MONTHLY STATUS REPORT - Odyssian Technologyodyssian.com/MDA/MDA/files/Phase I/6th Status...

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CONTRACTOR: ODYSSIAN TECHNOLOGY, LLC

CONTRACT NO.: F29601-03-M-0294

6 T H MONTHLY STATUS REPORT FEBRUARY 11 T H , 2 0 0 4 - MARCH 5 T H , 2 0 0 4

SBIR PHASE I

“Multifunctional Structures with Structurally Integrated Circuitry For Use on the Airborne Laser (ABL)”

Prepared by: Barton Bennett

Odyssian Technology, LLC (574) 257-7555 - Office (574) 850-4060 - Mobile

Submitted to: Capt. Russell Burks, AFRL/VSSV

Jim Guerrero, AFRL/VSSV David Stratmoen, AFRL/PKVV

Dreama Schmidt (ACO), DCMA South Bend

DISTRIBUTION All data IAW DODD 5230.24. Distribution authorized to U.S. Government Agencies only, Proprietary Information 05 September, 2003. Other requests for this document shall be referred to the Air Force Research Laboratory/VSSV, 3550 Aberdeen Avenue, SE, Kirtland AFB NM 87117-5776.

EXPORT CONTROL WARNING This document contains technical data whose export is restricted by the Arms Export Control Act (Title 22, U.S.C. Sec. 2751, et seq.) or the Export Administrator Act of 1979, as amended, Title 50 U.S.C. app. 2401 et seq. Violations of these export laws are subject to severe criminal penalties. Disseminate IAW the provisions of the DOD Directive 5230.25.

A Technology Service and Solutions Company

ODYSSIAN TECHNOLOGY

WARNING: DISTRIBUTION AND EXPORT RESTRICTED This document contains data whose distribution and export is restricted per the legend on the front cover of this document. All data IAW DODD 5230.24. Distribution authorized to U.S. Government Agencies only. This document contains technical data whose export is restricted by the Arms Export Control Act or the Export Administrator Act. Violations of these export laws are subject to severe criminal penalties. Disseminate IAW the provisions of the DOD Directive 5230.25.

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6th Monthly Report – March 10, 2004 SBIR PHASE I

1.0 PROGRAM INTRODUCTION

This phase I SBIR program is developing multifunctional structure (MFS) technology for use on the Airborne Laser (ABL). Boeing, the ABL Prime Contractor, has been a subcontractor on this phase I SBIR program to provide definition of application requirements, critique of design concepts, and input on technology impact to the ABL program. Odyssian Technology, SBIR prime contractor, has overall program responsibility and is developing conceptual designs using 3D solid modeling, is fabricating and evaluating a proof-of-concept demonstration article, and will provide a technology impact assessment using input from members of the Boeing ABL team and the Boeing Phantom Works organization.

The Boeing ABL program selected the chemical oxygen iodine laser (COIL) piping system for application of multifunctional technology. In phase I, Odyssian Technology has developed a multifunctional composite piping system for containment and monitoring of the COIL chlorine gas.

The official start date of this program was September 5, 2003 with completion of technical tasks scheduled to occur six (6) months after start date.

2.0 STATUS SUMMARY

This program was successfully executed to schedule with a vast majority of technical tasks completed over a month early. Technical activity was completed by the scheduled end date of March 5th, 2004 except for minor activity in soliciting input from Boeing and putting this input into a presentable form. Expenditures charged to this program were within budget due to cost sharing and development of the smart seal ring under separate funds. This cost share was done to expand the results and accomplishments of phase I and to improve the likelihood of phase II (and phase III) follow-on programs.

During this reporting period, the only remaining technical task, Task 4 - Technology Impact Analysis, was completed. Also during this reporting period, Odyssian Technology responded to an invitation to propose phase II of this program by writing and submitting a proposal.

3.0 MILESTONE/ TASK STATUS

The work plan of this program included the following five tasks; Task 1 – Application Definition Task 2 – Conceptual Design Study Task 3 – Proof-of-Concept Demonstration Task 4 – Impact Analysis Task 5 – Program Management and Reporting


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Tasks 4 and 5 were the only remaining tasks that were active during this reporting period. The technical activity involved the definition of the Task 4 Technology Impact Analysis and discussions with Boeing concerning phase II plans.

3 .1 – SCHEDULE STATUS

A copy of the updated program schedule is shown in Figure 1. As shown, this schedule shows completion of all technical tasks. The Task V program management and reporting task will have additional activity up through the end of June 5th to satisfy final reporting obligations.

Figure 1: Updated Program Schedule – Technical tasks have been completed. Additional low rate activity will be required up through June 5th to satisfy contractual reporting requirements.

3 .2 – TECHNICAL ACCOMPLISHMENTS

During this reporting period, technical progress was made under Task 4 – Technology Impact Analysis. A summary of this progress is provided in the following subparagraphs.

Task 4 – Technology Impact Analysis

Odyssian Technology and Boeing discussed the impact of this SBIR technology on the ABL program on many occasions. The results of these discussions are shown in Tables 1, 2, and 3. Boeing provided a preliminary set of requirements and guidelines for use during phase II. These

PROGRAM SCHEDULE (September 5, 2003 to March 5, 2004)

TASK

Task I – Application Definition

Task II – Conceptual Design Study

Task III – Proof-of-Concept Demo

Task IV – Impact Analysis

Task V – Program Mgt. & Reporting

Kick-off & Tech. Coordination Teleconference

Sept Oct Nov Dec Jan Feb

Tech Coord. Meeting


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requirements are listed in Table 1. As shown, static and dynamic loads are defined, as well as temperature and pressure requirements. Near the beginning of phase II, these requirements will be expanded upon to provide definition of phase II design priority.

Tables 2 and 3 provide a summary of the Task 4 Technology Impact Analysis. Technical issues

are summarized in Table 2. As shown, an attempt was made in ranking the relative concern of each technical issue. This ranking was made by Odyssian Technology and was based upon the level of emphasis made by Boeing personnel during technical discussions. Although lower rankings are made, it does not indicate an overall low importance. As shown, impact damage tolerance is listed first. Concern was expressed multiple times over the effect an impact may have on the strength and containment capability of composite tubing. During phase II, strength and leak testing will be conducted on tubing exposed to impact.

Table 3 provides a summary of the payoff or benefits of the smart piping system. The first item

listed is personnel safety. Research was conducted during phase I that showed that some of the ABL high energy laser chemicals are extremely hazardous to human life (see previous reports). In addition, this research showed that the laser chemicals can cause corrosive or explosive reactions with various metals under certain conditions. Therefore, one payoff of the smart piping system is the reduction in likelihood that the ABL weapon system would be exposed and compromised by exposure to the corrosive laser chemicals.

Figures 2 and 3 were previously presented in a prior report, but are presented once again to

support closure of Task 4. Shown in Figure 2 is the proposed phase II demonstration component and in Figure 3 curved pipe test articles that will be evaluated during phase II. Discussions occurred this period with Boeing concerning these conceptual designs and phase II plans. Boeing has expressed interest in fabricating a representative system such as illustrated in Figure 2 and demonstrating low cost and reliable fabrication of curved composite piping as illustrated in Figure 3. Near the beginning of phase II, the phase II test and demonstration plans will be reviewed and enhanced with solicited input from Boeing ABL personnel.


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.

Table 1 - Basic Generic Requirements (for Phase II Feasibility Demonstration)

1. Geometry, a. inside tube diameter, 1.00 to 1.25 inches (chlorine only) b. fitting, bolted flanged joint. c. Lengths range from 6 to 110 inches long for 1.0” diameter and 30 to 110 inches for

1.25” diameter.

2. Temperature, a. operating, 40F to 80F b. survival, -65F to 160F

3. Dynamic, a. acceleration, 9g in all 3 axis, followed by leak test at MEOP b. vibration, 3-axis random vibration, 0.04g2/Hz, 6.1grms, duration 90 minutes each

axis, analysis requires an uncertainty factor of four (4).

4. Operating Force Loads, (chlorine only) a. axial, 982 lbs. (P x A x 2) b. torsion, 60 in-lbs. (5 ft-lbs) c. pressure, 400 psia (MEOP)

5. Design Ultimate Loads (static), (chlorine only) a. axial, 2,450lbs. (P x A x 2) b. torsion, 90 in-lbs. (7.5 ft-lbs) c. pressure, 1000 psia d. abuse, 500 lbs over 4 inch footprint

6. Impact damage degradation, 100 ft-lbs using a 1.0 inch diameter tip (must be able to operate under all loading condition after impact)

7. Leak detection sensitivity, 3 PPM max

8. Duty cycles up to MEOP, 2,000 cycles

9. Design per MIL-STD-1522A a. Includes: design burst pressure of 2.5 times MEOP b. Includes: proof test pressure of 1.5 times MEOP

10. 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

11. Ground rules: a. A stress analysis shall be conducted using A-basis equivalent allowables. b. A methodology using composite laminate theory shall be employed. Effects of wind

angle, number of layers, fiber thickness, resin content, and geometrical


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Table 2 - Technology Impact Analysis

Rank Technical Issues Description Analysis and Comment

1 Impact Damage Tolerance

Adequate tolerance to impact

Impact damage tolerance to be tested during phase II. Dual walled design should provide adequate strength after impact.

1 Chemical Sensing Adequate sensitivity

without false alarms

Chemical sensing to be tested during phase II. Phase I sensor is a chlorine tin reaction sensor that should not be susceptible to other outside stimulus (causing false alarms).

1 Weight

No increase in overall system weight (smart piping and support system)

Phase II will demonstrate overall system weight. Phase I showed the baseline tubing to be 32% heavier than the dual walled composite tubing. Current design approach uses lightweight materials in the piping and fittings.

2 Sealing Integrity

Sealing of joints and electrical conductor pass-through

Leaking testing to be conducted during phase II. In phase I, proven o-ring seals were used for joint sealing and bond surface was maximized for optimized sealing.

2 Strength Adequate strength

Phase I analysis of the bonded fitting joint showed a safety factor of 10 over ultimate design load (see Table 3) and analysis of the composite tubing showed a safety factor of 3.5 over design ultimate burst pressure. During phase II testing will be conducted to determine actual strength.

2 Curved Piping Fabrication of curved pipe

Curved piping will be demonstrated in phase II. Segmented, bladder, and wash-out mandrels will be explored.

3 Maintenance and Repair

Ease and cost of maintenance and repair

The smart pipe will require change-out of piping segments and piping disassembly for repair. It is anticipated that the smart seal ring will be a low cost throw away component (if non-functional).

3 Chemical Compatibility

Materials compatibility to COIL chemicals

Phase I design used highly corrosive resistant FEP liner and Kynar (PVDF) inserts. These have been used extensively in the chemical industry for chlorine handling.

3 Support System

Size and compatibility of the support system (sys power, controls).

Modulated RF or power line signal transmission will be demonstrated in phase II. Low power RF transmission concepts will be further considered to prevent interference with on-board systems.

4 Dual Walled Pipe Fabrication of dual walled pipe

Concepts have been developed for fabrication of the phase II curved pipe (see Figure 3).


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Table 3 - Technology Impact Analysis

Payoff and Benefits Phase I Demonstration

Personnel Safety

The reactive conductor sensor was shown to detect the presence of chlorine gas. The integration of this sensor into piping and a seal was also demonstrated. The smart piping and seal ring technology will be used to increase ABL personnel safety by detecting the leakage of hazardous chemicals prior to leaking to the outside environment (ABL cabin).

Weapon System Protection

The smart piping and smart seal ring technology will protect the ABL structure, electronic systems, and supporting devices by reducing the likelihood of corosive or explosive reactions with the laser chemicals.

Weight Savings

Phase I demonstrated that the dual walled composite tubing was approximately 32% lighter than the single walled Hasteloy baseline tubing (running weight). During phase II, additional concepts will be explored to achieve weight savings.

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Figure 2: Phase II Demonstration Component – Shown is the proposed phase II demonstration component that includes curved smart piping and smart flange fittings.

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Figure 3 Phase II Test Article Designs – Shown are proposed phase II test articles that will be used to explore and demonstrate various methods for fabricating curved smart piping.


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3 .3 – PROGRAM AND TECHNICAL I S S U E S

Currently there are no technical issues.

4.0 FUTURE PLANS

Phase I technical activity concluded during this reporting period. Future plans include completion and submittal of reports to satisfy contractual reporting obligations. In addition, Odyssian will brief appropriate Boeing ABL personnel on the accomplishments of phase I and the proposed plans for phase II.

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Appendix A - BONDED JOINT STRENGTH ANALYSIS

Geometry, inches Diameters

Outside Tube Inside Diameter (IDo) 1.25

Outside Tube Outside Diameter (ODo) 1.28

Inside Tube Inside Diameter (IDi) 0.75

Inside Tube Outside Diameter (ODi) 0.78 Male Fitting Contact Length

Outside Tube ID Surface (LMotid) 1.25

Inside Tube OD Surface (LMitod) 1.25 Female Fitting Contact Length

Outside Tube ID Surface (LFotid) 0.75

Outside Tube OD Surface (LFotod) 0.188

Inside Tube OD Surface (LFitod) 0.75 Circumferential Shear Areas, sq. inches

Male Fitting (Cm) 8.0

Female Fitting (Cf ) 5.5 Tensile Lap Shear Adhesive Strength, psi

Hysol EA 9394 at 77°F 4200 Hysol EA 9394 at 250°F 2300

Bonded Joint Strength, lbs. Male, 77°F 33465

Male, 250°F 18326 Female, 77°F 23252

Female, 250°F 12733

Operating Pressure (PMEOP), psia 400 Design Ultimate Pressure (PDU), psia 1000 Normal Conditions,

Operating Pressure Load (Fp(normal)), lbs. 177

Design Ult. Press. Load (Fp-DU(normal)), lbs. 442 Leak Condition (full pressure in outside pipe)

Operating Pressure Load (Fp(leak)), lbs. 491

Design Ult. Press. Load (Fp-DU(leak)), lbs. 1227 Safety Factor (based on largest design ultimate load of 1227 lbs)

Male Fitting at 77°F 27 Male Fitting at 250°F 15

Female Fitting at 77°F 19 Female Fitting at 250°F 10

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Appendix A continued….

Cm=(LMotid * 2 * m * IDo / 2) + (LMitod * 2 * m * ODi / 2)

Cf=(LFotid * 2 * m * IDo / 2) + (LFitod * 2 * m * ODi / 2) + (LFotod * 2 * m * ODo / 2)

Fp(normal)=(m * IDi2 / 4) * PMEOP

Fp-DU(normal)=(m * IDi2 / 4) * PDU

Fp(leak)=(m * IDo2 / 4) * PMEOP

Fp-DU(leak)=(m * IDo2 / 4) * PDU Shown above are the relationships used during the analysis of the bonded joint strength.

MONTHLY STATUS REPORT - Odyssian Technologyodyssian.com/MDA/MDA/files/Phase I/6th Status...

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