TECHNOLOGY AREAS: Materials/Processes

The technology within this topic is restricted under the International Traffic in Arms Regulation (ITAR), which controls the export and import of defense-related material and services. Offerors must disclose any proposed use of foreign nationals, their country of origin, and what tasks each would accomplish in the statement of work in accordance with section 3.5.b.(7) of the solicitation.

OBJECTIVE: Develop a portable corrosion detector that can be used to inspect aircraft structure with complex geometries.

DESCRIPTION: Naval aircraft operate in a severely corrosive environment. Corrosion costs are the Navy�s top aircraft maintenance expense. NAVAIR is interested in optimizing corrosion related maintenance by using a portable corrosion detection device to confirm corrosion when the on-board corrosion sensors indicate that corrosion may be occurring. A typical example might be to do a quick-check on a magnesium gearbox housing (highly complex geometry casting up to 3 cu ft in size) or an aircraft skin lap joint. The corrosion detector should be hand-held, less than 8 pounds, and less than 0.3 cu ft. The system should be capable of detecting corrosion in the early stages of pitting under paint and between faying surfaces and providing a qualitative assessment of corrosion severity. In addition, the target per-unit price of the final product should be less than $5000.

PHASE I: Identify sensor type(s) to be used to detect early-stage pitting corrosion in a complex structure. Construct bread-board system. Manufacture/procure demonstration test-article(s) that include complex geometries. Create light pitting corrosion on test samples. Demonstrate sensor sensitivity to find early-stage pitting corrosion in complex geometry part. Demonstrate the feasibility to miniaturize system to desired size. Phase 1 size and weight goals for the breadboard system should be less than 0.5 cu ft and under 10 pounds.

PHASE II: Miniaturize the Phase I system and develop a prototype to meet final size goals. Refine the user interface and system perfomance. Manufacture/procure demonstration test-articles. Demonstration prototype system�s capability to detect light pitting corrosion and to qualitatively rate more severe corrosion.

PHASE III: Implement full-scale production of the NDE devices in quantities proportional to market and Navy demand. Desired production unit cost is less than $5,000.

PRIVATE SECTOR COMMERCIAL POTENTIAL.DUAL-USE APPLICATIONS: Successful development of a cost-effect, ultra-portable NDE device would benefit the commercial aircraft industry.

REFERENCES: 1. "Corrosion Monitoring Techniques," http://www.corrosionsource.com/technicallibrary/
corrdoctors/Modules/MonitorBasics/Types.htm

2. Paradiso, Joseph and Starner, Thad, "Energy Scavenging for Mobile and Wireless Electronics" http://www.media.mit.edu/resenv/pubs/papers/2005-02-E-HarvestingPervasivePprnt.pdf, Pervasive Computing, Jan-Mar 2005.

KEYWORDS: Corrosion Monitoring; Corrosion Detection; Health Monitoring; Sensors; Energy Harvesting; Energy Scavenging; Wireless Data Transmission

TPOC: (301)342-8020
2nd TPOC: (301)342-3761

** TOPIC AUTHOR (TPOC) **

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