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Final Design Review MEMS-based Corrosion Health Monitoring Fri aeiynCucfed JanineCrsohrO Mihe erncT io Liaison Engineers: Pec uces Tr lw Faculty Coach:

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Presentation on theme: "Final Design Review MEMS-based Corrosion Health Monitoring Fri aeiynCucfed JanineCrsohrO Mihe erncT io Liaison Engineers: Pec uces Tr lw Faculty Coach:"— Presentation transcript:

1 Final Design Review MEMS-based Corrosion Health Monitoring Fri aeiynCucfed JanineCrsohrO Mihe erncT io Liaison Engineers: Pec uces Tr lw Faculty Coach: Jh.AboePD E

2 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 inaccessible the chassis is relatively inaccessible within the aircraft corrosion free in most cases, the chassis is corrosion free wasted time and money are wasted by this inefficiency

3 Aim To reduce unnecessary corrosion related service activities with a stand alone system that can alert a technician of a needed inspection  Reliable measurement of the environmental corrosivity seen by the chassis  LED alert system viewed from exterior of the chassis 1-10 level of need for service activity

4 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)

5 Elements of Chassis Galvanic coupling of aluminum and nickel Aluminum = anode Nickel = cathode Electrolyte provides driving force for corrosion

6 Galvanic Corrosion As a result of nickel contact:  Corrosion potential of aluminum (M) increased  Corrosion rate of aluminum (M) is increased Nickel Aluminum Couple

7 Customer Requirements GENERAL NEEDS: Operate Under Harsh Conditions Non-Intrusive Feedback Long Life Span MEMS Based Light Weight Small Size

8 Hardware Design

9 Functional Diagram

10 Hardware Design Dimmed elements denote exploratory efforts not included in final design

11 Macroscopic System

12 Hardware Design  Near Linear Approximation  Module Expiration Detection  Manufacturability R = V / I appl R = ρL / πr 2 Electrical Resistance Sensor Concept:

13 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 (1 st Red LED) correlates to critical corrosion damage

14 Output Method Corrosion will cause reduction in ER sensor’s cross-sectional area At critical % area reduction critical voltage AA

15 Sensor Sampling Control Wire

16 Testing

17 Verification Testing Hardware Unit Test  Sensor Proof of Concept  5 days in Salt Spray Machine Software Unit Test  Data Interface to software and LED display Acceptance Testing  Functional Acceptance Test (Integration)  Environmental Acceptance Test (Survivability)

18 Proof of Sensor Concept  48 hour test -24 hours immersed in salt bath -24 hours in atmosphere

19 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

20 Testing ASTM B117 Salt Fog Chamber  Constant corrosive vapor applied for 5 days  5 Test coupons removed at daily intervals  Data samplings recorded as voltages Recorded using a datalogger Data sampling = once per minute Example of Salt Spray Chamber

21 Wireless - ZigBee Proven feasible up to 6” thickness of casing  Due mainly to chamber reflections  Minimal aperture required Wireless communication pursuit ended 2/7/05 given risk and manpower

22 Testing Results

23 Results

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25 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)

26 Measurement Correlation Coupons  Minimal corrosion product for 24 & 48 hr coupons  Visible Al 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

27 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

28 Environmental Survivability Harshest 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

29 Prototype Demonstration

30 LEVEL 7

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38 Conclusion

39 Recommendations Wireless Link Stand-Alone Custom GUI Additional Low Power Research Laser Etched Sensor Manufacturing

40 Acknowledgements Thank You…  Lockheed Martin  eyunss  lew  ling  Kaara  University of Florida  ohnAoPE  ithanfillD,  an M  Marilyn Marlow

41 Questions


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