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DISTRIBUTIONSBIR Data Rights. Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.

DISCLAIMER STATEMENTThe 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 ABL Smart Piping System for Containment and Control of Highly Corrosive and Hazardous Chemicalsof Highly Corrosive and Hazardous Chemicals ” ”

SBIR Phase II Contract: HQ0006-05-C-7254SBIR Phase II Contract: HQ0006-05-C-7254

Status MeetingStatus Meeting1 May, 20061 May, 2006

Air Force Program ManagerAir Force Program ManagerBrandon Arritt, AFRL/VSSVBrandon Arritt, AFRL/VSSV

Odyssian TechnologyOdyssian TechnologyBarton BennettBarton Bennett

Paul DitslerPaul DitslerBen SmithBen Smith

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OODYSSIANDYSSIAN TTECHNOLOGYECHNOLOGY

AGENDAAGENDA 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

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e-BoardMultifunctional

Sporting GoodsMultifunctional Structure

Thin Film IgnitersDeposition of Conductive Material

Small UAV Multifunctional

Structure

Smart Piping Systems

Integrated Leak Detection Sensors

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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

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Proprietary or Confidential DataDisseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.

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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

CY2005 CY2006

Task V – Testing, Evaluation

Mtg @ Odyssian Mtg @ Odyssian

Q1 Q2

Nov 2 –Feb 1

Q3

Feb 2 –May 1 May 2 –Aug 1 Aug 2 –Nov 1 Nov 2 –Feb 1 Feb 2 –May 1 May 2 –Aug 1

CY2007

> <May 1, 2006

Sensor & Controls Dev


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Phase II TeamPhase 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.



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AGENDAAGENDA

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Overview




AF/MDA Related Work



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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

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Flanged Pipe Design

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C:\Documents and Settings\Administrator\My Documents\_Homer\_Odyssian\_MDA Smart Pipe\Phase II\Presentations\Brandon Presentation\Flanged Pipe.EASM

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C:\Documents and Settings\Administrator\My Documents\_Homer\_Odyssian\_MDA Smart Pipe\Phase II\Presentations\Brandon Presentation\Smart Seal.EASM

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C:\Documents and Settings\Administrator\My Documents\_Homer\_Odyssian\_MDA Smart Pipe\Phase II\Presentations\Brandon Presentation\Sensor insert.EPRT

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• Flange Design – Based on ANSI B16.5 Standard– Estimated 50% Weight Savings Over Hastelloy Baseline– Smart Pipe Design Made of Aluminum with PVDF Insert

Baseline Smart Pipe Design

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• Curved Pipe– Braided or Wound– Mates to other Smart Pipe

Fittings– Lighter Weight than Elbow

Joints

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C:\Documents and Settings\Administrator\My Documents\_Homer\_Odyssian\_MDA Smart Pipe\Phase II\Presentations\Brandon Presentation\Curved Flanged Pipe.EASM

C:\Documents and Settings\Administrator\My Documents\_Homer\_Odyssian\_MDA Smart Pipe\Phase II\Presentations\Brandon Presentation\Reactive End Cap Curved.EPRT

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• Smart Collar– Usable on pre-existing

piping systems– Large array of commercial

uses– Developed under 21st

Century Fund cost match

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C:\Documents and Settings\Administrator\My Documents\_Homer\_Odyssian\_MDA Smart Pipe\Phase II\Presentations\Brandon Presentation\Smart Collar.EASM

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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

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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

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FEA Analysis• NEi/Nastran

• Complex Models Created

• Multiple Loading/Boundary Conditions Considered

• Verified Correlation between FEA Models and Classical Hand Analysis

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AGENDAAGENDA

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Overview




AF/MDA Related Work



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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

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• 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



MEMS Pressure Sensors

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• Features– Small size– 500 psi operating range– 1000 psi burst– -40o F to 250o F operating temp– Mounting and packaging options

• Supplier / Cost– Measurement Specialties (Entran)– $475 each– Custom features at additional cost



Sub-Miniature Pressure Transducers

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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

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• Activates at 40 psi• 3 cycles before failure• May be susceptible to vibration



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Developed under non-SBIR Funds

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• Activates at 35 psi• 6-8 cycles before failure• Eliminates failure due to vibration• Eliminates fatigue of spring conductor



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Developed Under non-SBIR Funds

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Pressure Vessel

Used for Testing Pressure Sensors

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AGENDAAGENDA

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Overview




AF/MDA Related Work



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Task IV: Process and Fabrication

• Table Rolling– Oven Curing

– Inexpensive, Re-usable Tooling

– High Quality Parts

– Compaction Pressure from Heat Shrink

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Table Rolling Process

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• Bias plies increase waste and production cost

• FEA analysis indicates that bias plies are unnecessary

• 20% Weight savings

No Bias Plies

Bias Plies

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Wash-out Mandrel

For Use in Fabricating Curved Pipe

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Curved Pipe Process

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• 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

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AGENDAAGENDA

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Overview




AF/MDA Related Work



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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


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AGENDAAGENDA

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Overview




AF/MDA Related Work



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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

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Phase II Test MatrixPhase II Test Matrix


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AGENDAAGENDA

Overview



AF/MDA Related Work



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Category Budget

Cummulative Actual

Expense

Cummulativ

e Paid

Previous Period Unpaid

Period Expense

Adjustments Applied this

Period

Current Period Payment RequestAmount Rate

Salary/Wages (direct) $ 318,085 $ 29,485 $ -

$ - $12,122

$ - $ 12,122

Fringe $ 103,378 $ 6,262 $ -

$ - $ 3,056 25.2%

$ - $ 3,056

Labor Overhead $ 63,641 $ 510 $ -

$ -

$ -

$ -

$ -

Materials/Supplies $ 41,392 $ 2,857 $ -

$ - $ 2,721

$ - $ 2,721

Equipment $ -

$ -

$ -

$ -

$ -

$ -

$ -

Travel $ 8,625 $ 1,123 $ -

$ -

$ -

$ -

$ -

Consultants/Subcontractiors $ 64,230

$ -

$ -

$ -

$ -

$ -

G&A Expense $ 95,080 $ 18,153 $ -

$ - $ 4,846 31.9%

$ - $ 4,846

Fee $ 55,554 $ 4,181 $ 2,361 $ 1,820 8.0% $ - $ 1,820

Total $ 749,985 $ 62,571 $ 31,879 $ - $24,564

$ - $ 24,564

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Backup SlidesBackup Slides

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Phase II Piping RequirementsPhase 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)


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Phase II Piping RequirementsPhase 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=-15Cb. NH3: P=345 psia, T=20F to 90F (Excludes gaseous NH3 exhaust ducts)c. I2: P=50 to 200 psia, T=230F to 660Fd. H2O2: P=1000 to 1300 psia, T=40F to 80F

MEOP – Maximum estimated operating pressure


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Phase II SBIR ProgramPhase II SBIR Program

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Documents

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