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A02-237 TITLE: High Temperature Tribological Lubricants for Low Heat Rejection, High Temperature Operation Diesel Engine TECHNOLOGY AREAS: Ground/Sea Vehicles ACQUISITION PROGRAM: Future Combat System (FCS) OBJECTIVE: Research, formulate, develop, and test a high temperature tribological lubricants. The lubricants are to operate in an insulated/coated low heat rejection engine in a boundary lubrication mode of top ring reversal-liner area. The lubricants are to continuously and efficiently operate at top ring reversal temperature of 410C max., and at lubricant sump temperature up to 175 C. DESCRIPTION: The new researched, formulated, and developed high temperature lubricants will operate with an insulated/coated low heat rejection diesel engine. The new lubricants are to continuously and efficiently operate at extreme temperature of maximum of 410C top ring reversal, and at 175 C sump temperature. The lubricants must maintain a working viscosity, and cause to preserve the integrity of reciprocating and rotating parts with low friction range 0f 0.08 to 0.1, and wear rate of 0.6 mg/hr maximum. The new lubricants must work at various and full range of engine loads and speeds during its life cycle, and operate satisfactorily in a military and commercial vehicles mission profiles. The lubricants must maintain efficient working viscosity for the duration of engine's oil change interval of 200 hours minimum. PHASE I: Formulate or select various lubricants that have the potential to meet the requirements of this topic. Provide proven test specifications data of the selected or formulated lubricants. Perform a preliminary laboratory test on a single cylinder engine. PHASE II: Perform design improvements of the selected or formulated lubricants of Phase I. Conduct an engine laboratory test on the new lubricants. The test engine should be a low heat rejection engine with coated liner-ring, and piston with coated monolithic ceramic. Build a prototype for further testing at government laboratory for performance and endurance, and for meeting the requirements of this topic. PHASE III DUAL USE APPLICATION: The new high temperature lubricants would be used on low heat rejection engine with high power density, it will have both military and commercial use. OPERATION SUPPORT COST REDUCTION: The proposed research of the new high temperature tribological lubricants should include data on the projected total production costs compared to the costs of the standard lubricants. The savings that could be attained (with the use of the new lubricants) from improved engine performance and fuel economy should be factored in the actual production costs of the new lubricants. REFERENCES: 1) ASME 2000, paper no. 2000-ICE-254 Journal bearing wear monitoring with a new enhancement technique. Barney E. Klamecki, University of Minnesota. 2) ASME 2000, paper no. 2000-ICE-259 Evaluation of Ion beam assisted Diamond Like Carbon (DLC) Coatings for low heat rejection diesel engine piston rings. LIoyd Kamo, Adiabatcs, inc., Walter Bryzik and Milad Mekari, U.S. ARMY, TACOM. 3) 2000-01-1236 Thermal Barrier Coatings for Monolithic Ceramic Low Heat Rejection Diesel engine components. LIoyd Kamo and Melvin Woods, Adiabatics inc., Walter Bryzik and Milad Mekari, U.S. Army Tacom, R & D Center. 4) ASME 2000-ICE-267 Interactions of oil vaporization, film thickness, and oil replenishment along the engine cylinder liner. William E. Audette III and Victor W. Wong, Massachusetts Institute of Technology. 5) Problems of Maintenance and reliability Aviation techniques- Collection of scientific work. KIUCA-Kiev 1998. The property of various lubricants with unsteady modes of friction. N. F. Dmitrichenko, R. G. Mnatsakanov, Saad Philipe Fernand. 6) Tribologia - Theory and Practice. - Issn 0208-7774 year XXIX NR 2/98 (158)- Warsaw- Poland. Experimental-Theoretical model of wear intensity in high dynamic load condition, p. 193-206. N. F. Dmitrichenko, R. G.Mnatsakanov, International University of Civil Aviation, Kiev, Ukraine. Steven Danyluk, Georgia Institute of Technology, Atlanta, USA, Philipe Fernand Saad, International University of Civil Aviation, Kiev, Ukraine. KEYWORDS: Tribology, lubricants, friction, wear, low heat rejection, monolothic ceramic, coating and plating. A02-238 TITLE: Development of Methodology for Evaluating Air Cleaner Vibration Levels Experienced in Vehicles to Verify Performance of Advanced Filter Media TECHNOLOGY AREAS: Ground/Sea Vehicles ACQUISITION PROGRAM: PM, Light Tactical Vehicles OBJECTIVE: Survey advanced air filter media(s) which claims to provide improved performance when evaluated in vehicles where vibration effects through vehicle operation are on-going. Determine through single panel pleated design experiments (or equivalent) if advanced filter media provides improved performance (efficiency and dust capacity/service life) when simultaneously subjected to a vibration profile similar to what an air cleaner would see mounted in a vehicle. Select the best performing advanced filter media(s) and conduct simultaneous full scale air cleaner performance/vibration evaluations between current production air cleaner filter media (cellulose/paper based) and advanced air cleaner filter media(s). DESCRIPTION: Present test methods and procedures for conducting air cleaner/filter element performance tests (efficiency and dust capacity/service life) are done without any vibration input to air cleaner housing/filter element. Developers of new advanced filter media(s) claim this test method does not reflect or maximize the actual performance of their filter media(s) because vibration effects are ignored. The vibration effects are claimed to release dirt/dust from the filter media and increase filter element dust capacity/service life. Vibration tests are done separately on air cleaner assemblies to the required performance specification document without dust into the air cleaner intake. Recent industry cooperative research program efforts have shown oil and fuel filter performance is realistic when measured on an engine that is operational and running compared to current established test methods using single and multi-pass flow benches. This type of methodology approach needs to be done with an air cleaner to make sure the filter element performance is realistically measured. Without this methodology study, a potential true advantage of advanced filter media(s) will never be known. PHASE I: Research current advanced filter media(s). Two examples media(s) include Spun-bond and Polyproplene which may provide improved performance when feeding dust to a specified dust feed rate during performance tests when accompanied by vibration effects. Conduct trade-off studies to select the best advanced filter media(s). Through a methodology approach develop a vibration profile, which is reflective of an air cleaner housing/filter element vibrating when operating on a specified vehicle. The vibration profile per a specified air cleaner housing performance requirements will be evaluated to determine compatibility with other established vibration levels to come up with a best vibration profile. The vibration profile should consider the vehicle’s operating conditions, which include but are not limited to: idling, cross-country, secondary roads, improved roads and highway. Conduct design experiments on single panel pleated filter media where dust feed and best approach vibration profile are conducted simultaneously. Repeat the design experiments without vibration effects. The single pleated panel filter design experiments will be conducted with current production filter media and compared to advanced filter media samples. Provide a full scale concept drawing of at least one new design filter element for a specified air cleaner with advanced filter media. At end of Phase I a proof-of-principal concept through design experiments will be made to verify that advanced filter media(s) through vibration effects have demonstrated increased service life and increased cleaning durability (ability to withstand repeated cleanings). PHASE II: Build full scale filter elements with advanced filter media for a specified air cleaner housing. Filter elements will be prototyped with up to three different advanced filter media(s) based on the analysis in Phase I. The previously established vibration profile will be optimized to assure it reflects real vehicle vibrations levels as measured on an air cleaner housing/filter for a specified vehicle. Vibration profiles will be verified through measurements taken on a specified vehicle operating over the various vehicle modes indicated in Phase I. Through a methodology approach develop a best defined vibration profile which represents a typical vehicle operating scenario. Compare this vibration profile to the air cleaner assembly/filter element performance specification vibration profile for a specified vehicle and provide an analysis as to differences and rationale for the best feasible vibration profile. Conduct dust test experiments in conjunction with vibration profile on full scale filter elements with advance filter media(s) and conduct comparison tests on present production filter elements on a specified vehicle. Down select to the best performing advance filter media(s). Conduct cleaning durability evaluations to verify the improved service life and repeated cleanings that advanced filter media has over current production filter media. The filter element with advanced filter media will be tested to verify its meets all the performance specification of present production filter element for a specified vehicle. The specified vehicle can be any number of military vehicles. An example would be a High Mobility Multi-Purpose Wheeled Vehicle (HMMWV) which also has a commercial version. Design harden the filter element with advanced filter media and make improvements to increase durability and performance. Repeat dust test experiments to assure durability and performance is achieved. At completion of Phase II a minimum of three (3) final configured prototype filter elements with advanced filter media will be provide to government. Phase III: The filter element with advanced filter media would cover a wide range of military and commercial vehicles. Once it has been determined that increased performance is obtained through a longer service life and increased durability, commercial application would expand. The durability issue is important because some advanced filter media(s) can withstand repeated cleanings without damage. This provides for a lower maintenance cost of the air cleaner system. Commercial application would quickly spread since cost savings transfer into increased profits. The advanced filter media can be used in any air cleaner system thus it’s potential is unlimited. REFERENCES: 1) Proceedings Booklet, 4th International Filtration Conference, January 16 – 18, San Antonio, Texas; Topic Presentation: Dynamic Filter Efficiency, Presenter Rob Murad, HY-PRO, Charles Juhasz, Larson Testing Laboratories; Conference sponsored by Southwest Research Institute (SwRI) 2) TARDEC Technical Report No. 13802, TITLED: Lab Test of Prototype HMMWV Filter Elements Constructed with Spunbond Polyester Media, DATED July 2001, Contractor U.S. Army Tank-Automotive research, Development and Engineering Center (TARDEC)
· Conceptualize and evaluate feasibility of virtual test and evaluation process for complex vehicle system. Determine which critical components (i.e., joints, fasteners, structural members, etc.) must be analyzed for successful evaluation of fracture and fatigue of an entire vehicle system. · Conceptualize and investigate feasibility of standardized laboratory evaluation process for structural integrity of multiple vehicle systems. · Determine applicable commercial software code availability and software development requirements. The contractor should access commercially available software codes to determine suitability for the analysis process. Based on this assessment, determine what analysis processes will require software code development. PHASE II: · Initial model development. Develop necessary models of vehicle system to represent and determine dynamic and structural responses to operational loads. · Develop experimental laboratory and/or bench test validation procedures. Process for initial validation of modeling methods at component or subsystem level. · Determine statistical and mechanical methods for determination of critical flexible bodies. Establish which vehicle model components require flexibility in order to capture desired level of fidelity for fatigue and fracture prediction. This may include field data collection of load conditions and/or use of data mining techniques to determine critical areas of vehicle system. · Initial software development as determined in Phase I for evaluation of fracture and fatigue issues. · Develop virtual test and evaluation methods for pre-prototype to production vehicle structural integrity assessment. PHASE III: · Selection of pilot vehicle for evaluation. The factors that play into the selection of the pilot vehicle include availability, accessibility (can modifications be made for instrumentation or evaluation purposes), and pertinence to Army needs. · Develop field test validation procedure and execute validation process necessary to prove out methodology. · Subject pilot vehicle to virtual, laboratory, and field structural evaluation methods developed in Phase I and II. · Methods and software developed will have dual use applications in that they will be valid for military and commercial markets including automotive, and aerospace engineering applications. · Refine methodology and software developed in first two phases to improve user interface for commercial market. Improvements in ease-of-use of the product will increase marketability for engineers and program managers alike. REFERENCES: 1) Stadterman, T., Connon, W., Choi, K.K., Freeman, J., and Peltz, A., “Dynamic Modeling & Durability Analysis from the Ground Up”, Institute of Enviromental Sciences and Technology (IEST), Phoenix, AZ, April 22-25, 2001. 2) Freeman, J., Choi, K. K., Tang, J., Lin, W. T., “Modeling and Analysis of the High Mobility Trailer for Fatigue Durability”, 6th U.S. National Congress on Computational Mechanics, Detroit, MI, Aug 104, 2001.
1) http://www.smalltimes.com/document_display.cfm?document_id=2173 2) http://www.nexus-emsto.com/almanac/Ukrainian_National_Academy_of_Sciences.html 3) http://www.wimserc.org/ KEYWORDS: MEMS, water purification, on-vehicle water creation A02-241 TITLE: Lightweight Composite Armor Body Panels for Commercial Vehicles TECHNOLOGY AREAS: Materials/Processes ACQUISITION PROGRAM: PM, Light Tactical Vehciles OBJECTIVE: To develop armor panels for military and commercial vehicles that offer ballistic protection and contribute towards achieving a relatively low manufacturing costs. DESCRIPTION: Most vehicle body panels with ballistic protection are manufactured by lining production panels with expensive Kevlar and Fiberglass plaques, which are installed by completely disassembling the vehicle, bonding or fastening the panels in place and then reassembling the vehicle. This process involves a great amount of labor and usually adds significant weight to the vehicle due to the redundancy of panels (exterior body and ballistic interior). By combining the ballistic and structural function of the panels into the body panels, weight savings can be realized, as well as making it easier to convert an unprotected vehicle to a ballisticlly-protected vehicle, which results in labor cost savings. The panels that will be prototyped in this project will offer protection against threats contained in the Operational Requirements Document (ORD) for the Tactical Wheeled Vehicle Crew Protection Kit (CPK). The panels will be formed to duplicate vehicle fit and finish, thereby disguising the fact that the panels have ballistic protection capability. The panels should attach to the vehicle’s primary structure in a manner consistent with the production vehicle attachment method and be identical in appearance to the production panel. The ballistic panels should be replaced as a complete unit in order to facilitate low cost conversion PHASE I: Develop an armor system for a vehicle door for a vehicle such as the Ford F350 Series Truck and the High Mobility Multi-purpose Wheeled Vehicle (HMMWV) that meets ballistic requirements described in the ORD for the Tactical Wheeled Vehicle CPK (attachment). Develop attachment methods that conform to production vehicle attachment methods and space claims. Special emphasis shall be given to the development of innovative attachment methods. The contractor shall validate the ballistic results. PHASE II: Develop an armor system for a vehicle cab that meets ballistic requirements in the ORD that is referenced above and conforms to production vehicle attachment methods. The contractor shall coordinate their development efforts with the Government contractor responsible for fabricating a vehicle mock-up of the NAC’s Smart Truck and shall demonstrate installation of the armor system developed on a government furnished HMWWV. The contractor shall validate the ballistic results. PHASE III DUAL USE APPLICATIONS: The armor system could be used on a broad range of military tactical trucks and civilian trucks where ballistic protection is required. Commercial applications include armored trucks, limos, and private vehicles. REFERENCES: 1) Operational Requirements Document for the Tactical Wheeled Vehicle Crew Protection Kit KEYWORDS: Armor, Tactical Vehicle, HMWWV, Polymer Composites, Armor Panels A02-242 TITLE: Removal of Sulfur in Defense Mobility Fuels to meet EPA mandates. TECHNOLOGY AREAS: Ground/Sea Vehicles ACQUISITION PROGRAM: PM, PETROLEUM AND WATER SYSTEMS OBJECTIVE: Design, build and demonstrate a portable sulfur scrubbing unit that can be mounted on trucks or refueling stations, function unattended, and be capable of continuously removing sulfur containing compounds from a wide variety of liquid hydrocarbon fuel feedstocks, blends, additives, or contaminants. DESCRIPTION: Internal combustion engines meeting the EPA requirements for the year 2006 and beyond will require fuel that is very low in sulfur to function properly. Current advances in liquid phase sulfur scrubbing techniques are promising to be small enough to be refueling station or vehicle mounted. This technology would permit the use of OCONUS high sulfur fuels in the high performance engines that are damaged or hindered by the acids formed by combusting sulfur bearing fuels. These technologies have been demonstrated on a larger scale, requiring operator attention. This applications research project would seek to miniaturize the scrubber itself and build a control system that is complete enough that the average truck driver or gas station attendant can oversee maintaining system and also demonstrate the system operation. PHASE I: Develop an overall system design that includes specification of system size and space claim, system operating temperatures, and system technology limitations. Complete preliminary cost analysis to identify proper applicatoin of technology. PHASE II: Develop and demonstrate a prototype system in a realistic environment. Conduct testing to prove feasibility over extended operating conditions. Refine cost analysis requirements. PHASE III DUAL USE APPLICATIONS: This system could be used in a broad range of military and civilian security applications where automatic surveillance and tracking are necessary – for example, in overseas peacekeeping and commercial operations or in enhancing interoperability in transportation industries. Detail and finalize cost analysis for application efficiencies. REFERENCES: 1) Rich Johnson, Phillips 66, rcjohns@ppco.com, 918-661-1949, Z-Sorb technologies, gas-phase process, http://www.fuelstechnology.com 2) Jean-Luc Nocca, IFP North America, Inc, 713-552-9666 ext. 103, Prime (D+, G+) and Sulfrex technologies, http://www.ifpna.com and http://www.ifpna.com/cgi-bin/serve.cgi?/Brochures/fdb/Fiche_Sulfrex_Axens.pdf
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