Air force 14. 1 Small Business Innovation Research (sbir) Proposal Submission Instructions
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DESCRIPTION: Fifth-generation fighters and modern bombers require materials that can withstand joint flexure without cracking, shrinking or thermally expanding over the life of the aircraft. When damaged, current material systems require extensive maintenance man-hours resulting in high rates of aircraft downtime. Although these materials systems must pass 'qualification' testing, the materials continue to fail at high rates indicating insufficient and/or inadequate test protocol. Thus, a novel standardized test producing accurate stress/strain fields and realistic environmental conditions for outer mold line (OML) treatment stack-ups is desired. Focus should be placed on developing a novel, multi-configuration test fixture along with testing methodology that simulates stress concentrations due to geometry, tensile, compression, and shear fatigue mechanisms across aircraft joints that occur around quick access, infrequent, and frequent access panels. The testing methodology should accurately simulate the harsh environmental conditions, stresses, vibration, flexure and fatigue and aircraft's OML joints experience over the life cycle of the aircraft. The proposed protocol must be performed as a laboratory test that can be carried out with either standard or customized laboratory equipment available at a reasonable cost. A single test fixture is preferred, but multiple test fixtures to simulate the aforementioned joint configurations is acceptable. The test fixture should accommodate testing on an individual material as well as a multi-material stack so conditions can be broadened/focused as needed. The test method should also address Coefficient Thermal Expansion (CTE) mismatch and thermal expansion of coating materials in and over the joints. For CTE’s evaluation, the substrates utilized should be constructed of conventional aircraft materials (e.g. aluminum, carbon fiber and titanium). Cycling of stresses and thermal loads is desired over a temperature range of -65ºF to 700°F. An accurate in situ determination of disbonds, cracking, delaminations and electrical discontinuities is needed to determine material performance in real time. The generation of materials property data, including hysteresis and error is required. The test method should be as simple as possible while able to be adjusted for a variety of simulated flight environments, profiles, and ground conditions. Utilizing aircraft manufacturers to assist in providing information on current joint geometries, methods and procedures is highly recommended. Researchers should be familiar with current ASTM practices and procedures for aircraft materials (see references). PHASE I: Demonstrate test fixture(s), test methodology, and data collection protocol on COTS or otherwise available materials under ambient conditions. Identify improvements over current ASTM standards. Specify all COTS/custom equipment and software requirements. Demonstrate the operating envelope, reliability, and reproducibility of the fixtures and methodology. Develop Phase II transition plan. PHASE II: Demonstration of test fixture(s), test methodology, and data collection protocol on materials stack-ups under variable conditions (temperature, pressure, humidity, vibration, etc.) to simulate operational aircraft environment. Demonstrate the accuracy of the test instrumentation and ability to determine failure mechanism (disbonds, cracking, delaminations, electrical discontinuities, etc.). Develop test bias, reliability and reproducibility information. Refine transition plan. PHASE III DUAL USE APPLICATIONS: Commercialization of the test fixtures, methodology, and data collection protocol and the establishment of the protocol as standard test methods (ASTM, SAE, etc.). REFERENCES: 1. ASTM D2240--Standard Test Methods for Rubber Property—Durometer Hardness. 2. ASTM D7028--Standard Test Methods for Glass Transition Temperature of Polymer Matrix Composites by DMA. 3. ASTM D1002--Standard Test Method for Apparent Lap Shear Strength of Single Lap Joint Adhesively Bonded Metal Specimen by Tension Loading. 4. November 19, 2008, Xingcun Colin Tong, Advanced Materials and Design for Electromagnetic Interference Shielding, 5. March 1, 2009, John S. Dick, Rubber Technology 2E: Compounding and Testing for Performance. KEYWORDS: Adhesive, tape, bond, filler, gap, mechanical, environmental, standard. AF141-168 TITLE: Chrome-Free Room Temperature Curing Fuel Tank Coating KEY TECHNOLOGY AREA(S): Materials / Processes OBJECTIVE: Develop an alternative non-chromated fuel tank coating that can cure at room temperature and meets the requirements of Society of Automotive Engineers (SAE) AMS-C-27725. DESCRIPTION: SAE AMS-C-27725 fuel tank coating is a proven technology for inhibiting corrosion and microbial growth in aircraft structures that are in contact with jet fuel. Hexavalent chromium, an ingredient in SAE AMS-C-27725 materials is an Environmental Protection Agency (EPA) toxic material and a significant occupational health concern with exposure limitations proposed by the Occupational Safety and Health Administration (OSHA). In addition, the elevated heat curing of some currently approved fuel tank coatings increases manufacturing costs and is not feasible for field level repair. The use of currently approved chromated and/or heat cured fuel tank coatings is financially and logistically cumbersome, affecting the aircraft throughout the entire lifecycle.
PHASE I: Identify and develop innovative material(s) to meet fuel tank coating requirements and demonstrate the feasibility of meeting the requirements of AMS-C-27725 and the requirements listed above. Develop initial transition plan and business case analysis. PHASE II: Develop, test, and demonstrate the characteristics of the proposed materials to meet or exceed the requirements of AMS-C-27725. Validate material compatibility with the JSF fuel tank system. Update transition plan and business case analysis. PHASE III DUAL USE APPLICATIONS: Transition to the Fleet via specification modifications and revisions to aircraft weapon system technical manuals. Resolve any logistical constraints that may negatively affect program schedules. REFERENCES: 1. SAE AMS-C-27725, Coatings, Corrosion Preventive, Polyurethane for Use to 250° F (121° C). 2. SAE AMS-3277, Sealing Compound, Polythioether Rubber Fuel Resistant, Fast Curing Intermittent Use to 360 o F (182 o C). 3. SAE AMS-3281, Sealing Compound, Polysulfide Synthetic Rubber for Integral Fuel Tank and Fuel Cell Cavities, Low Density (1.20 to 1.35 specific gravity, for Intermittent Use to 360 o F (182 o C). 4. OSHA Request for Information, Occupational Exposure to Hexavalent Chromium (CrVI). Federal Register, Vol. 67, No. 163, 22 August 02. KEYWORDS: Chrome; Heat-Cure; Room Temperature; Fuel Tank; Coatings; Materials AF141-169 TITLE: Automated Surface Microstructure Nondestructive Evaluation (NDE) Process for Aerospace Materials
OBJECTIVE: Develop and demonstrate an automated technique to nondestructively measure and quantify location specific grain sizes in metallic aerospace materials. DESCRIPTION: The move toward lighter weight, higher performance components for Air Force applications is driving designers toward the use of tailored microstructures to provide the necessary location-specific properties for materials like nickel and titanium. An example is the dual microstructure engine disk, which contains a transition from fine grains at the bore to coarse grains at the rim. Similar desired properties exist within other structural applications as well, including airframes. Critical to fielding such components is the ability to nondestructively inspect and evaluate the microstructure. AFRL Materials and Manufacturing Directorate is interested in the development of a nondestructive evaluation system that can detect AND characterize this tailored surface grain size distribution in aerospace nickel and titanium alloys. For example, due to location-specific failure mechanisms in nickel turbine engine disks, fatigue at the bore and creep at the rim, engine manufacturers have developed heat treatment methods to tailor grain size, 5µm-8µm at the bore and 44µm-70µm at the rim1,2. Failure may also initiate from the so-called “as large as” (ALA) surface grains in the material so it is critical to know the location and size of these type anomalies. In titanium alloys, clusters of similarly oriented primary alpha grains, called microtextured regions, may span length scales of several millimeters. Crack extension occurs easily in these regions due to the lack of high angle grain boundaries leading to reductions in fatigue life3. Because these microstructural anomalies (large grains, microtextured regions) may occur at any arbitrary location on the surface of a component, inspection approaches will need to reliably and repeatably measure and record spatially resolved surface grain size and morphology. Current inspection techniques, including eddy current and fluoro-penetrant, can be limited by geometry size and complexity and do not provide the detailed quantitative picture of surface morphology required to assess location specific grain sizes, most notably in the grain size transition regions. Without an automated solution, manual data collection to characterize the surface becomes extremely costly and time consuming. Given the potential for large quantities of production inspections, successful solutions must provide high level quantitative imagery, including spatially resolved grain orientation maps, and be cost and cycle time competitive with existing inspection techniques. For successful implementation of this new capability, the offeror’s proposed detection and characterization technique is required to be: noncontact (i.e. probes will not directly touch the part being assessed); nondestructive; automated with minimal manual intervention and reduced setup; integrate-able with existing/preferred fixturing and tooling; compliant with existing industry inspection system requirements; and, able to record and store data clearly indexed to the workpiece. In its final implementation state, output from this inspection system must integrate with existing data systems used for statistical process control analysis. The system should be capable of mapping the microstructure to a minimum resolution of = 20 µm and a desired resolution of = 7 µm at a rate in excess of 2,000 points per second on material with a maximum surface roughness of 120 µ-inch RMS. The prototype system should be able to scan flat, convex and concave surfaces and cover a part volume with dimensions 36” x 36” x 18”. Scalability to encompass larger volumes is desired but not required. Successful approaches should stress not only potential scanning technologies but equally, the data interpretation algorithms/methods development necessary to provide the desired information regarding grain size and orientation distribution. PHASE I: Develop and demonstrate the feasibility of the system concept described above. Stress data analysis to characterize the microstructure. System design should include analysis methods, software, hardware, and external interface components including assembly tooling requirements and assessment of high-risk technologies required for characterization of complex geometries at the desired resolution. PHASE II: Develop, integrate and demonstrate the critical components of the proposed system developed in Phase I, stressing system performance. Demonstration should include a representative inspection piece, environment and set-up of the final product. Demonstration should provide defined approaches to address complex geometry, surface roughness variations, surface treatment variations, and assess the effects of possible coatings. Develop to MRL 5-6 maturity, with systems design & implementation plans. PHASE III DUAL USE APPLICATIONS: Automated NDE for tailored microstructural materials has future applications for military aircraft engines and structures. Once proven in the military, the proposed technology will have similar commercial applications, both in commercial engines and in advanced structures. REFERENCES: 1. Tab M. Heffernan “Spin Testing of Superalloy Disks with Dual Grain Structure”, NASA/CR - 2006-214338, EDR–90712, May 2006. 2. T. P. Gabb et al. “Fatigue resistance of the Grain size Transition Zone in a dual Microstructure Superalloy Disk,” NASA/TM-2010-216369. 3. A.L. Pilchak and J.C. Williams, “Observations of Facet Formation in Near-a Titanium and Comments on the Role of Hydrogen,” Metall. Mater. Trans. A, 42A, 2011, pp. 1000-1027. 4. R Smith, S Sharples, W Li , M Clark and M Somekh, “Orientation imaging using spatially resolved acoustic spectroscopy,“Journal of Physics: Conference Series 353 (2012). 5. Steve D. Sharples, Matt Clark, Mike G. Somekh, Elizabeth E. Sackett, Lionel Germain, Martin A. Bache, “Rapid grain orientation imaging using spatially resolved acoustic spectroscopy,” Proceedings of the International Congress on Ultrasonics, Vienna, April 9-13, 2007, Paper ID 1620. KEYWORDS: tailored microstructure, NDE, hybrid disk, surface morphology, grain orientation, automation, analysis, non-contact AF141-170 TITLE: Efficient shaping or reshaping of complex 3D parts using engineered residual stress KEY TECHNOLOGY AREA(S): Materials / Processes OBJECTIVE: Develop a computational design tool for defining a surface treatment process to produce a desired shape change in a complex, 3-dimensional part and to validate this model in a representative environment. DESCRIPTION: Aircraft The fabrication of integral components is a machining-intensive process that employs non-conventional machining at high material removal rates. One method is high speed milling (HSM), which combines high spindle speeds with high feed rates to produce a high material removal rate. At the present time, one of the biggest limitations of HSM of integral structures is distortion. Distortion results from changes in the residual stress state within the machined component. The removal of material originally containing residual stresses causes the residual stresses to re-distribute elsewhere within the component. In addition, the machining process itself induces additional residual stress. Excessive distortion is a significant concern for aerospace OEMs. Distortion can lead to the introduction of excessive fit-up stresses during assembly, can result in improper joints/connections, and can result in parts being scrapped. In certain instances, machine shops are allowed to use mechanical means (e.g., plastic bending over a fixture) to rectify some of the distortion. This can be effective, but is limited to use on simple geometry and this approach is lacking in quality and traceability. An improved process for correcting distortion (i.e., reshaping back within drawing tolerance) in complex aerospace parts might result in significant cost savings to the aerospace industry. It is well established that compressive residual stresses provide improved fatigue performance and damage tolerance enhancement. To take advantage of this concept, many surface treatment processes have been developed over the past 60+ years that are capable of imparting compressive residual stress into the surface layer of a component. The surface treatment processes vary in the amount of residual compressive stress they impart (magnitude and depth) as well as many other factors such as: cost, applicability to specific geometric features, and traceability/quality control. When surface treatments are applied, the induced plastic deformation (which is the driver for compressive residual stress) also causes distortion. In most cases this distortion is an undesirable consequence that is managed by keeping the processed region small or by having a very stiff part. In certain cases (e.g., shot peen forming, which is used to create curved thin panels for aircraft wings) the distortion itself is the motivation for the use of the surface treatment. The use of surface treatments for shaping of parts is currently limited to pretty simple configurations due, in-part, to the difficulty of achieving a desired complex shape without a computational model of the process. Predictive software tools, which are currently configured to solve the forward problem (solve for distortion and residual stress based on a defined surface treatment process/area), could be adapted to solve the reverse distortion problem (solve for the surface treatment process/area required to produce a desired shape change). When properly developed, this would provide an effective tool for the use of engineered residual stress for shaping complex 3D parts. The objectives of this program would be to develop a computational design tool for defining a surface treatment process to produce a desired shape change in a complex, 3-dimensional part and to validate this model in a representative environment. PHASE I: The focus of Phase I effort is the demonstration of a proof of concept and development of the software tools that will be used to compute the surface treatment needed to reshape the part to the desired dimensions. A simulation of the developed software tools is desired in Phase I. PHASE II: Develop prototype system based on the Phase I development. Integrate 3-D scanning techniques that can used on the part to be reshaped, focusing on critical part interfaces. Use scan data to determine required deformations. A total system demonstration is desired that will reshape a part using these parameters. Optimization and validation of the system shall be demonstrated to be effective in an operational environment (TRL/MRL 7). PHASE III DUAL USE APPLICATIONS: Integrate into a production and/or sustainment environment. REFERENCES: 1. Publication number US6410884 B1 Contour forming of metals by laser peening. 2. http://ceramics.org/ceramic-tech-today/manufacturing/removing-distortion-from-thin-ceramics-with-shot-peening?wpmp_tp=0&wpmp_switcher=mobile Removing Distortion from thin ceramics with shot peening American Ceramic Society Newsletter, Published on April 2nd, 2012 | Edited by: Eileen De Guire. 3. http://www.shotpeener.com/library/pdf/2011063.pdf The Method Of Corrective Shot Peening : How To Correct The Distortion On The Machined Parts, Sutarno and Maris Munthe, Indonesian Aerospace Industry (IAe) Jl. Pajajaran 154 Bandung 40174 Indonesia. KEYWORDS: Aerospace, shaping, reshaping, complex 3D parts, residual stress AF141-172 TITLE: Reliable and Large-Scale Processing of Organic Field Effect Transistors for Biosensing Applications
OBJECTIVE: Develop techniques and processes for scale-up and production of high performance organic field effect transistors that are suitable for biofunctionalization and can be investigated for biosensing applications. DESCRIPTION: Biological sensors are analytical devices that incorporate a biological sensing element that binds to a desired target. The sensitivity and selectivity of biological sensing elements in conjunction with field effect transistors provide a means by which to transduce a binding event using a label-free method into an electrical output. Biosensing using organic field effect transistors (OFET) based on soft matter materials is of interest for a variety of applications in chem-bio detection, environmental monitoring, human performance monitoring and in future platforms as an extension of the human skin for enabling man-machine interfaces. OFETs are ideal due to its low-cost, low-power and operation in aqueous environments.
PHASE I: Develop OFETs functionalized with peptides, aptamers or antibodies. Demonstrate stable and reproducible signal in response to analyte. Demonstrate device-to-device reproducibility with a dynamic detection range, fast response times, stable operation in aqueous conditions (buffer, sweat, or serum). Develop technical roadmap to fabricate devices on a large-scale. PHASE II: Scale-up and optimize OFET fabrication process of devices in sufficiently large quantity for desired application demonstrations, while maintaining cost effectiveness for potential implementation. Fabricated prototype devices with biosensing functionalities must demonstrate <10% variance in performance and stable operation for > 10,000 measurements cycles. PHASE III DUAL USE APPLICATIONS: Military Application: Advance sensors for chem-bio, human performance monitoring and man-machine interfaces. Commercial Application: Sensors for healthcare, environmental monitoring. Sensor modules can also find use with law enforcement and first responders. REFERENCES: 1. Hammock M. L. et al., (2013). Investigation of Protein Detection Parameters Using Nanofunctionalized Organic Field-Effect Transistors ACS Nano 7, 3970-3980. 2. Roberts M. E. et al. (2008) Water-stable organic transistors and their application in chemical and biological sensors PNAS 105, 12134-39. 3. Kwon O. S. et al. (2012) Flexible FET-Type VEGF Aptasensor Based on Nitrogen-Doped Graphene Converted from Conducting Polymer ACS Nano 6, 1486-1496. Directory: wp-content -> uploads -> 2016 2016 -> 2017 afoCo Landmark Scholarship Program 2016 -> Instructions for the Preparation of Camera-Ready Contributions to the Conference Proceedings 2016 -> Step student Scholarships for Year 10-13 2016 -> The united church of canada 2016 -> Idan raichel biography – May 2016 Brief Producer, keyboardist, Lyricist, composer and Performer Idan Raichel 2016 -> An introduction to centre’s interventions expanding access to justice 2016 -> Sanchar Shakti 2016 -> Unit analysis should help here. We want number of bananas 2016 -> The Autobiography of Elder Joseph Bates 2016 -> The Great Heat and the Rhode Island Deep Water Bay Scallop (Argopecten irradians) Fishery 1875-1905 Download 1.72 Mb. Share with your friends:
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