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

PHASE II: : Develop a prototype cold work evaluation apparatus and develop related software algorithms that will implement the framework from phase I. Demonstrate a procedure for using the prototype to acquire data and show how that data can be used to improve predictive maintenance programs.

PHASE III DUAL USE APPLICATIONS: Deployment to other critical applications would be available in private industry, which arise in the civil aviation, automotive, railroad, heavy equipment, chemical, oil drilling and refining, construction and medical industries.

1. T. Nicholas, J.P. Barber and R.S. Bertke “Impact Damage on Titanium Leading Edges from Small Hard Objects.” Experimental Mechanics (1980): Vol.20, No.10, pp.357-364.

AF141-208 TITLE: Material and Process Specification Optimization

OBJECTIVE: Design, develop, and qualify specifications and processes required for procurement and application of materials that meet the weapons systems quality requirements, reduces cost and improves efficiencies.

DESCRIPTION: As part of the overhaul and repair process for aircraft gas turbine engines, Landing Gear and other critical parts, the repair depots routinely apply large amounts of thermal spray coatings for use in substrate repair build-up, wear, corrosion resistance, thermal barrier and chrome replacement coatings. These coatings are applied at a high cost to the Department of Defense in terms of materials and manpower. In addition to the high cost of coating materials, application of the coatings requires expensive consumable materials including fuels, power and thermal spray equipment components. Other major costs include masking, calibration/maintenance of the spray equipment, laboratory metallurgical testing, reworking of parts that do not meet metallographic requirements, engineering time supporting unacceptable coatings, determining cause and rework. Quite often the needs of the warfighter are jeopardized by inability to supply engine or landing gear components due to failure to determine quality of spray during application of coatings. Additionally, AF programs such as High Velocity Maintenance (HVM) requirements and current/future budgetary constraints are forcing improvements in efficiencies and reduction in waste for the coating processes in the application shops. For example, rework of an engine component normally costs several thousand dollars each time it is recycled. The specifications that are currently used to procure coating feedstock allow acquisition of non-usable materials that fail to meet rigid metallurgical laboratory requirements and result in unacceptably applied coatings. Also, the current set of process parameters do not perform acceptably when used with all materials from all vendors when purchased with the current material specification. To meet the needs of the warfighter and to achieve the requirements of AF budget reductions, a new set of material and process specifications are needed for AFSC Complexes that will eliminate purchase of non-usable raw coating materials, reduce application process variation and reduce the amount of metallurgical laboratory testing required.

PHASE I: Perform research methodology that can identify and characterize all currently used thermal spray materials, vendors, processes, success/failure rates and associated loss or wasted costs in Air force. Demonstrate the applicability of the test and analysis plan by evaluation on a family-type of material and application systems that is compatible to those used in the AFSC Complexes.

PHASE II: Perform testing and analysis per plan of Phase I to define, develop, and qualify the new set of material and process specifications needed for procurement and application of materials that meet rigid metallurgical test requirements at the Air Force ALC’s. Deliverable will be: A) new set of material specifications, B) new set of process parameter specifications, C) laboratory data supporting those specifications.

PHASE III DUAL USE APPLICATIONS: A reliable set of specifications could be used throughout the thermal spray industry worldwide to improve quality, improve efficiency and reduce overall cost of ownership.

REFERENCES:

1. Maria Oksa, et al., “Optimization and Characterization of High Velocity Oxy-fuel Sprayed Coatings: Techniques, Materials, and Applications”, Coatings 2011, 1, 17-52.

AF141-209 TITLE: Dimensional Evaluation of Aircraft Fuel Cells

OBJECTIVE: Provide improved technologies for the dimensional evaluation of aircraft fuel cells.

DESCRIPTION: Aircraft fuel cells are flexible rubber-coated fabric enclosures for the containment of fuel within aircraft cavities. The overall envelope dimensions and locations of interface fittings and attachment elements such as lacing ferrules and hanger baskets are critical to the proper function and durability of the fuel cells. Some applications consider these components Critical Safety Items and their dimensional characteristics are critical features.
The existing method of dimensional inspection is to install the fuel cells in a facsimile structure and evaluate the fit of the cell within the facsimile structure. This approach is sensitive to the installation methodology used and does not directly produce quantitative dimensional data. It also requires large, expensive tooling and is labor-intensive.
The critical technological innovation desired as a result of this project is a means of directly measuring dimensional data for fuel cells. Methods which lessen fixturing, labor, and training requirements and improve repeatability will be regarded as especially desirable.
Benefits of a capability to perform dimensional evaluation of aircraft fuel cells will improve the identification of bladder issues prior to installation and provide a quality evaluation of supply assets. This will result in lower risk of in-flight emergencies and improve higher reliability of remaining assets.
Potential applications of such a technology include multiple military and commercial aircraft systems, military and commercial land and sea vehicles, and additional military and commercial applications utilizing flexible container liners with critical interfaces.

PHASE I: Develop an innovative technology, methods and approach that will provide a means to directly measure aircraft fuel cells. Provide a final report that provides the results of the technical approach and describes the concept demonstration for Phase II. The approach should show application to multiple aircraft configurations.

PHASE II: Based on the outcome of Phase 1 concept demonstration, develop the technology for a prototype system that demonstrates the capabilities involved and establishes repeatability for two or more aircraft configurations. Test the prototype system in a real-world environment and obtain MIL-SPEC approval for use of the process within Air Force Material Command (AFMC).

PHASE III DUAL USE APPLICATIONS: A dimensional measurement test for fuel bladders has applications across the AF inventory including many helicopters as well as many commercial aircraft.

REFERENCES:

1) Basic Fuel Requirements, http://www.faa.gov/regulations_policies/handbooks_manuals/aircraft/amt_airframe_handbook/media/ama_ch14.pdf.

AF141-210 TITLE: Economic Alternative to Wc-Co HVOF Composition for ID Applications for Landing

Gear
KEY TECHNOLOGY AREA(S): Air Platforms

OBJECTIVE: Develop economic alternatives to High Velocity Oxygen Fuel (HVOF) spray powder compositions for component bores to replace expensive Tungsten-Carbide-Cobalt (Wc-Co) powders currently used.

DESCRIPTION: Currently, the United States Air Force (USAF) Landing Gear community is implementing Electrolytic Hard Chrome Plate (EHC) replacement for line of sight applications utilizing High Velocity Oxygen Fuel (HVOF) technology. The chemical formulations chosen for this application are Tungsten Carbide-Cobalt (Wc-Co) and Tungsten Carbide-Cobalt-Chrome (Wc-Co-Cr). There are multiple benefits with utilizing this powder chemistry such as superior wear resistance and corrosion protection, however due to its high hardness, grinding and finishing processes are more difficult for HVOF versus EHC. Since Wc-Co and Wc-Co-Cr HVOF coating formulations were developed for Outer Diameter (OD) use and are quite costly, the need exists for more economic alternatives suitable for the less demanding Inner Diameter (ID) applications.
Typical application for landing gear will be component bores from 3 to 5 inches in diameter with the ability to spray deep bores, approximately 18 to 48 inches. Landing gear substrates include 4340 and 300M High Strength Steel (HSS). Testing to be performed includes seal compatibility (Acrylonitrile-Butadiene Elastomer), hydraulic fluid compatibility (both Petroleum and Synthetic Hydrocarbon based), hydraulic pressure (100-3000 psi) and nitrogen sealing ability (10-3000 psi). Since adhesion may be an issue for ID application, with dust and debris contamination in the spray environment, spallation must be tested. In addition, grinding in component bores is quite difficult especially with high hardness coatings. Grinding and or machining processes to achieve the requisite finish requirements for sealing is needed. Corrosion testing will also be required.
Additionally, using HVOF technology is not a hard and fast requirement. Other thermal spray technologies, such as Plasma, which is currently being used in industry and has the potential to be modified (if required or needed) for ID Landing Gear applications is acceptable and will be evaluated with the same scrutiny as HVOF applied coatings. The ability to apply other than EHC coatings to non-line of sight Landing Gear applications will greatly increase the Air Force’s, other Department of Defense (DoD) and commercial entities ability to comply to the mandate of reducing Hexavalent Chrome Emissions as well as the new Occupational Safety and Health Administration (OSHA) standards.

PHASE I: Conduct initial testing on feasibility of powders to replace the current Wc-Co compositions, meeting same performance baselines. Perform initial corrosion testing. Perform seal compatibility testing and spallation. Down select to 2 powder compositions.

PHASE II: Conduct extended testing of Phase I down selected candidates. Perform extended corrosion testing if required. Establish grinding process parameters and establish manufacturing readiness.

PHASE III DUAL USE APPLICATIONS: Implement successful candidates from Phase II. Industry and other DoD Services may also implement a successful substitute.

REFERENCES:

1. TO 4S1-1-182.

AF141-211 TITLE: Enhanced Fuel Cells From Wastewater Treatment (Bacteria Generated System) as a

Renewable Energy Source
KEY TECHNOLOGY AREA(S): Materials / Processes

OBJECTIVE: Develop and design an innovative fuel-cell technology that will allow generation of electricity from access to bacteria such that it can offset wastewater treatment plant operational costs associated with Military facility/utility operations.

DESCRIPTION: Fuel Cells are promising new energy technology that focuses on new and innovative approaches in which electrochemical/chemical reactions release electricity (electrons) and heat, and a byproduct which is only water. In waste water system, bacteria growth naturally generates electrons as they breakdown organic materials. A microbial fuel cell uses a chemical reaction inside bacteria as the source of its electrons. Since a fuel cell concept already exists that powers the electric grid, a bacteria powering the fuel cell will in turn power the electric grid. Research efforts are required to maximize this concept to make fuel cell energy output more efficient. By accomplishing this task, wastewater treatment processes optimized for fuel cell technology advancements will prove to be a renewable energy technology that will be chartered for military as well as applications.

PHASE I: Demonstrate the feasibility of a prototype fuel cell technology focused on wastewater treatment products and processes that employ bacteria as a source of electron produced naturally as they breakdown organic materials captured in the composition of the wastewater. The system should support real-time characteristics of wastewater and/or industrial wastewater systems suitable for military sites.

PHASE II: Provide a prototype system that demonstrates fuel cell capabilities to generate wattage based on microbial fuel cell theoretical principles, emphasizing chemical reactions that releases electricity and heat energy and produces only water as a by-product. The system design should be expandable to eventually generate enough power to supply the waste water facility itself and eventually feed into the grid itself.

PHASE III DUAL USE APPLICATIONS: Integrate the prototype concepts that are enhanced for acquiring electricity generation that will be applied to the electric grid, thereby realistically recovering enough energy to operate a sizeable wastewater treatment facility.

REFERENCES:

1. Thomas A Clarke, Gaye White, Julea N Butt, David J Richardson, Zhri Shi, Liang Shi, Zheming Wang, Alice C Dohnalkova, Matthew J Marshall, James K Fredrickson and John M Zachara. Rapid electron exchange between surface-exposed bacterial cytochromes and Fe(III) minerals. Proceedings of the National Academy of Sciences, March 25, 2013.

AF141-212 TITLE: Environmentally Friendly Stripping of Low Hydrogen Embrittlement (LHE) Chromium

Plate
KEY TECHNOLOGY AREA(S): Air Platforms

OBJECTIVE: Develop Low Hydrogen Embrittlement (LHE) chromium plate stripping method for landing gear eliminating the liberation of hexavalent chrome in the stripping process.

DESCRIPTION: While the current state-of-the-art is changing for landing gear applications, the use of hexavalent chromium (Cr+6) as a wear and/or corrosion preventative surface is still widespread. Current stripping processes for low Hydrogen embrittlement (LHE) Chromium plate can liberate levels of Cr+6 in excess of established OSHA PELs. High Velocity Oxygen Fuel (HVOF) coatings are being introduced, but removal of legacy chrome plated components will be occurring for some time.
Stripping methods that prevent liberation of Cr+6 are desired. Mechanical strip processes could alternately be considered but must consider substrate safety/compatibility (e.g. grinding burns, substrate pitting and degradation). Aqueous stripping processes must consider safety/material compatibility in terms of Hydrogen Embrittlement (HE) on High Strength Steel (HSS) substrates such as 300M and 4340M. All stripping processes must consider material compatibility (fatigue, material removal) and may also require reductive immobilization of Cr+6 from waste products. Replacement processes should be economically viable and preferentially abiotic, with the objective of causing no impacts to labor and processing time in the maintenance cycle.
Substantial research into environmental Cr+6 clean-up and immobilization efforts has been performed, with primary application to soils chemistry. These methods primarily focus on conversion of Cr+6 to Cr+3 through reduction of Cr+6 contaminants by electron-donating compounds and bio-stimulaters.
Bio-stimulaters (e.g. Hydrogen-Release Compound [HRC]) are polylactates that encourage microbial fermentation and a rich, steady supply of Hydrogen as electron donors in the natural conversion of Cr+6 to Cr+3. Abiotic compounds (e.g. Metals Remediation Compound [MRC], Iron Humate, Oxihumolite, Sodium Bisulfite, Iron Oxides, etc.) react directly with Cr+6 in the waste stream, creating a reductive environment for chemical conversion of Cr+6 to Cr+3, which then either precipitates out of solution as solid trivalent chromium hydroxide or binds strongly to iron-oxides in the sorbents or humic acid matrices. Strong binding between Cr+3 and sorbents reduces the likelihood of subsequent liberation into the environment. Abiotic compounds tend to encourage faster reduction and immobilization of Cr+6 and can frequently work at “natural” pH levels (~ 3.9 – 7 pH).
Other methods of reduction of Cr+6 involve eco-friendly stripping methods utilizing acid peroxide solutions to chemically strip Cr+6 from the substrate, then filtering the chromium metal “sheets,” from solution and using electrolytic methods to recover Cu2+ and Ni2+ for reuse. The chromium “sheets” can then be reused, disposed of, or converted to Cr+3 per methods described above. One example of this process can be found in Patent EP1591545B1. The feasibility of these example processes are unknown for landing gear overhaul applications.

PHASE I: Conduct process and material feasibility/safety testing for landing gear applications in the Description of eco-friendly Cr+6 chemical, mechanical, and aqueous stripping, reduction, and immobilization methods/compounds. Downselect to one or two candidates. Provide business case analyses, data, reports, to support feasibility/safety/economic/materials compatibility with landing gear HSS to USAF.

PHASE II: Conduct extended compatibility testing of Phase I downselected candidates, demonstrating compatibility with HSS for fatigue, strength, HE, and corrosion and safe, economic Cr+3 disposal; scale for production; perform prototype processing on various landing gear components with complex geometries within USAF facilities constraints; perform manufacturing readiness studies on Phase I methods. Provide reports/data supporing HSS feasibility/compatibility. Downselect to a single method as appropriate.

PHASE III DUAL USE APPLICATIONS: Implement full scale Phase II method production at USAF Landing Gear Overhaul facility, including all technical data & technical orders for processes, fixture designs and prototypes, recovery and disposal methods, waste stream management and process implementation plans. Ensure seamless transition.

REFERENCES:

1. TO 4S-1-182.

AF141-213 TITLE: Method for Evaluating Candidates for Additive Manufacturing (AM) Processes

OBJECTIVE: Investigate, determine, and recommend a method to evaluate legacy components which are candidates for Additive Manufacturing (AM) process(es).

DESCRIPTION: With the USAF facing challenges of aging systems, reduced budgets, and increasingly complex supply chains and diminishing industrial base, the need to develop cost-reduction and alternative manufacturing process driven programs now more important than ever. The diminishing industrial base creates a list of hard-to-source components/parts across maintenance organizations that continue to grow, adding workload pressures and backlog within the local alternate sourcing program offices. Besides identifying alternate sources for the same or similar part, the sourcing office is often tasked with identifying alternate manufacturing processes and materials to reduce cost, improve product efficiency through government-contractor developed initiatives. Here in lies the opportunity to leverage the emerging manufacturing process, namely Additive Manufacturing (AM), and combined with part redesign has a positive repercussion on cost saving. One current challenge lies in understanding what legacy components are even viable candidates given the capabilities of the AM technologies and the emerging industrial base. To fully exploit the inherent benefits of additive manufacturing, the responsible configuration design engineer must first identify candidate components/assemblies and then re-engineer the necessary configuration and manufacturing processes required in using AM processes and material configurations. AM does not have the geometric constraints of traditional manufacturing processes, and this absence of geometric constraints allows focusing redesign efforts on part functionality and assembly. Assembling processes and costs can be reduced by rationalizing part count and fabricating devices in their assembled state. The challenge lies in an understanding amongst the sustainment engineers in how to think beyond conventional processes boundaries/constraints and exploit the capabilities of the available AM technologies, equipment, and materials. Conventional redesign parameter examples are component geometry characteristics, dimensional tolerances, shape volume, surface finish, material requirements, loading and cycle conditions, and cost.
The goal of this research effort is to help establish the viability of an AM benchmark and guidelines for sustainment engineers to apply in identification of candidate parts when considering whether AM is a viable and economical alternative to conventional manufacturing methods for legacy components. The methodology would advise on the most promising and efficient AM process, based on Form, Fit, and Function. How performance testing could be waived due to current AM powder material processing already meeting current acceptable specifications should be a very critical parameter.

PHASE I: Research a methodology approach to provide AM benchmark and guidelines on subset of AM technologies/capabilities addressing the above goal. Provide concept demonstration with several AFSC example parts thru the methodology. Examples should show both good and poor candidates for AM success. Concept should include parts requiring different AM processes and materials.

PHASE II: With the success of demonstrated concept in Phase I, continue with expanding the provided methodology with additional AM technologies and processes. Additional AFSC part examples will be demonstrated and validated thru the process. Guidelines should also provide what testing may be necessary or could be waived to satisfy re-engineering requirements.

PHASE III DUAL USE APPLICATIONS: With the success of Phase II validations the transition to high confidence rating for engineering implementation would be performed and have potential for AM and OEM partnerships within AFSC Complexes.