1. 1 DISTRIBUTION SBIR Data Rights. Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted. DISCLAIMER STATEMENT The views, opinions, and findings contained in this report are those of the author(s) and should not be construed as an official Department of Defense position, policy, or decision. ABL Smart Piping System for Containment and Control of Highly Corrosive and Hazardous Chemicals SBIR Phase II Contract: HQ0006-05-C-7254 Status Meeting 1 May, 2006 Air Force Program Manager Brandon Arritt, AFRL/VSSV Odyssian Technology Barton Bennett Paul Ditsler Ben SmithABL Smart Piping System for Containment and Control of Highly Corrosive and Hazardous Chemicals SBIR Phase II Contract: HQ0006-05-C-7254 Status Meeting 1 May, 2006 Air Force Program Manager Brandon Arritt, AFRL/VSSV Odyssian Technology Barton Bennett Paul Ditsler Ben Smith

2. 2AGENDA Overview Recent Program Accomplishments –Design and Analysis –Sensor Development and Evaluation –Process Development Plans for Next Quarter Open Technical Discussion AF/MDA Related Work Closing Session –Financial Overview –Related Federal Appropriation Request Lab Tour – Overview of Other Technology HQ0006-05-C-7254

3. 3 e-Board Multifunctional Sporting Goods Multifunctional Structure Thin Film Igniters Deposition of Conductive Material Small UAV Multifunctional Structure Smart Piping Systems Integrated Leak Detection Sensors

4. 4 Program Status Overview Recent Accomplishments Smart Pipe Designs –Flanged Fitting –Compression Fitting –Integrated Sensor Circuitry Sensor Research and Development (non-SBIR funded) –Pressure Sensor Process Development –Straight and Curved Composite Dual Wall Pipe –Electrical Tracings HQ0006-05-C-7254 Proprietary or Confidential Data Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.

5. 5 TASKS Aug 2 –Nov 1 Task I – Rqts & Criteria Definition Task II – Task III – Design & Modeling Task IV – Process Dev. and Fabr Task VI– Program Mgt. & Reporting Q4 Q1 Q2 Kick-off Mtg @ MDA Mtg @ MDA Q3 Q4 CY2005CY2006 Task V–Testing, Evaluation Mtg @ Odyssian Q1 Q2 Nov 2 –Feb 1 Q3 Feb 2 –May 1May 2 –Aug 1Aug 2 –Nov 1Nov 2 –Feb 1Feb 2 –May 1May 2 –Aug 1 CY2007 > < May 1, 2006 Sensor & Controls Dev

6. 6 Phase II Team Odyssian Technology Contribution: Overall program responsibility. System design, development, fabrication, and evaluation. Boeing ABL and Phantom Works Contribution: Requirements and criteria definition and general program oversight. Dr. Lieberman (University of Notre Dame) Contribution: Consultation and research on chemical sensors and chemical exposure testing. Facilities and experience for handling hazardous chemicals. Dr. Corona (University of Notre Dame) Contribution: Structural analysis modeling and mechanical testing of smart piping system. Facilities for mechanical testing. Dr. Lee (Purdue University) Contribution: Chemical sensor testing. Facilities and experience for handling hazardous chemicals. Proprietary or Confidential Data Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.

7. 7AGENDA HQ0006-05-C-7254 Overview Recent Program Accomplishments –Design and Analysis –Sensor Development and Evaluation –Process Development Plans for Next Quarter Open Technical Discussion AF/MDA Related Work Closing Session –Financial Overview –Related Federal Appropriation Request Lab Tour – Overview of Other Technology

8. 8 ABL SMART PIPING SYSTEM Task III: Design and Modeling Positive Electrical Pin (for shown circuit) Common GroundChlorine Sensor (Tin Fuse) Copper foil conductor Secondary O-ring Positive Electrical Pin (for circuit on other side of seal) Primary O-ring Threaded Pipe Design HQ0006-05-C-7254 Proprietary or Confidential Data Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.

9. 9 ABL SMART PIPING SYSTEM Task III: Design and Modeling Flanged Pipe Design HQ0006-05-C-7254 Proprietary or Confidential Data Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.

10. 10 ABL SMART PIPING SYSTEM Task III: Design and Modeling HQ0006-05-C-7254 Proprietary or Confidential Data Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.

11. 11 ABL SMART PIPING SYSTEM Task III: Design and Modeling HQ0006-05-C-7254 Proprietary or Confidential Data Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.

12. 12 ABL SMART PIPING SYSTEM Task III: Design and Modeling Flange Design –Based on ANSI B16.5 Standard –Estimated 50% Weight Savings Over Hastelloy Baseline –Smart Pipe Design Made of Aluminum with PVDF Insert BaselineSmart Pipe Design HQ0006-05-C-7254 Proprietary or Confidential Data Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.

13. 13 ABL SMART PIPING SYSTEM Task III: Design and Modeling Curved Pipe –Braided or Wound –Mates to other Smart Pipe Fittings –Lighter Weight than Elbow Joints HQ0006-05-C-7254 Proprietary or Confidential Data Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.

14. 14 ABL SMART PIPING SYSTEM Task III: Design and Modeling HQ0006-05-C-7254 Proprietary or Confidential Data Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.

15. 15 ABL SMART PIPING SYSTEM Task III: Design and Modeling Smart Collar –Usable on pre-existing piping systems –Large array of commercial uses –Developed under 21 st Century Fund cost match HQ0006-05-C-7254 Proprietary or Confidential Data Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.

16. 16 ABL SMART PIPING SYSTEM Task III: Design and Modeling Tubing Materials Composite Material System, Toray T700G 12K / #2510 –Unidirectional Carbon/Epoxy Prepreg –Toughened Matrix / Intermediate Modulus Fiber –Boeing Certified –250F Degree Oven Cure Toray T800HB / Cytec CYCOM 823 –VaRTM Material System –12K Intermediate Modulus Fiber –250 Degree Cure VaRTM Resin –Room Temperature Injection Chemical Resistant Liners (to be explored), PVDF Sleeve – Straight Pipe FEP or PVDF Heat Shrink – Curved Pipe HQ0006-05-C-7254 Proprietary or Confidential Data Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.

17. 17 Flanged Fitting Materials Aluminum 6061 T6 –Bolted Region PVDF Insert –Bonded Region Bolts –Carbon Steel, ANSI Standard Flared Fitting Materials Hasteloy C276 (Chlorine) Inconel 625 or Stainless Steel 316L (BHP) Seal Materials PVDF body with Viton O-rings (Threaded and Flanged) SAE AS1098 teflon ring seal (flared) –To be explored Copper Tracing / Gold Plated Electrical Contacts HQ0006-05-C-7254 Proprietary or Confidential Data Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.

18. 18 ABL SMART PIPING SYSTEM Task III: Design and Modeling FEA Analysis NEi/Nastran Complex Models Created Multiple Loading/Boundary Conditions Considered Verified Correlation between FEA Models and Classical Hand Analysis HQ0006-05-C-7254 Proprietary or Confidential Data Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.

19. 19AGENDA HQ0006-05-C-7254 Overview Recent Program Accomplishments –Design and Analysis –Sensor Development and Evaluation –Process Development Plans for Next Quarter Open Technical Discussion AF/MDA Related Work Closing Session –Financial Overview –Related Federal Appropriation Request Lab Tour – Overview of Other Technology

20. 20 ABL SMART PIPING SYSTEM Task II: Sensors and Controls Ultra Wide Band (UWB) –Newer Technology –Low Power Consumption Rate Zigbee –Mature Technology On-Off Keyed (OOK) –Very low power –Sensor networking –Simple Signals Development Kits and Chipsets Identified HQ0006-05-C-7254 Proprietary or Confidential Data Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.

21. 21 Features –Small size –300 psi operating range –1500 psi burst –Must be mounted and encapsulated Suppliers / Cost –Silicon Microstructures, Memstech –$5 each (bare die) –500 piece minimum purchase ABL SMART PIPING SYSTEM MEMS Pressure Sensors HQ0006-05-C-7254 Proprietary or Confidential Data Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.

22. 22 Features –Small size –500 psi operating range –1000 psi burst –-40 o F to 250 o F operating temp –Mounting and packaging options Supplier / Cost –Measurement Specialties (Entran) –$475 each –Custom features at additional cost ABL SMART PIPING SYSTEM Sub-Miniature Pressure Transducers HQ0006-05-C-7254 Proprietary or Confidential Data Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.

23. 23 ABL SMART PIPING SYSTEM Prototype Pressure Transducers Activates at 75 psi 2-3 cycles before failure Simple design and materials Activates at 30 psi Unknown failure Simple design and materials Spring Contact Concept Diaphragm Concept HQ0006-05-C-7254 Proprietary or Confidential Data Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.

24. 24 Activates at 40 psi 3 cycles before failure May be susceptible to vibration ABL SMART PIPING SYSTEM Prototype Pressure Transducers HQ0006-05-C-7254 Proprietary or Confidential Data Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted. Developed under non-SBIR Funds

25. 25 Activates at 35 psi 6-8 cycles before failure Eliminates failure due to vibration Eliminates fatigue of spring conductor ABL SMART PIPING SYSTEM Prototype Pressure Transducers HQ0006-05-C-7254 Proprietary or Confidential Data Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted. Developed Under non-SBIR Funds

26. 26 ABL SMART PIPING SYSTEM Pressure Vessel Used for Testing Pressure Sensors HQ0006-05-C-7254 Proprietary or Confidential Data Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.

27. 27AGENDA HQ0006-05-C-7254 Overview Recent Program Accomplishments –Design and Analysis –Sensor Development and Evaluation –Process Development Plans for Next Quarter Open Technical Discussion AF/MDA Related Work Closing Session –Financial Overview –Related Federal Appropriation Request Lab Tour – Overview of Other Technology

28. 28 ABL SMART PIPING SYSTEM Task IV: Process and Fabrication Table Rolling –Oven Curing –Inexpensive, Re-usable Tooling –High Quality Parts –Compaction Pressure from Heat Shrink HQ0006-05-C-7254 Proprietary or Confidential Data Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.

29. 29 ABL SMART PIPING SYSTEM Table Rolling Process HQ0006-05-C-7254 Proprietary or Confidential Data Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.

30. 30 ABL SMART PIPING SYSTEM Task IV: Process and Fabrication Bias plies increase waste and production cost FEA analysis indicates that bias plies are unnecessary 20% Weight savings No Bias Plies Bias Plies HQ0006-05-C-7254 Proprietary or Confidential Data Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.

31. 31 ABL SMART PIPING SYSTEM Wash-out Mandrel For Use in Fabricating Curved Pipe HQ0006-05-C-7254 Proprietary or Confidential Data Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.

32. 32 ABL SMART PIPING SYSTEM Curved Pipe Process HQ0006-05-C-7254 Proprietary or Confidential Data Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.

33. 33 ABL SMART PIPING SYSTEM Task IV: Process and Fabrication Flat Flexible Cable –Expensive –Crimped Terminations –Easily installed Conductive Polymer –Silver Filled –Expensive –Can be Printed –Flexible Pattern –Could be Copper Electroplated –Must be Insulated from Pipe Copper Foil –Solderable –Must be Insulated from Pipe –High conductivity HQ0006-05-C-7254 Proprietary or Confidential Data Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.

34. 34AGENDA HQ0006-05-C-7254 Overview Recent Program Accomplishments –Design and Analysis –Sensor Development and Evaluation –Process Development Plans for Next Quarter Open Technical Discussion AF/MDA Related Work Closing Session –Financial Overview –Related Federal Appropriation Request Lab Tour – Overview of Other Technology

35. 35 ABL SMART PIPING SYSTEM Plans for Next Quarter HQ0006-05-C-7254 1.Achieve Better Definition of Current ABL Piping Flange Design Seal Design Cost 2.Complete Design and Analysis (Task III) Pipe, fitting, seals Phase II Demo 3.Continue Sensor Development Determine Feasibility of COTS Sensors –MEMS –Subminiature Transducers Develop BHP Reactive Sensor Concepts Develop Additional Pressure Sensor Concepts 4.Conduct Chemical Compatibility Testing 5.Complete Process Dev/Eval of Curved Pipe Braided VaRTM Curved Pipe Wound Prepreg Curved Pipe 6.Develop initial sensor circuit design Proprietary or Confidential Data Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.

36. 36AGENDA HQ0006-05-C-7254 Overview Recent Program Accomplishments –Design and Analysis –Sensor Development and Evaluation –Process Development Plans for Next Quarter Open Technical Discussion AF/MDA Related Work Closing Session –Financial Overview –Related Federal Appropriation Request Lab Tour – Overview of Other Technology

37. 37 Issues / Discussion Topics Input from Shery Welsh 3-17-2006 (Current ABL Pipe, Flange and Seal Design Details) –Clarification on requirements (geometry); ¼ to 1 flared, 1.25-12 flanged –AF SPO Approval for ABL Specifications Lightweight NASA Flange Designs SAE Seal Ring AS1098 Female Boss Fitting Design Requirements Definition –Purchase of Test Equipment in Lieu of Boeing Subcontract Testing –Purchase of Test Equipment in Lieu of ND Testing –Add Braided and Wound Pipe –Vibration –Pressure Burst Increased Strain Requirement –0.41% vs 0.15% –Composite allowable strain 2% Curve Shape Definition –Use of Pre-shaped Pipe Segments? –On-site Bending? –Flexible Tooling Needed? Phase II Demonstration –More Straight Piping –Circulation/pressurized –Meeting Setup with U of I HQ0006-05-C-7254 Proprietary or Confidential Data Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.

38. 38 Phase II Test Matrix Proprietary or Confidential Data Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.

39. 39AGENDA Overview Recent Program Accomplishments –Design and Analysis –Sensor Development and Evaluation –Process Development Open Technical Discussion AF/MDA Related Work Closing Session –Financial Overview –Related Federal Appropriation Request Lab Tour – Overview of Other Technology HQ0006-05-C-7254

40. 40 HQ0006-05-C-7254 Category Budget Cummulative Actual Expense Cummulativ e Paid Previous Period Unpaid Period Expense Adjustments Applied this Period Current Period Payment Request AmountRate Salary/Wages (direct) $ 318,085 $ 29,485 $ - $12,122 $ - $ 12,122 Fringe $ 103,378 $ 6,262 $ - $ 3,05625.2% $ - $ 3,056 Labor Overhead $ 63,641 $ 510 $ - Materials/Supplies $ 41,392 $ 2,857 $ - $ 2,721 $ - $ 2,721 Equipment $ - Travel $ 8,625 $ 1,123 $ - Consultants/Subcontra ctiors $ 64,230 $ - G&A Expense $ 95,080 $ 18,153 $ - $ 4,84631.9% $ - $ 4,846 Fee $ 55,554 $ 4,181 $ 2,361 $ 1,8208.0% $ - $ 1,820 Total $ 749,985 $ 62,571 $ 31,879 $ - $24,564 $ - $ 24,564

41. 41 Backup Slides

42. 42 Phase II Piping Requirements Geometry, –Type A Pipe inside tube diameter, 1.00 to 1.25 inches (chlorine only) fitting, bolted flange joint. Lengths range from 6 to 110 inches long for 1.0 diameter and 30 to 110 inches for 1.25 diameter. –Type B Pipe inside tube diameter,.75 inches fitting, Threaded compression fitting Lengths range from 6 to 110 inches long for 1.0 diameter and 30 to 110 inches for 1.25 diameter. Temperature, –operating, 40F to 80F –survival, -65F to 160F Dynamic, –acceleration, 9g in all 3 axis, followed by leak test at MEOP –vibration, 3-axis random vibration, 0.04g2/Hz, 6.1grms, duration 90 minutes each axis, analysis requires an uncertainty factor of four (4). Operating Force Loads, (chlorine only) –Type A axial, 628-982 lbs. (P x A x 2) torsion, 60 in-lbs. (5 ft-lbs) pressure, 400 psia (MEOP) –Type B axial, 353 lbs. (P x A x 2) torsion, 60 in-lbs. (5 ft-lbs) pressure, 400 psia (MEOP) Proprietary or Confidential Data Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted. HQ0006-05-C-7254

43. 43 Phase II Piping Requirements Phase II Piping Requirements (continued) Design Ultimate Loads (static), (chlorine only) –Type A axial, 1570 - 2,450lbs. (P x A x 2) torsion, 90 in-lbs. (7.5 ft-lbs) pressure, 1000 psia abuse, 500 lbs over 4 inch footprint –Type B axial, 663 lbs. (P x A x 2) torsion, 90 in-lbs. (7.5 ft-lbs) pressure, 1000 psia abuse, 500 lbs over 4 inch footprint Impact damage degradation, 100 ft-lbs using a 1.0 inch diameter tip (must be able to operate under burst pressure after impact) Leak detection sensitivity, 3 PPM max Duty cycles up to MEOP, 2,000 cycles Strain of 0.41% Design per MIL-STD-1522A –Includes: design burst pressure of 2.5 times MEOP –Includes: proof test pressure of 1.5 times MEOP Pressure/Temperature ranges for other ABL Fluid Systems. Excluding GN2, He and Oil lube. a. BHP: P=300 psia, T=-15C b. NH3: P=345 psia, T=20F to 90F (Excludes gaseous NH3 exhaust ducts) c. I2: P=50 to 200 psia, T=230F to 660F d. H2O2: P=1000 to 1300 psia, T=40F to 80F MEOP – Maximum estimated operating pressure Proprietary or Confidential Data Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted. HQ0006-05-C-7254

44. 44 Phase II SBIR Program