Air force 14. 1 Small Business Innovation Research (sbir) Proposal Submission Instructions
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PHASE II: Further develop the product from Phase I. Identify and include additional factors for improvement following the Phase I proof of concept. Demonstrate the model assisted characterization method on a generic but representative structural aircraft or turbine engine component. With assistance from the TPOC, demonstrate the capability for at least one relevant fabrication or repair application with at least one prospective end-user. Develop a business model for application of the methodology. PHASE III DUAL USE APPLICATIONS: Further optimize the methodology based on Phase II results. Develop a toolset that will rapidly estimate the dimensions of life-limiting defects and their probability of occurrence in additively manufactured and/or repaired components. Establish a commercialization plan, and transition technologies. REFERENCES: 1. Gorelik, M., Peralta, A., Singh, S., “Role of Quantitative NDE Techniques in Probabilistic Design and Life Management of Gas Turbine Components – Part II”, GT2009-60358, Proceedings of IGTI 2009 Conference, Orlando, FL. 2. Bordas, S. P. A., Conley, J. G., Moran, B., Gray, J., Nichols, E., “A simulation-based design paradigm for complex cast components,” Engineering with Computers, Vol. 23, pp. 25-37, (2007). 3. Aldrin, J. C., Medina, E. A., Lindgren, E. A., Buynak, C. F., Steffes, G., Derriso, M., “Model-assisted Probabilistic Reliability Assessment for Structural Health Monitoring Systems,” Review of Progress in QNDE, Vol. 29, AIP, pp. 1965-1972, (2010). 4. Achenbach, Jan D., Structural health monitoring – What is the prescription? Mechanics Research Communications 36 (2009) 137–142. KEYWORDS: additive manufacturing, non-destructive inspection, probability of detection, design of experiments, defect characterization, probabilistic methods, repair AF141-163 TITLE: Fabrication of aberration-free gradient index nonlinear optical materials KEY TECHNOLOGY AREA(S): Materials / Processes 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 5.4.c.(8) of the solicitation and within the AF Component-specific instructions. Offerors are advised foreign nationals proposed to perform on this topic may be restricted due to the technical data under US Export Control Laws. Please direct questions to the AF SBIR/STTR Contracting Officer, Ms. Kristina Croake, kristina.croake@us.af.mil. OBJECTIVE: To prepare aberration-free gradient index linear and nonlinear optical materials, this SBIR will investigate materials fabrication techniques that enable the control of the real and imaginary linear and nonlinear indices in three dimensions. DESCRIPTION: The Materials and Manufacturing Directorate of the Air Force Research Laboratory has an interest in developing materials for nonlinear optics applications. Current solid state nonlinear optical materials consist of a monolithic polymer or sol-gel chemistry-based prepared as a slab or step concentration gradient. These materials contain a uniform dispersion of a nonlinear optical material or a semiconductor. The materials respond to laser radiation by various mechanisms including multiphoton absorption, nonlinear refraction, nonlinear absorption and free carrier effects. Examples of these nonlinear optical materials are two-photon-absorbing dyes, polymers like poly(phenylene vinylene), phthalocyanines, platinum acetylides, semiconductor dispersions and quantum dots. Problems with system integration result from linear loss, optical aberrations, laser damage, thermal lensing, formation of scattering centers and excimer formation. Thus, these materials do not perform well in real world optical systems. Improvement of performance and system integration requires invention of materials that have enhanced nonlinear optical response via custom engineered nonlinear light propagation capability in three dimensions. The ability to control the real and imaginary components of the linear and nonlinear refractive index would give the designer additional freedom to achieve system integration. This SBIR will fund research on methods for preparing nonlinear gradient index optical materials with the capability of three-dimensional control of the real and imaginary linear and nonlinear indices of refraction, including the fabrication of axial index gradients, radial index gradients and combination gradients. This capability would make possible optical designs far beyond what can be done today with monolithic elements. Specific applications include design of a multilens system in one element, waveguides, optical interconnects, tailor-made optical elements with designed concentration gradients in three dimensions, management of thermal lensing and optimizing the focal volume. Technologies like multilayer processing, three dimensional laser lithography, ink jet printing and aerosol jet printing make possible fabrication of these new optical elements. Currently it is feasible to fabricate GRIN optics by multilayer processing. It is also feasible to prepare axial concentration step gradients composed of machined polymer slabs. The next step is to prepare a nonlinear optical element with a designed three-dimensional nonlinear index gradient. A fundamental problem with fabricating these materials is inventing techniques to prepare a three-dimensional array of submicron-sized voxels each having a user-specified composition and XYZ coordinate. The performance of a material in an optical system is strongly influenced by the specifications of the optical system. These methods will improve system integration by making possible system-specific optical element design. An example of a cylindrical optical element that could be prepared by this technique would be composed of a mixture of a linear optical polymer with a nonlinear optical polymer. Example specifications are length = 1 mm, diameter = 1 cm, parabolic radial nonlinear index gradient with nonlinear optical susceptibility at the center = 1000x that of silica. Deliverables include optical slabs with designed concentration gradients in three dimensions similar to a Wood lens and an all-in-one optical system composed of linear and nonlinear elements. Final success of this technology would involve design of a nonlinear optical system by beam propagation modeling, fabrication and proof of concept by measurement of the beam profile entering and exiting the system. PHASE I: Prepare a cylindrical (1 cm diameter x 1 mm thickness) solid state nonlinear GRIN lens with a parabolic radial nonlinear index gradient. The difference in third order susceptibility between the center and edge should be 1,000x that of silica. The lens is a three-dimensional array of sub-micron scale voxels having specific XYZ coordinates and mixtures of a linear and nonlinear optical material. . PHASE II: The Phase II research program will build on the knowledge obtained in the Phase I program by fabricating gradient optical systems with variation of the real and imaginary refractive index in three dimensions. The research will demonstrate gradients containing nonlinear materials including chromophores, nonlinear polymers, semiconductor quantum dots and two photon absorption materials. Deliverables of the materials will be provided to AFRL for linear and nonlinear optical characterization PHASE III DUAL USE APPLICATIONS: The Phase III research program will focus on fabrication of optical elements according to a design. The designs include commercial devices like optical interconnects and waveguides. The measured nonlinear optical performance of these elements will be compared to beam propagation modeling data. REFERENCES: 1. Moore, D.T. "Gradient index optics - a review" Appl. Optics. 19, 1035(1980). 2. Vacirca, N.A.; Kurzweg, T.P. "Inkjet printing techniques for the fabrication of polymer optical waveguides" SPIE Proc 7591 (2010). 3. Fozdar, D.Y.; Lu, Y.; Sheo, D.; Chen, S. "Nano/microfabrication techniques in organic electronics and photonics" Handbook of organic electronics and photonics" 1: 113(2008). 4. Yulin, L.; Tonghai, L.; Guoshua, J.; Baowen, H.; Junmin, H.; Lili, W. "Research on micro-optical lenses fabrication technology" Optik 118: 395(2007). 5. Ingrosso, C.; Panniello, A.; Comparelli, R.; Curri, M.L.; Striccoli, "Colloidal inorganic nanocrystal based nanocomposites: functional materials for micro and nanofabrication" Materials 3, 1316 (2010). KEYWORDS: gradient, GRIN, nanocomposite, photonics,microlens AF141-164 TITLE: Programmable Accelerated Environmental Test System for Aerospace Materials KEY TECHNOLOGY AREA(S): Materials / Processes OBJECTIVE: Develop a programmable materials test apparatus that can reliably control simulated environmental conditions. DESCRIPTION: Compliance with ASIP (Aircraft Structural Integrity Program), specifically the five tasks stated in MIL-STD-1530C, including establishment of a corrosion control program (Task I) and corrosion assessment (Task II), is mandatory for all USAF aircraft weapon system programs. However, there are currently no design trade tools available to the ASIP community to account for the effects of corrosion protection materials and processes, particularly outer mold line organic coatings, in an effective manner analogous to the way fatigue is accounted for using damage tolerance models for crack growth. This goal is made more challenging because increasingly stringent environmental regulations are restricting the materials that can be used on aircraft e.g. hexavalent chromium, while at the same time the service life of some aircraft platforms have been extended far beyond what was intended for the original design. This necessitates consideration of emerging coatings which can have an array of corrosion inhibition mechanisms (e.g., Mg-rich Zn primer). Currently, ASTM B 117 (5% NaCl neutral salt spray at 35ºC) is used as the standard test method for coated aluminum substrates, but is not viable for evaluating the emerging coatings because it often yields an inaccurate or misleading prediction of in-service performance. This is most likely because ASTM B117 does not expose test articles to combinations of environmental factors that lead to degradation of materials in service. The apparatus to be developed in this program is needed so that new, more accurate accelerated test methods can be created to advance the development of environmentally compliant coatings for corrosion protection by facilitating rapid performance analysis of new materials. The apparatus must be able to apply and control the following conditions: salt spray with ability to alternate between 3 or more electrolyte solutions (NaCl, CaCO3, NaHCO3, etc.) during the same test, temperature (-65ºF to 250ºF), pressure monitoring, relative humidity (up to 100%, variability +/- 5%), and irradiation using an energy spectrum close to that of natural sunlight, with higher than natural spectral irradiance up to 50 W/cm2 in the UVA range (320-400 nm). The apparatus must also be able to apply and control ozone, CO2, and at least one other interchangable background gas during operation. The ozone concentration range must be 30 ppb minimum up to 30 ppm maximum with variability +/- 5% and ozone monitoring sampling rate of 30 Hz. The CO2 and other background gases must be regulated, i.e. using mass flow control. The test apparatus must have user-friendly, software-programmable control on/off for all environmental conditions as well as feedback sensors that detect the flow of ozone and automatically shut off and vent the chamber if a valve or seal fails. The applied environmental conditions must be uniform over the area containing the test articles. It is desirable for the system to include the ability to perform cyclic mechanical loading within the test chamber. It is also desirable to be able to monitor material properties of the test articles (e.g., electrochemical processes, elemental composition, optical characterization) in situ during testing using contact and non-contact methods and apply statistical algorithms to collected data to identify significant interactions between applied environmental conditions. PHASE I: Prove feasibility by design and construction of durable small-scale prototype chamber that can subject a planar area of approximately 1 ft2 to the required environmental conditions and associated tolerances listed in the above description. State plans for inclusion of mechanical loading, material property monitoring, and data analysis. Demonstrate prototype software user interface for control of environment. PHASE II: Design and construct durable full-scale test chamber capable of subjecting a planar area approximately 6-10 ft2 to the required environmental conditions and associated tolerances listed in the above description. Incorporate cyclic mechanical loading, material property monitoring, and data analysis if applicable. Demonstrate software user interface for controlling all environmental parameters. Deliver prototype system with software to AFRL. PHASE III DUAL USE APPLICATIONS: Phase III commercialization opportunities abound with aerospace equipment manufacturers, coating formulators, and DoD laboratories. In addition to aerospace, the technology will be directly applicable to facilities and infrastructure protective coating testing and qualification. REFERENCES: 1. Military Handbook (MIL-HDBK)-1530C, Aircraft Structural Integrity Program, Revision C, (USAF, 1 November 2005) 2. ASTM B 117, “Standard Practice for Operating Salt Spray (Fog) Apparatus” 3. GM9540P, “Accelerated Corrosion Test” 4. SAE J1563, “GUIDELINES FOR LABORATORY CYCLIC CORROSION TEST PROCEDURES FOR PAINTED AUTOMOTIVE PARTS” 5. ASTM D 5894, “Standard Practice for Cyclic Salt Fog/UV Exposure of Painted Metal, (Alternating Exposures in a Fog/Dry Cabinet and a UV/Condensation Cabinet)” KEYWORDS: Accelerated corrosion, hexavalent chromium, ozone, ultraviolet (UV) radiation, organic AF141-165 TITLE: Standard Test Method for Prepreg Resin Impregnation Level KEY TECHNOLOGY AREA(S): Materials / Processes OBJECTIVE: Develop a standard test method to quantitatively validate prepreg resin impregnation levels with improved fidelity as compared to current practice for better material and process control in the manufacturing environment. DESCRIPTION: The resin impregnation level is important to downstream processing of the prepreg/tape lay-up material and the resultant composite part quality because of its affect on prepreg lay-down efficiency and air/volatile evacuation prior to and during the composite cure cycle. Partial impregnation is a common practice used to manufacture prepreg materials for the defense industry while full impregnation is used for automated tape materials. The products are used on multiple DoD aircraft platforms to benefit part quality through improved process-ability. Air transport occurs via different mechanism depending on the product form (dry mid-plane of prepreg verses interstitial gap in tow/tape placement). Successful air evacuation is especially vital to new generation, vacuum bag only (atmospheric pressure only) cured systems. Improved process-ability translates to improved repeatability and generally improved mechanical performance. This effort will focus on the development of a standard test method which will measure the level of resin impregnation into a fiber bed during prepregging. Current, state-of-the-art test methodologies correlate water uptake levels with fiber bed free volume in a partially impregnated prepreg material. The accuracy/repeatability of this technique is estimated to be +/-5%. A test method with an accuracy of +/-1% is desired to provide composite part fabricators and end users with better confidence in their raw materials, products, and reduced manufacturing cost of quality by enabling material specifications to incorporate prepreg batch acceptance requirements for impregnation level. PHASE I: The Phase I effort would include the development of methods to quantify level of impregnation (LOI) along with experimental validation proving feasibility. A down-select to the most promising and industry practical method is desired. Develop a preliminary transition plan including test method specification acceptance. PHASE II: Phase II would focus on developing and building a prototype measuring device and developing American Standard Test Method (ASTM) or similar test method guideline. The effort would include demonstration of the selected technique for measuring LOI with a +/-1% accuracy for prepreg and automated tape-grade materials at the material or part supplier. Refine transition plan. PHASE III DUAL USE APPLICATIONS: Phase III would involve commercialization of the product and LOI method. Demonstration that this method is able to quantitatively measure the LOI in prepreg batches for supplier part quality correlation would be desired. Submission to ASTM committee for new standard acceptance is expected. REFERENCES: 1. Peltonen, P., et al. "The influence of melt impregnation parameters on the degree of impregnation of a polypropylene/glass fibre prepreg." Journal of Thermoplastic Composite Materials 5.4 (1992): 318-343. 2. T. Centea, P. Hubert, Modelling the effect of material properties and process parameters on tow impregnation in out-of-autoclave prepregs, Composites Part A: Applied Science and Manufacturing, Volume 43, Issue 9, September 2012, Pages 1505-1513. KEYWORDS: composite, prepreg, partial impregnation, standard test method AF141-166 TITLE: Aircraft Fastener Smart Wrench KEY TECHNOLOGY AREA(S): Air Platforms 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 5.4.c.(8) of the solicitation and within the AF Component-specific instructions. Offerors are advised foreign nationals proposed to perform on this topic may be restricted due to the technical data under US Export Control Laws. Please direct questions to the AF SBIR/STTR Contracting Officer, Ms. Kristina Croake, kristina.croake@us.af.mil. OBJECTIVE: Develop a handheld, computer controlled wrench capable of installing commonly used aircraft nuts and collars. The device should be capable of measuring the number of exposed threads and informing the user of improperly installed fasteners. DESCRIPTION: Aircraft manufacturing involves the installation of thousands of a variety of fasteners critical to the structural integrity and performance of the airframe and has strict quality control requirements. Current Air Force acquisition programs have numerous Critical to Quality (CTQ) features for fastener installation that require careful visual and manual inspection and measurements to ensure compliance with engineering specifications. These aircraft inspection and measurement methods are very labor intensive. Because of the large volume of fasteners involved, many hours are needlessly spent conducting post-installation inspections of aircraft fasteners that are already compliant with fastener installation requirements. The objective of this effort is to develop an intelligent, hand held smart wrench system capable of installing a variety of structural aircraft nuts and collars and measuring and storing installation inspection/measurement results. Aircraft manufacturers and Air Force systems would benefit from a system capable of real-time manipulation and feedback. The system should be capable of installing commonly used nuts and collars during the assembly process for current manufactured AF aircraft systems. The system should have the ability to swage the Alcoa Eddie Bolt 2 eddie nut shown in the reference section. The system should have the ability to measure post-installation fastener thread protrusion to the nearest 0.0083 inch, to store and deliver data and installation reports compatible with OEM data storage systems, and immediately inform the user of any fastener installation corrective action that is required. The system should be configured to provide a logical user interface and calibration procedures should be straightforward and quickly performed. The prototype should be robust and maintain operability in an environment where the unit could be inadvertently dropped from heights of up to 5 feet with no adverse impact on system capability. Because the system will be used in a variety of different structural configurations, it will be critical for potential offerors to work closely with an aircraft original equipment manufacturer (OEM) and a working relationship already established with an OEM is preferred. The overall goal of this SBIR project is to deliver a mature prototype unit to an Air Force approved OEM that provides specified requirements capabilities at an affordable cost of no more than $2500 / unit. The Phase I effort should focus on demonstration of the hand held proof of concept. The Phase II effort should focus on optimizing the Phase I design, developing an acceptable user interface and calibration tools, designing a system that is applicable for use in the necessary structural configurations, hardening the system against inadvertent drops and demonstrating that the system meets TRL-7 and MRL-7 requirements. Periodic technology and manufacturing readiness level assessments should be incorporated into this project. PHASE I: The focus of Phase I effort is the demonstration of a proof of concept hand held system on actual aircraft fastener parts. Perform initial business case analysis, manufacturing assessment, and transition plan. PHASE II: Develop prototype unit based on the Phase I development and results. Deliver a prototype and perform initial field testing in coordination with an aircraft OEM. Demonstrate system operability to TRL-7 and MRL-7. Based on test results, identify and perform, if possible, all required iterative modifications. Update the business case analysis and manufacturing/transition plan. PHASE III DUAL USE APPLICATIONS: Finalize transition to other military and commercial partners. REFERENCES: 1. Alcoa Eddie Bolt & Nut Brochure http://www.alcoa.com/fastening_systems/aerospace/en/pdf/eddie_bolt_2_flyer_lr.pdf. 2. Example Pin Protrusion Gauges http://www.deltaintl.com/Hi%20shear/gages/Pin%20Protrusion%20Gages.html. KEYWORDS: Aircraft Fastener, aircraft wrench, aerospace fastener AF141-167 TITLE: Realistic Test Methods for Aircraft Outer Mold Line Treatment Materials KEY TECHNOLOGY AREA(S): Materials / Processes 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 5.4.c.(8) of the solicitation and within the AF Component-specific instructions. Offerors are advised foreign nationals proposed to perform on this topic may be restricted due to the technical data under US Export Control Laws. Please direct questions to the AF SBIR/STTR Contracting Officer, Ms. Kristina Croake, kristina.croake@us.af.mil. OBJECTIVE: Develop a repeatable and accurate test fixture, testing methodology, and data collection protocol to assess the durability of outer mold line treatment stack-ups applied to external joints of a high performance fighter and/or bomber aircraft. 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