Air force 14. 1 Small Business Innovation Research (sbir) Proposal Submission Instructions

AF141-199 TITLE: Optical Isolator for Infrared (IR) Applications (2-15 micron)

OBJECTIVE: Identify, develop and demonstrate materials and techniques based on the magneto-optic effect or nonlinear processes, which can realize nonreciprocal response for optical isolation in Short-IR, Mid-IR, and Long-IR laser applications (2-15 micron).

PHASE I: Develop materials and techniques suitable for constructing an optical isolator based on the magneto-optic effects, time-dependent modulation, and/or nonlinear processes. Strongly asymmetric transmission should be achieved in the 2-15 micron spectrum for free space and/or wave-guide setting, including on-chip solutions. A free-space design should account for thermal management at high powers.

PHASE II: Using the results from Phase I, fabricate and demonstrate a device capable of transmitting the light in one direction while blocking the light in the opposite direction with return loss of up to 30-40 dB at power levels of up to 500W. The device may be free space, fiber coupled, polarization sensitive or polarization independent. Identify and propose a design, which will allow for broadband operation of the optical isolator.

PHASE III DUAL USE APPLICATIONS: Based on the results of Phases I and Phase II, develop and demonstrate an on-chip fiber-coupled broadband optical isolator in the 2-15 micron spectrum with return loss of 40 dB or better and insertion losses of less than 5 dB.

REFERENCES:

1. Lei Bi, et al, "On-chip optical isolation in monolithically integrated non-reciprocal optical resonators," Nature – Photonics, 5, 758 (2011).

AF141-203 TITLE: Improved LHE Zn-Ni and Cd Plating Process

OBJECTIVE: Show feasibility of reduced Hydrogen Embrittlement relief post-plate bake times for cadmium, chromium and ZnNi on high strength steel landing gear parts. The current industry standard is a 23 hour bake; much shorter bake times are desired.

DESCRIPTION: Relief baking and plating operations are currently required by LHE (low hydrogen embritteling) MIL-STD-870 (cadmium plate), USAF drawing 201027456 (Zn-Ni plating) and MIL-STD-1501 (Chromium plate). Recent HE testing has shown that hydrogen can effectively be relieved with much lower final bake times. Lower bake times represent a significant savings to the USAF and industry in terms of processing hours and cost.
To demonstrate safety of flight with reduced bake time, the following required qualification tests will be accomplished on 260-280 Ksi UTS 4340 HSS test coupons:

• Hydrogen Embrittlement (ASTM F519-05)

• Stress Corrosion Cracking (ASTM E 1681 or approved equivalent)
The HE testing standard will be a 200 hour (75% NFS) sustained tensile stress test. HE coupon testing will utilize test samples of 4340 high strength steel (260-280ksi). Currently the only facility applying LHE ZnNi plating per USAF drawing 201027456 is located at Hill AFB. All parameters and results will be recorded and reported. All test procedures and test criteria shall be coordinated and approved by the USAF requirements office and be accomplished according to approved industrial standards with deviations approved by the TPOC. This project has applicability to all commercial /industry plating operations utilizing LHE varieties of cadmium and ZnNi plating. All test plans and data results will be subject to customer review and expert panel review (ASTM F.07 HE committee), at the discretion of the TPOC.
The following required qualification tests will be accomplished High Strength Steel (HSS) including Aermet 100, 4340, S53 and possibly 300M test coupons and landing gear components to determine a safe minimum post bake time for HSS:

• Adhesion and Paint Adhesion (ASTM B571)

• Hydrogen Embrittlement (ASTM F519)

• Fatigue (ASTM E466)

• Corrosion (ASTM B117)

• Stress Corrosion Cracking (TBD)

PHASE I: Each F 519 sample group will be cad plated, and tested as described above with varying bake times utilized. Sample groups shall consist of 4-8 specimens. At a minimum; sample group bake times will vary 1, 1.5, 2, 3, 4, 8 and 23 hours. The process will be repeated for LHE ZnNi plated specimens. All samples shall be pulled to failure after the HE testing is complete.

PHASE II: Testing outlined in phase one will be repeated based on a rigorous design of experiments approach. Additional testing will be accomplished chromium plate added to additional groups of ZnNi and Cad plated coupons. Testing will also include comparative stress corrosion cracking resistance (per ASTM E 1681 or approved equivalent) and general corrosion. Anomalies noticed in phase I will also be re-evaluated/defined and possibly re-tested; thicker material sections will also be considered.

PHASE III DUAL USE APPLICATIONS: Will be implemented by the USAF if justified. Acceptance by industry through ASTM F.07 Hydrogen Embrittlement Committee review.

REFERENCES:

1. AF Dwg 201027456.

AF141-204 TITLE: Improve Energy Source for NDI Equipment Tools

OBJECTIVE: Design, develop, and create an improved energy source that can be used as the primary power source for Eddy Current (EC) and Ultrasonic (UT) nondestructive testing inspection (NDI) equipment currently in use throughout the Air Force.

DESCRIPTION: Nondestructive testing equipment in the AF is normally used in flight lines and hangars where current use of batteries are required but are costly and require daily recharging. EC and UT equipment currently in use in the AF has the options of using Lithium-ion, NiMH, NiCAD, or Alkaline battery in any of this equipment. Transport and disposal of spare batteries is a shipping and environmental cost to the AF. With the advances in technology in the utilization of alternate power sources such as solar energy and fuel cell designs, there is a good possibility that other forms of energy power can also be used as the primary power source for AF NDI equipment. The goal is to reduce costs of electrical consumption, eliminate use of harmful toxins that destroy our environment, increase portability and usability of equipment, increase utilization of instruments at deployed locations, and increase safety of personnel. Considering the numbers of this equipment in the AF, cost savings and reduction of hazardous materials can be significant.
Research feasibility and applicability of improved alternate energy source to current battery configurations as source of power supply for EC and UT NDI equipment currently in use in the AF. Design a new alternate source that could be used interchangeably between EC and UT NDI equipment. Research capability of alternate source design that will have high capacity and operating time as long as if not longer than the most efficient storage battery currently in use. Validate and verify performance of new alternate source when used for EC and UT NDI equipment.

PHASE I: Research the operating parameters for the various NDI hand tools noted above and develop concept design for utilizing new energy capability to replace existing required battery sources in the hand tools. Phase I report should describe details of the design; necessary test plans and performance parameters, demonstrate power requirements and how proposed solar power design can be accomplished.

PHASE II: Based on approved design approach from Phase I, develop working prototypes for the selected models and perform validation testing IAW Test Plan from Phase I with users in AFSC and field groups.

PHASE III DUAL USE APPLICATIONS: If this project will prove successful, it will flow throughout the nondestructive testing industries such as aerospace, oil, auto, construction, and others where NDI is a major factor and the same and similar types of NDI equipment are used.

REFERENCES:

1. Tech Order 33B-1-1 (Nondestructive Inspection Methods, Basic Theory).

AF141-205 TITLE: Non-Destructive Inspection for Medium Caliber Gun Barrel Fatigue Crack

OBJECTIVE: Development of a non-destructive inspection (NDI) for medium caliber gun barrels to assess the presence and severity of fatigue cracks in the barrel walls.

DESCRIPTION: Barrels have a variety of failure modes that must be monitored over the life of a barrel. Each barrel type typically has a driving failure mode that dictates the replacement schedule that must be adhered to when fielded. Fatigue cracking is one of the more critical failure modes that must be prevented as it will result in a catastrophic barrel rupture. This is typically prevented by assigning a maximum rounds count to the barrel set. This mandatory replacement point is the worst case crack growth rate with an appropriate safety factor applied. However, most barrel sets do not see these worst case conditions therefore more life could be gleaned from most barrels sets if a means of accurately determining fatigue crack length could be developed.
An NDI method is being sought after that will accurately and reliably assess fatigue cracking in gun barrels and compare it against a maximum allowable crack length. The new method would require the barrel wall to be assessed throughout its thickness and over its entire length. The machine must automatically compare any cracks found to the given limits with little to no manual intervention. The machine will preferably be portable, such that it can be used on flight lines without removing barrels from the aircraft. In addition, it is also preferred that is technology be incorporated into existing laser bore mapping equipment, such that all barrel inspections can be accomplished through one machine.
Currently, a method in which existing NDI equipment can be used to assess barrel wall fatigue cracking is unknown. This project will most likely require new equipment to be developed to accomplish the crack assessment along with new procedures for the use of the new equipment. This project may potentially require the coordination of the contractor with USAF testing facilities and the loaning of USAF barrels for inspection testing. The technical point of contact will coordinate the required access to USAF testing facilities.

PHASE I: Develop the ability to accurately and reliably detect fatigue cracks in medium caliber gun barrels. Define the resolution, defect detection and localization with sub-mm accuracy.

PHASE II: Demonstrate the non-destructive evaluation of cracking in barrels and comparison against crack limits with complete autonomy other than manpower necessary to interface the machine with the barrel.

PHASE III DUAL USE APPLICATIONS: Incorporation of the NDI equipment into existing bore mapping equipment.

REFERENCES:

1. Title: Measurement and Inspection of Gun Tubes AD Number: ADA270439 Corporate Author: ARMY TEST AND EVALUATION COMMAND ABERDEEN PROVING GROUND MD Personal Author: (Not Available). Report Date: May 14, 1993 Media: 47 Page(s).

AF141-206 TITLE: Nonparametric Recurrent Event Data Analysis

OBJECTIVE: Provide a capability for analysis/evaluation of usage and event data of fielded repairable parts/systems. This capability will provide “ility” performance measures to identify trends and the ability to determine root cause and best course of action.

DESCRIPTION: The required knowledge, software tools and resources to analyze and/or evaluate usage and event data are not generally available across the USAF enterprise. The reasons for this lack of availability are complex and varied. These reasons include inadequate component reliability/health metrics, legacy data architectures lacking sufficient indenture, and a lack of understanding that appropriate statistical analysis is a reliability improvement tool.
Historically, Mean Time Between Failure (MTBF), not Mean Cumulative Function (MCF), has been the component reliability/health metric used by the Air Force. Mean Time Between Failure (MTBF), is too lagging to be actionable in the best case, and is not representative of actual system reliability in the worst case. Although the necessary usage and event data is being collected, these data are not readily accessible. When mature, this project will provide reliability analysts access to current Air Force data systems, a full suite of data and statistical analysis tools and the understanding to access and utilize usage and event data in new and powerful ways. Weapon system engineers and supply chain professionals will have fully integrated access to the data and tools necessary for early identification and analysis of those data trends, outliers, and anomalies indicating potential areas of focus for studies and/or corrective action in the repair process.
This notice is intended to insure that any software that is developed will be able to pass Government certifications so the software can be used on Government Networks. If the research effort includes computer systems that meets the requirements of the 2005 National Defense Acquisition Act (NDAA) (10 U.S.C 2222(j)(2)) the following shall be required: an outline during the Phase I R&D effort such that compliance with 10 U.S.C 2222(j)(2) can be accomplished at the point of commercialization (SBIR III). If the project successfully transitions to Phase II, the outline will be used to assist the contractor and government with the documentation necessary to secure National Defense Authorization Act (NDAA) approval. The SBIR PH I NDAA Outline shall be further developed during the Third Quarter of the Year 1 PH II SBIR project such that all documentation required for NDAA can be completed. All documentation for compliance with NDAA 10 U.S.C. 2222(j)(2) shall be accomplished by the Seventh Quarter of the Year 2 PH II SBIR project. The NDAA documentation is required prior to SBIR PH III Commercialization.

PHASE I: Use current software/data management capabilities as a baseline to define the requirements of a new or improved data analysis and data management software package and provide a final report outlining system requirements, flexibility and customizability of parameters, data, and data fields, and Air Force system compatibility assessments. NDAA requirements possible, see above Description for details.

PHASE II: Develop & demonstrate a new or improved data analysis and management software package that provides software tools and resources to evaluate usage and event data from current Air Force Systems to find trends, outliers, or anomalies in the data and provide information to reliability analysts as potential areas of focus for studies and/or corrective action in the repair process. The system must have flexible/customizable parameters, data, and data fields, and be compatible with AF Systems.

PHASE III DUAL USE APPLICATIONS: Implement the data analysis and management software package into Air Force sustainment activities. Import historic usage and event data into the package with parameters provided by the program office and provide output in the form of recommended focus areas for repair of the part/system.

REFERENCES:

1. N. S. Trindade D, "Statistical Analysis of Field Data for Repairable Systems," 2008.

DESCRIPTION: The Air Force and industry partners perform many manufacturing processes with the aim of inducing residual stress in metals to prevent the onset of fatigue induced cracking. Cold working of metal alloys to create localized compressive residual stresses can greatly improve fatigue behavior, particularly in areas of stress concentration. Further, the application of compressive residual stress on the leading edge of compressor or fan blades can reduce an engine’s susceptibility to foreign object damage (FOD). In fatigue loading, compressive residual stresses effectively lower the mean net stress state. Therefore, locations such as fastener holes can greatly benefit from compressive residual stresses, as they tend to mitigate the effects of the geometric stress concentration at that location. In a FOD situation, this can prevent a crack from growing from a damage site.

PHASE I: Develop the basis of an assessment technique that can evaluate coverage and intensity of cold working treatments on materials of interest to the Air Force and how it could be verified through coupon level testing during Phase II of the development.