final design review mems-based corrosion health monitoring fri aeiyncucfed janinecrsohro mihe ernct...
TRANSCRIPT
![Page 1: Final Design Review MEMS-based Corrosion Health Monitoring Fri aeiynCucfed JanineCrsohrO Mihe erncT io Liaison Engineers: Pec uces Tr lw Faculty Coach:](https://reader035.vdocuments.us/reader035/viewer/2022062620/551aadc95503466b3a8b5edb/html5/thumbnails/1.jpg)
Final Design Review
MEMS-based Corrosion Health Monitoring
Fri aei ynCucfed
Janine CrsohrO
Mihe ernc T io
Liaison Engineers: Pec uces
Tr lw
Faculty Coach: Jh .AboePD E
![Page 2: Final Design Review MEMS-based Corrosion Health Monitoring Fri aeiynCucfed JanineCrsohrO Mihe erncT io Liaison Engineers: Pec uces Tr lw Faculty Coach:](https://reader035.vdocuments.us/reader035/viewer/2022062620/551aadc95503466b3a8b5edb/html5/thumbnails/2.jpg)
Introduction Corrosion occurs on electronic chassis of aircraft
causes loss of integrity of EMI seal
Lockheed Martin technicians responsible for avoiding critical corrosion damage monitor the health of the chassis on a scheduled basis
the chassis is relatively inaccessibleinaccessible within the aircraft in most cases, the chassis is corrosion freecorrosion free time and money are wastedwasted by this inefficiency
![Page 3: Final Design Review MEMS-based Corrosion Health Monitoring Fri aeiynCucfed JanineCrsohrO Mihe erncT io Liaison Engineers: Pec uces Tr lw Faculty Coach:](https://reader035.vdocuments.us/reader035/viewer/2022062620/551aadc95503466b3a8b5edb/html5/thumbnails/3.jpg)
AimTo reduce unnecessary corrosion related service
activities with a stand alone system that can alert a technician of a needed inspectionReliable measurement of the environmental
corrosivity seen by the chassisLED alert system
viewed from exterior of the chassis 1-10 level of need for service activity
![Page 4: Final Design Review MEMS-based Corrosion Health Monitoring Fri aeiynCucfed JanineCrsohrO Mihe erncT io Liaison Engineers: Pec uces Tr lw Faculty Coach:](https://reader035.vdocuments.us/reader035/viewer/2022062620/551aadc95503466b3a8b5edb/html5/thumbnails/4.jpg)
Business Case
Life cycle cost for the Apache Helicopter fleet* $14.3 billion Percent Dedicated to Inspection** x 25%
------------------ Inspection cost for the Apache Helicopter $3.575 billion Percent inspections eliminated by SDX-4912 x 33%
------------------ TOTAL PROGRAM SAVINGS $1.18 billion Life cycle of Apache helicopter* ÷ 20 years
------------------ TOTAL ANNUAL SAVINGS* $59 million TOTAL LIFE CYCLE SAVINGS/helicopter*** $1.5 million
*These estimates, in constant fiscal 1994 dollars, are provided in Annex D of the Longbow Apache Test and Evaluation Master Plan, which cites December 1993 estimates from the Longbow Program Office and the President’s fiscal 1995 budget as the original source.
**Provided from the Military Analysis Network created by the FAS, Federation of American Scientists (non-profit, tax exempt, 501c3 organization)***Costs assuming that the SDX-4912 is installed in full apache fleet (assuming fleet size ≈ 800)
![Page 5: Final Design Review MEMS-based Corrosion Health Monitoring Fri aeiynCucfed JanineCrsohrO Mihe erncT io Liaison Engineers: Pec uces Tr lw Faculty Coach:](https://reader035.vdocuments.us/reader035/viewer/2022062620/551aadc95503466b3a8b5edb/html5/thumbnails/5.jpg)
Elements of Chassis Galvanic coupling of aluminum
and nickel
Aluminum = anode Nickel = cathode
Electrolyte provides driving force for corrosion
![Page 6: Final Design Review MEMS-based Corrosion Health Monitoring Fri aeiynCucfed JanineCrsohrO Mihe erncT io Liaison Engineers: Pec uces Tr lw Faculty Coach:](https://reader035.vdocuments.us/reader035/viewer/2022062620/551aadc95503466b3a8b5edb/html5/thumbnails/6.jpg)
Galvanic CorrosionAs a result of nickel
contact:Corrosion potential
of aluminum (M) increased
Corrosion rate of aluminum (M) is increased
Nickel
Aluminum
Couple
![Page 7: Final Design Review MEMS-based Corrosion Health Monitoring Fri aeiynCucfed JanineCrsohrO Mihe erncT io Liaison Engineers: Pec uces Tr lw Faculty Coach:](https://reader035.vdocuments.us/reader035/viewer/2022062620/551aadc95503466b3a8b5edb/html5/thumbnails/7.jpg)
Customer Requirements
GENERAL NEEDS:
Operate Under Harsh ConditionsNon-Intrusive Feedback
Long Life SpanMEMS BasedLight WeightSmall Size
![Page 8: Final Design Review MEMS-based Corrosion Health Monitoring Fri aeiynCucfed JanineCrsohrO Mihe erncT io Liaison Engineers: Pec uces Tr lw Faculty Coach:](https://reader035.vdocuments.us/reader035/viewer/2022062620/551aadc95503466b3a8b5edb/html5/thumbnails/8.jpg)
Hardware Design
![Page 9: Final Design Review MEMS-based Corrosion Health Monitoring Fri aeiynCucfed JanineCrsohrO Mihe erncT io Liaison Engineers: Pec uces Tr lw Faculty Coach:](https://reader035.vdocuments.us/reader035/viewer/2022062620/551aadc95503466b3a8b5edb/html5/thumbnails/9.jpg)
Hardware Design
Sensor(s)
Processing
Feedback
Aircraft In-situ Operation
Power Supply
Location
Aircraft Structure
Maintenance Opportunity
Storage
Functional Diagram
![Page 10: Final Design Review MEMS-based Corrosion Health Monitoring Fri aeiynCucfed JanineCrsohrO Mihe erncT io Liaison Engineers: Pec uces Tr lw Faculty Coach:](https://reader035.vdocuments.us/reader035/viewer/2022062620/551aadc95503466b3a8b5edb/html5/thumbnails/10.jpg)
Hardware Design
Dimmed elements denote exploratory efforts not included in final design
![Page 11: Final Design Review MEMS-based Corrosion Health Monitoring Fri aeiynCucfed JanineCrsohrO Mihe erncT io Liaison Engineers: Pec uces Tr lw Faculty Coach:](https://reader035.vdocuments.us/reader035/viewer/2022062620/551aadc95503466b3a8b5edb/html5/thumbnails/11.jpg)
Macroscopic System
![Page 12: Final Design Review MEMS-based Corrosion Health Monitoring Fri aeiynCucfed JanineCrsohrO Mihe erncT io Liaison Engineers: Pec uces Tr lw Faculty Coach:](https://reader035.vdocuments.us/reader035/viewer/2022062620/551aadc95503466b3a8b5edb/html5/thumbnails/12.jpg)
Hardware Design
Near Linear Approximation Module Expiration
Detection Manufacturability
R = V / Iappl
R = ρL / πr2
Electrical Resistance Sensor Concept:
![Page 13: Final Design Review MEMS-based Corrosion Health Monitoring Fri aeiynCucfed JanineCrsohrO Mihe erncT io Liaison Engineers: Pec uces Tr lw Faculty Coach:](https://reader035.vdocuments.us/reader035/viewer/2022062620/551aadc95503466b3a8b5edb/html5/thumbnails/13.jpg)
Sensor Sampling Data sample taken hourly
All data stored on Flash
Light Emitting Diodes (LEDs) 4 red, 3 yellow, 2 green 1-10 level of corrosion damage
Relate to need for technician to perform service activity Level 7 (1st Red LED) correlates to critical corrosion damage
![Page 14: Final Design Review MEMS-based Corrosion Health Monitoring Fri aeiynCucfed JanineCrsohrO Mihe erncT io Liaison Engineers: Pec uces Tr lw Faculty Coach:](https://reader035.vdocuments.us/reader035/viewer/2022062620/551aadc95503466b3a8b5edb/html5/thumbnails/14.jpg)
Output MethodCorrosion will cause reduction in ER sensor’s
cross-sectional areaAt critical % area reduction critical voltage
A
Theoretical Voltage v. Area
6.00E-05
7.00E-05
8.00E-05
1.98E-072.08E-072.18E-072.28E-072.38E-072.48E-072.58E-072.68E-072.78E-07
Cross-sectional Area (m2)
Vo
ltag
e (V
)
![Page 15: Final Design Review MEMS-based Corrosion Health Monitoring Fri aeiynCucfed JanineCrsohrO Mihe erncT io Liaison Engineers: Pec uces Tr lw Faculty Coach:](https://reader035.vdocuments.us/reader035/viewer/2022062620/551aadc95503466b3a8b5edb/html5/thumbnails/15.jpg)
Sensor Sampling
Control Wire
![Page 16: Final Design Review MEMS-based Corrosion Health Monitoring Fri aeiynCucfed JanineCrsohrO Mihe erncT io Liaison Engineers: Pec uces Tr lw Faculty Coach:](https://reader035.vdocuments.us/reader035/viewer/2022062620/551aadc95503466b3a8b5edb/html5/thumbnails/16.jpg)
Testing
![Page 17: Final Design Review MEMS-based Corrosion Health Monitoring Fri aeiynCucfed JanineCrsohrO Mihe erncT io Liaison Engineers: Pec uces Tr lw Faculty Coach:](https://reader035.vdocuments.us/reader035/viewer/2022062620/551aadc95503466b3a8b5edb/html5/thumbnails/17.jpg)
Verification Testing
Hardware Unit TestSensor Proof of Concept5 days in Salt Spray Machine
Software Unit TestData Interface to software and LED display
Acceptance Testing Functional Acceptance Test (Integration)Environmental Acceptance Test (Survivability)
![Page 18: Final Design Review MEMS-based Corrosion Health Monitoring Fri aeiynCucfed JanineCrsohrO Mihe erncT io Liaison Engineers: Pec uces Tr lw Faculty Coach:](https://reader035.vdocuments.us/reader035/viewer/2022062620/551aadc95503466b3a8b5edb/html5/thumbnails/18.jpg)
Proof of Sensor Concept 48 hour test
-24 hours immersed in salt bath
-24 hours in atmosphere
![Page 19: Final Design Review MEMS-based Corrosion Health Monitoring Fri aeiynCucfed JanineCrsohrO Mihe erncT io Liaison Engineers: Pec uces Tr lw Faculty Coach:](https://reader035.vdocuments.us/reader035/viewer/2022062620/551aadc95503466b3a8b5edb/html5/thumbnails/19.jpg)
Proof of Sensor Concept Ground to 50% diameter along
longitudinal plane and polished Large cathode (Ni) to anode (Al)
ratio
Damage to nickel plating on aluminum wire
![Page 20: Final Design Review MEMS-based Corrosion Health Monitoring Fri aeiynCucfed JanineCrsohrO Mihe erncT io Liaison Engineers: Pec uces Tr lw Faculty Coach:](https://reader035.vdocuments.us/reader035/viewer/2022062620/551aadc95503466b3a8b5edb/html5/thumbnails/20.jpg)
Testing
ASTM B117 Salt Fog ChamberConstant corrosive vapor applied for 5 days5 Test coupons removed at daily intervalsData samplings recorded as voltages
Recorded using a datalogger Data sampling = once per minute
Example of Salt Spray Chamber
![Page 21: Final Design Review MEMS-based Corrosion Health Monitoring Fri aeiynCucfed JanineCrsohrO Mihe erncT io Liaison Engineers: Pec uces Tr lw Faculty Coach:](https://reader035.vdocuments.us/reader035/viewer/2022062620/551aadc95503466b3a8b5edb/html5/thumbnails/21.jpg)
Wireless - ZigBee
Proven feasible up to 6” thickness of casingDue mainly to chamber reflectionsMinimal aperture required
Wireless communication
pursuit ended 2/7/05
given risk and manpower
![Page 22: Final Design Review MEMS-based Corrosion Health Monitoring Fri aeiynCucfed JanineCrsohrO Mihe erncT io Liaison Engineers: Pec uces Tr lw Faculty Coach:](https://reader035.vdocuments.us/reader035/viewer/2022062620/551aadc95503466b3a8b5edb/html5/thumbnails/22.jpg)
Testing Results
![Page 23: Final Design Review MEMS-based Corrosion Health Monitoring Fri aeiynCucfed JanineCrsohrO Mihe erncT io Liaison Engineers: Pec uces Tr lw Faculty Coach:](https://reader035.vdocuments.us/reader035/viewer/2022062620/551aadc95503466b3a8b5edb/html5/thumbnails/23.jpg)
Results
![Page 24: Final Design Review MEMS-based Corrosion Health Monitoring Fri aeiynCucfed JanineCrsohrO Mihe erncT io Liaison Engineers: Pec uces Tr lw Faculty Coach:](https://reader035.vdocuments.us/reader035/viewer/2022062620/551aadc95503466b3a8b5edb/html5/thumbnails/24.jpg)
Salt Fog Testing
-0.5
0
0.5
1
1.5
2
2.5
3
0 12 25 37 50 62 75 88 126
Time (Hours)
Vo
ltag
e (V
olt
s) Corrosion Sensor
Corrosion Sensor Control
Humidity
Temperature
Circuit Control Voltage
Coupon 1 Coupon 2 Coupon 3
![Page 25: Final Design Review MEMS-based Corrosion Health Monitoring Fri aeiynCucfed JanineCrsohrO Mihe erncT io Liaison Engineers: Pec uces Tr lw Faculty Coach:](https://reader035.vdocuments.us/reader035/viewer/2022062620/551aadc95503466b3a8b5edb/html5/thumbnails/25.jpg)
Results ASTM D3359 Coating Adherence Test
Measures Amount of Undercut Nickel Plating Designations: 5A (Least Corrosion)–0A (Most Corrosion) 5 coupons tested
24 hr: 5A 48 hr: 4A 71 hr: 2A 139 hr (1): 1A 139 hr (2): 2A
Coupon 139 hr (1)
![Page 26: Final Design Review MEMS-based Corrosion Health Monitoring Fri aeiynCucfed JanineCrsohrO Mihe erncT io Liaison Engineers: Pec uces Tr lw Faculty Coach:](https://reader035.vdocuments.us/reader035/viewer/2022062620/551aadc95503466b3a8b5edb/html5/thumbnails/26.jpg)
Measurement CorrelationCoupons
Minimal corrosion product for 24 & 48 hr coupons Visible Al203 for 71 &139 hr coupons
Measurements Rapid Increase in ER sensor at onset
Minimal Corrosion Product forming Al+3 ions lost in aqueous solution
Resistance change levels off Corrosion product protection
![Page 27: Final Design Review MEMS-based Corrosion Health Monitoring Fri aeiynCucfed JanineCrsohrO Mihe erncT io Liaison Engineers: Pec uces Tr lw Faculty Coach:](https://reader035.vdocuments.us/reader035/viewer/2022062620/551aadc95503466b3a8b5edb/html5/thumbnails/27.jpg)
Sensor Lifespan
Electrical resistance sensor Survived 5-day salt fog Provided data throughout lifespan of operating board
Temperature Survived 2-day salt fog
Humidity Survived 1-day salt fog Potentially a conformal coating problem on board
![Page 28: Final Design Review MEMS-based Corrosion Health Monitoring Fri aeiynCucfed JanineCrsohrO Mihe erncT io Liaison Engineers: Pec uces Tr lw Faculty Coach:](https://reader035.vdocuments.us/reader035/viewer/2022062620/551aadc95503466b3a8b5edb/html5/thumbnails/28.jpg)
Environmental SurvivabilityHarshest of Possible Environments
Environmental Sensors not conformally coated survivable in constant spray for 1-2 days
Macroscopic System conformal coating spot failures spot corrosion
emitted heat from conducting wires
survivable in constant spray for 4 days
![Page 29: Final Design Review MEMS-based Corrosion Health Monitoring Fri aeiynCucfed JanineCrsohrO Mihe erncT io Liaison Engineers: Pec uces Tr lw Faculty Coach:](https://reader035.vdocuments.us/reader035/viewer/2022062620/551aadc95503466b3a8b5edb/html5/thumbnails/29.jpg)
Prototype Demonstration
![Page 30: Final Design Review MEMS-based Corrosion Health Monitoring Fri aeiynCucfed JanineCrsohrO Mihe erncT io Liaison Engineers: Pec uces Tr lw Faculty Coach:](https://reader035.vdocuments.us/reader035/viewer/2022062620/551aadc95503466b3a8b5edb/html5/thumbnails/30.jpg)
Salt Fog Testing
-0.5
0
0.5
1
1.5
2
2.5
3
0 12 25 37 50 62 75 88 126
Time (Hours)
Vo
ltag
e (V
olt
s) Corrosion Sensor
Corrosion Sensor Control
Humidity
Temperature
Circuit Control Voltage
Coupon 1 Coupon 2 Coupon 3
LEVEL 7
![Page 31: Final Design Review MEMS-based Corrosion Health Monitoring Fri aeiynCucfed JanineCrsohrO Mihe erncT io Liaison Engineers: Pec uces Tr lw Faculty Coach:](https://reader035.vdocuments.us/reader035/viewer/2022062620/551aadc95503466b3a8b5edb/html5/thumbnails/31.jpg)
1 2 3 4 5 6 7
![Page 32: Final Design Review MEMS-based Corrosion Health Monitoring Fri aeiynCucfed JanineCrsohrO Mihe erncT io Liaison Engineers: Pec uces Tr lw Faculty Coach:](https://reader035.vdocuments.us/reader035/viewer/2022062620/551aadc95503466b3a8b5edb/html5/thumbnails/32.jpg)
![Page 33: Final Design Review MEMS-based Corrosion Health Monitoring Fri aeiynCucfed JanineCrsohrO Mihe erncT io Liaison Engineers: Pec uces Tr lw Faculty Coach:](https://reader035.vdocuments.us/reader035/viewer/2022062620/551aadc95503466b3a8b5edb/html5/thumbnails/33.jpg)
![Page 34: Final Design Review MEMS-based Corrosion Health Monitoring Fri aeiynCucfed JanineCrsohrO Mihe erncT io Liaison Engineers: Pec uces Tr lw Faculty Coach:](https://reader035.vdocuments.us/reader035/viewer/2022062620/551aadc95503466b3a8b5edb/html5/thumbnails/34.jpg)
![Page 35: Final Design Review MEMS-based Corrosion Health Monitoring Fri aeiynCucfed JanineCrsohrO Mihe erncT io Liaison Engineers: Pec uces Tr lw Faculty Coach:](https://reader035.vdocuments.us/reader035/viewer/2022062620/551aadc95503466b3a8b5edb/html5/thumbnails/35.jpg)
![Page 36: Final Design Review MEMS-based Corrosion Health Monitoring Fri aeiynCucfed JanineCrsohrO Mihe erncT io Liaison Engineers: Pec uces Tr lw Faculty Coach:](https://reader035.vdocuments.us/reader035/viewer/2022062620/551aadc95503466b3a8b5edb/html5/thumbnails/36.jpg)
![Page 37: Final Design Review MEMS-based Corrosion Health Monitoring Fri aeiynCucfed JanineCrsohrO Mihe erncT io Liaison Engineers: Pec uces Tr lw Faculty Coach:](https://reader035.vdocuments.us/reader035/viewer/2022062620/551aadc95503466b3a8b5edb/html5/thumbnails/37.jpg)
![Page 38: Final Design Review MEMS-based Corrosion Health Monitoring Fri aeiynCucfed JanineCrsohrO Mihe erncT io Liaison Engineers: Pec uces Tr lw Faculty Coach:](https://reader035.vdocuments.us/reader035/viewer/2022062620/551aadc95503466b3a8b5edb/html5/thumbnails/38.jpg)
Conclusion
![Page 39: Final Design Review MEMS-based Corrosion Health Monitoring Fri aeiynCucfed JanineCrsohrO Mihe erncT io Liaison Engineers: Pec uces Tr lw Faculty Coach:](https://reader035.vdocuments.us/reader035/viewer/2022062620/551aadc95503466b3a8b5edb/html5/thumbnails/39.jpg)
Recommendations
Wireless LinkStand-Alone Custom GUI Additional Low Power ResearchLaser Etched Sensor Manufacturing
![Page 40: Final Design Review MEMS-based Corrosion Health Monitoring Fri aeiynCucfed JanineCrsohrO Mihe erncT io Liaison Engineers: Pec uces Tr lw Faculty Coach:](https://reader035.vdocuments.us/reader035/viewer/2022062620/551aadc95503466b3a8b5edb/html5/thumbnails/40.jpg)
Acknowledgements
Thank You… Lockheed Martin
eyunss lew ling Kaara
University of Florida ohnAoPE ithanfillD, an M Marilyn Marlow
![Page 41: Final Design Review MEMS-based Corrosion Health Monitoring Fri aeiynCucfed JanineCrsohrO Mihe erncT io Liaison Engineers: Pec uces Tr lw Faculty Coach:](https://reader035.vdocuments.us/reader035/viewer/2022062620/551aadc95503466b3a8b5edb/html5/thumbnails/41.jpg)
QuestionsQuestions