysis by similarity to the previous forged part 

and rendering the claim as to "process change" to be a non-factor. After rescission of the current AD, and 

in order to comply with CFR Part 29.621 it is recommended that a new AD be issued requiring operators 

to return affected hooks to the manufacturer for reprocessing. Reprocessing to include 100% magnetic 

particle and 100% radiographic inspections of the hook body in accordance with SAE AMS 2175 Class 1 / 

Grade A thus satisfying the requirements of CFR part 29.621. Upon reprocessing the hooks will be 

issued a new part number or lot number for identification purposes and then may be returned to service. 

LSC will be please to provide any analysis or support to enable FAA to perform the required evaluation. 

Respectfully, 

Sam Maness 

CEO 

Enclosures; Exhibit A - E 
Exhibit A 
THE HOT ISOSTATIii PtmeSSim OF CAST STBaS 

I. Stroa», Polytechnic of U»Xm$, Pont^priaa. UK 

D. Evtnt, HXP LiMtma, c/t«i%rfi«l<*. UK 

ABSTRACT 

Th« reUtlonshlp betwewsthe iwcrostriiicture 

snct the fflechanlcsl propirtles of « thick 

sectlontd high st>lsngth cast stwV has been 

Investigated. The' intdwnlcsl proptirties 

were found to vary frbiri thii ed ^ tfl tfe| 

centfft of the casting. This jlias bttn 

related to the Inddente of trifcropproilty 

Mthieh ii^fect*^ the ductflityl related 

j«%>pertie*» * *Jons(»t1on| < treductiieiB In 

ares and Chii'py V*iiotiCfc values to tgreiitBr 

extent 1*8n t*e proiof jtriss i>r ijansHe 

strength. the presiihce of si»rfa?e 

mlcroporosll^ reveal^ after wacli^l^ng also 

drastfwlly Induced the ffitlgut istrength. 

Similar specimens liere suWectf)^ to Jwt 

Isfltatlc presslnjgi at 'different 

te«p*ratureJ8' and tht resttttlnj ntecharttcaV 

pfOl»iNs1e$ deterilfled*i. < The efftctlve 

closuf* .ofh \nUm^y-«ifi^pQpQiv$^^^ a 

ViSlgnimcsnt'i^n»W-«iii8t--ffc-::-th« .;)ij^8ii*,pa1 , 

::;pwiperttes 1s.::*epoi»^Bed»- /W.tiJBCliSiBSt HffM ' 

tOi 70X In tUf l^tipie *t«tojBl* t»i* 

obtained. The SJJP t*iperetti^ wit. vafletf 

fn»! 930*c to i2ao»C, "'4it is sjrtwn^ithat » 

HIP tonperature of SW'^tfvwas suffldimt to 

e.ff«i«*1ve1y close the Bifcfo^rcfslty ana 

secure the sasie level ;»f tucrease In the 

weehanlcal proi;irt1e*, as th»t obtalhed it 

higher HIP temi^retuires. The liichentcat 

properties achieved after HIP are 

cosfarabte Mlth,th&« ^|«ined in similar 

wrought. steiBls. l 

tmmaim 

The Intlderwe of internal mlcrpporoslty In 

cast steel has an advirse eff«ict on the 

mechanical propertltl particularly the S 

elongation and I reduction in area. In 

addition any surface porosity resalts 1n a 

marked reduction In the fatigue strength. 

It has also been shew by^Evehs et;.at..(l) 

that the mechanical properties of "sound" 

cast steels ire inferior to those of 

comparable wrought steels. 

In the past, efforts have beeft made to 

mlnffrilse the Incidence of porOslty by 

improved foundry methods but an alternative 

approach to the problem is now available. 

The cloisure of Internal porosity in cast 

metals by neans of hot Isostatic pressing Is 

ntw a flntily established process and the 

consetjuent Improvement In fltechantcal 

properties has been repqtrted (2). HIP Hti 

been extensively applied to cast stainless 

stepls and superalliiy'compositions (3) but 

sighlfleant advantases may also be -gained by 

i ts applitatlon to lo*f alloy e)»st steets 

(4). Itesults ha«« been previously; repbirted 

on the IppllcatlpB of HIP- to thick tectlbhtd 

cast carbon steels fS) and Is s chros^sim <iH 

steel (6). In these steels a fixed Hip 

timpeiriture t»as used. Ittt^e present vrtirk a 

high strength alloy. east siliel was lelected 

end the optiitwrn Hlf: temperiij/re dftirwlnei 

consistent wltf^i atchlevihfjg tlMK= niax^ * 

obtatnabie ffieehsniisal pro^rtlis. Special 

«Bph*$ls was given to the fatigue strerigth 

which Is of particular Importance in Islgh 

strength steels, 

ixPERWEStAt DffiiitLS • '', ' 

The steel was pro^tocfd cbnJBierclalf.ly by ^ 

electric n-H process:. Thf eiiposiwon {«tJf) 

1$ ,is foll^ : C QM, Si <J.40, $ 0.^18, 

P Q.QZ7, in 0.94, m 1.32, fer l.l| , Mo Oi*!, 

€u 0,11, $ft O.Oll. t«st specJiliBens were 

c^-^alned ffrrtB rtBttangulae castlifgs SSSORW 

long and IBOno sqirare cast vertlsatly Ili a 

iiry sand mould having grevlSy ffede'r 

heads(5). T^e tasting was sUbse<juei>tly 

sectioned Into sllciis and cut to obtain 

specimens from the edge, mid-section and 

centre Fig.l. 

The heat trfeattnent consisted of oil 

quenching frtwn 880*C. When sufficiently 

cool, the specimens Were ijpersed tn liquid 

nitrogen to obtain the: fnsximimt 

transformation of retained austenlte to 

martenslte. These were subsequently 

tempered at COO'C prior to wichlnlng to the 

final : dlniensions. The microstfUcture is 

shown in Fig.2. 

Some of the specimens were subjected to HIP 

using gaseous argon and the parameters shown 

in Table 1. These were subsequently given 

the same heat treatment as the original 

specimens. 
4.8 TA8LC I RESULTS 

.::5 

• - . i 

i t 

1100 

1160 

103 2 

103 4 

_Ji2 L-. 

Dimsinsions 

In mm 

f1g.i JNwtiisnlng of Casting 

Fig. Microstructyre 

Tensile tests were conducted in accordance 

with 8S18 and Charpy tests as specified In 

BS131. Round fatigue specimens 4.1 mm. 

diameter were carefully prepared to give a 

final surface finish of >0,010 Raum, and 

tested using a rotating bending machine 

with a zero mean stress at a speed of 50Hz. 

The results are presented as stress v log N 

curves. Both the fatigue limit (FL) and 

the fatigue ratio (FR«Fatigue limit/tensile 

strength) are reported. The fractured ends 

of the fatigue specimens were examined by 

both optical microscopy and a scanning 

electron microscope. 

The macrostructure Fig.3 showed columnar 

crystals extending to a depth of 

approximately lOmn from the edge of the 

casting. No microporosity was observed in 

this region, but the area containing 

equlaxed crystals contained microporosity 

which increased In severity toward the 

centre of the casting Fig.4. 

Fig.3 Macrostructure 

ia?r«*jj'T^feir'-''^si7:vlSiSi' '•••.••'•• 

Fig,4 Microporosity 

After HIP no porosity was observed. SEM 

photographs of fractured fatigue specimens 

from the m1d-sect1on and centre of the 

casting showed fatigue cracks originating at 

areas of porosity Fig.5. The closure of 

microporosity by HIP resulted In Increased 

fatigue strength and broken specimens showed 

a normal fatigue fracture Fig.6. 
I 

A. 10 TABLE 3 

"HTAT TREATHW : OO ^O' C t^MPER eoo-c. 

TEMp°C MN/m' WM/m' % S V(J1 

NO HIP 

HID 

gao'c 

MID 

llOO'C 

CENTRE 

1100*C 

857 

995 

992 

890 

890 

910 

864 

-wr 

976 

1085 

1078 

1028 

1025 

1026 

1007 

"XT 

5.0 

13.4 

12,2 

15.8 

14.3 

9.5 

14.5 

3.4 

49.7 

52.2 

28.0 

26.0 

23.0 

•27.2 

30 

40 

40 

TABLE 4 

H^Af Yfe^AMwT; 66 ^bK tmtR m ^ 

mrmTTi 

MID 

CENTRE 

CENTRE 

3 60 

320 

220 

•05r 

0.365 

0.330 

0.230 

REDUCTION 

7 . 7 

18.0 

38.0 

TABLE 5 

HgAt tRgAMNT-.QO §SO*C tfeWpS 

TiTP 

TEMP.'C 

-m— 

NO HIP 

MID 

930«C 

MIO 

llOO'C 

MIO 

1160*C 

MID 

1210"C 

CENTRE 

llOO'C 

MN/n» w r 

INCREASE 

360 

530 

540 

560 

S50 

550 

0.365 

0.500 

0-530 

0.545 

0.535 

0.540 

-

47.0 

50.0 

53.0 

56,5 

71.9 

f 

3 »o 

V, IS). 

turmiii aatitii*Mo*c • (get nitiriiM 

> M D • 

• ciwrae » I 

CTCLES TO fWLUHeil.) 

\ SSO^ I 

a 

3 

»00— • 

CM) »M1 ) f«a mitwi 

• M<IM r. HIP ISOt OO--TtNP m T 

»« (Tci-ts TO MiLune iw 

FIG.8 Effect of HIP at 930»C on Fatigue 

Strength 

I 

!!«' 

> " • •M.iUlW t 

I«««posmw 

» • • «HIHW t 

CTCLIS TO MHUdl « l 

FIG.9 Effect Of HIP at llOO'C on Fatigue 

Strength 

- ^ 

•\^*' 

•'^^^. 

f.4i<t"tiii>''i!'^iyii;'ftMPia'c' 

• dit>TiM*5'-6a.,TO«>*«'C 

« aa.-rty>oo' m c 

5 500. 

» 

£ 5 i»1 

3 

a - w»-

MS-

\ 

• ' \ 

• 

C'tlSS TO FAILUSE IN; 

FIG.7 Effect of Microporosity on Fatigue 

Strength 

FIG.10 Effect of HIP at XISCC and 1210°C 

on Fatigue Strength 
I • Cast Steels after H.I.P 1100 "C 

700H "Wrought Sfeels 

600-

SOOH 

400 

300-

200-

100-

• Cast steets 

Unnofched-Wrought 

Endurance 

Rafio 05 

Notched-Cast 

Wrought 

"~i 1 1 1 rUtiO 600 800 

— f 

120 

FIG.11 Comparison of Fatigue Properties 

with that of Evans et-al,,(l) 

DISCUSSION 

The mechanical properties of cast steel 

are related to the solidification process. 

A thick sectioned casting will cool rapidly 

at the edge forming columnar crystals which 

have superior mechanical properties to that 

found In the central areas. The rate of 

cooling progressively decreases with 

increasing distance froni the edge, formlnf 

equlaxiel crystals end associated microporosity. The mechinical properties are 

shown to deteriorate toward the centre of 

the casting due BJalnly to the increased 

incidence of microporosity. The proof 

stress and tensile strength are only 

marginally affected but the S elongation 

and t reduction in area are drastically 

reduced, Table 2. This Is a characteristic 

feature of thick sectioned steel castings 

(7). The minimum mechanical properties 

required by standard specifications are 

those generally obtained from thin 

sectioned test pieces such as "keel 

blocks". The macrostructure consists 

entirely of columnar crystals and will 

provide the highest attainable mechanical 

properties. It is therefore evident that 

these will not be representative of the 

mechanical properties obtained in thicker 

sections. 

It has previously been shown (5)(6) that 

hot isostatic pressing at a ten^)erature of 

llOCC to UIO'C is an effective means of 

closing internal porosity and improving the 

mechanical properties of cast steels. 

However, in the present work similar 

results were obtained in a cast steel with 

a tensile strength of 1000 HN/m* at a HIP 

temperature of 930°C. The mechanics! 

properties of specimens from the mid-section 

and centre of the casting were restored to 

the same values as that of the nonnel edge 

specimens Tables 2 end 3. The improvement 

in the X elongation and S reduction in e m 

was greater than that of the proof stress 

and tensile strength. It is therefore clear 

that HIP produces uniform mechancial 

properties from the edge to the centre of 

the casting. 

After machining the mid-section and centre 

specimens, surface microporosity was 

revealed which caused a reduction tn the 

fatigue limit of up to 38X, Table 4, Fig.7. 

Notched fatigue values determined on edge 

specimens showed that this is equivalent to 

a stress concentration (Kt) of 2.2 which is 

considerably greater than the Kt of <1.4 

generally recommended in the design of steel 

castings (8). The severe stress concentration caused by the microporosity is due 

to the acuity of the root radius of the 

cavity, Fig.4. SEM photographs of broken 

fatigue specimens clearly show that microporosity form nucleating sites for the 

initiation of fatigue cracks, Fig.5. After 

HIP and the closure of microporosity a 

normal fatigue fracture occurs F1g-6, After 

HIP at temperatures frcM» gSC C to 1210"C the 

mid-section and centre specimens showed an 

Increase in the fatigue limit of from 

47-70S, Table 5, F1g.8. As in the case of 

the tensile ductility so with the fatigue 

strength there is no advantage to be gained 

by using HIP temperatures in excess of 

930*C, Figs.9 & 10. Tidbury and Ricklnson 

(9) have also shown that effective closure 

of microporosity was achieved in en alloy 

cast steel at a KIP temperature of 900''C. 

It will be observed that a fatigue limit of 

530-550 MN/m» achieved after HIP is greatly 

In excess of the 390 MN/m* obtained in the 

normal edge specimens. Since the tensile 

strength is only marginally improved due to 

the closure of microporosity by HIP, the 

increase in the fatigue ratio is 

considerable, from 0.39 in the edge 

specimens without HIP to 0.54 in the 

mid/centre specimens after HIP, A similar 

fatigue ratio was obtained in the edge 

specimens after HIP. It is therefore clear 

that during the HIP cycle both the closure 

of microporosity and the consolidation of 

the dendritic structure occurs. When the 

mechanical properties achieved after HIP are 

compared with the work of Evans et.al.,(l) 

Fig.11 it is seen that the fatigue limit 

after HIP is considerably higher than that 

of normal cast steels at the same strength 

level and approaches that of comparable 

wrought steels. It is therefore evident 

that the HIP process is capable of 

transforming a severely "notched" cast steel 

with inferior nwchancial properties into a 

material with the highest integrity without 

the anisotropy in mechanical properties 

4.11 
.-a-aiv 

.fiSfti: m SU'i. 

4.12 which Is characteristic of wrought steels. 

In view of the advantages of casting es a 

production route this aspect will be of 

considerable interest to design engineers. 

After HIP at 930'C the grain size was much 

small'er than that obtained after HIP at 

higher temperatures. With the advent of 

faster cooling rate* In modem HIP 

equipment (10), a combined HIP plus heat 

tnsatraent cycle Is feasible. The use of an 

air hardening cast steel with a HIP 

t«i^)erature of 930»C followed by rapid 

cooling and tempering at 600*C should 

produce acceptable mechanical properties. 

The econcHfllc advantage Is self evident. 

CONCLUSIONS 

1) Microporosity in cast steel has an 

adverse effect on the mechanical properties 

particularly the i elongation % reduction 

In an a and fatigue strength. 

2) Internal microporosity may be 

effectively closed at a HIP twoperature of 

SSO'C resulting In uniform tensile 

properties throHjghotit a 400B»I thick 

casting. 

3) After HIP, specimens machined from the 

central areas of the casting showed an 

increase fn fatigue limit of 50-70S. The 

fatigue ratio was substantially higher than 

that normally obtained In cast steels. 

4) By means of HIP, cast steels with a 

conqjarable Integrity to wrought steels may 

be produced. 

ACKNOWLEDGEMENTS 

The authors wish to acknowledge the 

assistance of roenbers o f the technician 

staff. Polytechnic of Wales with the 

machining of specimens and Mrs. C. Tyndall, 

Science Department for the operatio n o f the 

scanning electron microscope. 

REFERENCES 

5) t. Strode, M.B. Bassett, C. Oavles: 

Effect of Hot Isostatic Pressing on 

Fatigue Strength of Cast Steel, Metals 

Technology, 9, Sept.1982, 349-354. 

6) I. Strode, Hot Isostatic Pressing of H12 

Cast Die Steel. Proc. Third Int.Conf. on 

Isostatic Pressing. London, Vol.1, 1986, 

37.1-37.U 

7) P.J. Ahearn, G.W. Form, J.F. Wallace: 

High Strength Steel Castings Mass Effect 

on Tensile Properties, Irans . Amer, 

Foundrywens Soc., 1962, 70, 1154-1160. 

8) C. Vishnevsky and J.F. Wallace: A Study 

of the Notch Effect and of Specimen 

Design and Loading on Fatigue Properties 

of Cast Steel, Amer. Foundrymens Soc , 

Cast Metals Research Jnl., 4,2,1968, 

95-102. 

9) I.E. Tidbury and B.A. (Dickinson, 

Opportunities for combined HIP/HEAT 

Treatment. Proc. Third Int.Conf, on 

Isostatic Pressing, London, 1986, Vol.2. 

34,2-34.9 

10) Mammoth Isostatic Press Gommlssloned, 

Metals and Materials, 3,1, Jan 1987, 20. 

i 

1) E.B. Evans, L.J. Ebert and C.W. Briggs: 

Fatigue Properties of Cwnparable Cast 

and Wrought Steels, Proc. ASTM, 56, 

1956, 979-1010, 

2} H.D. Hanes, D.A. Seifert and C.R. Watts: 

Hot Isostatic Pressing, Pub,No. 

MCIC-77.34, 1979, Columbus. Ohio, 

Battelle Memorial Institute, 

3) Superalloys "80", ASM, Proc.Conf. 

Champion, Pa., U.S.A., 21-25 Sept.1980. 

4) B.A. Rickinson, HIPping Brings Hew 

Horizons for Casting Manufacture, 

Metals and Materials, 1,2, Feb.1985. 

104-107. 

m. 

m 
Exhibit B 
>

-

UJ 

> 

• <E LD 

• L L 

g o en 

> 

1= V 

CO " I 

x o ; 

l et -i ' I t — r-~ X '4; 1:1 « in ,% a. oci 

u 
Exhibit C 
Lifesaving Systems Corp. 

Test Data Sheet 

Test Name: 

Reference: 

Lot Number: 

Serial Number: 

Test Device: 

Date: 

Load Test D-LOK Cast Hoist Hook Body 

LSCp/nMW-lC 

Preproduction Sample 

n/a 

LSC Load Cell and Pull-Test Fixture 

30 November 2007 

Test Resluts: 

U410-JC D-LOK cast hook body finished in accordance with the processes 

defined for part (-L hook body) of drawing Ml 0-01 rev. C was threaded 

(1/2-20) and suspend by threaded shank to the free end of a hydraulic 

cylinder in LSC's pull test fixture. A ring was placed on the throat of the 

hook body as would he used in actual service. The opposite side of the ring 

was secured to a fixed load cell for force measurements. 

The hook body was then subjected to static load test in which the following 

observations were made: 

8000 lbs load No observable deformation 

10,000 lbs load Slight deformation amounting to 0.020" 

defection in the nose of the hook 

^—• / 

Test Performed By: Sam Maness, CEO 
Exhibit D 
Lifesaving Systems Corp. 

Test Data Sheet 

Test Name; 

Reference: 

Lot Number: 

Serial Number: 

Test Device: 

Date: 

Cycle Test of D-LOK Cast Hoist Hook Body 

LSCp/nU4'lO-lC 

Preproduction Sample 

n/a 

LSC Load Cell and Pull-Test fixture 

16 January 2008 

Test Resluts: 

U410-1C D-LOK cast hook body finished in accordance with the processes 

defined for part (~1. hook body) of drawing Ml 0-01 rev. C was threaded 

(1/2-20) and suspend by threaded shank to the free end of a hydraulic 

cylinder in LSC's pull test fixture. A ring was placed on the throat of the 

hook body as would be used in actual service. The opposite side of the ring 

was secured to a fixed load cell for force measurements. 

The hook body was then subjected to 100 cycles at SI00 lbs. For each cycle 

the load was applied momentarily (2-3 seconds), and then the load released 

momentarily (2-3 seconds) prior to repeating cycle. Upon completion of the 

cycle test, the hook was visually inspected and dimenstonally compared to 

its pretest measurements. No damage or deformation was observed from the 

cycle test. 

The same hook body was then subjected to a 9.400 load (max capability of 

LSC's test fixture) without failure. Slight permanent deformation of the 

hook hodv did occur. 

<K 

Test Performed By: 

UAa^ L'-"--"' 

>Sw Maness, CEO 
Exhibit E 
CAST D-LDK HnDK EDDY 

GROSS FLAW. 55,170 THRU-HDLE 

INTRDDUCED FDR FATIGUE TESl 

LIFESAVING SYSTEMS CORP. 

aaO ELSBERRY RD, APOLLD BEACH, FL 33572 

TELi 813-645-2748 FAX. 813-645-2768 

COPYRIGHT <R) 2007 REV. REVISIDN DATE 

SCALE DRAWN BY 

MATERIAL DATE APPRDVED NAME DRAWING ND.