PHASE I SBIR FINAL TECHNICAL REPORT - DRAFT 04/04/04odyssian.com/MDA/MDA/files/Phase I/Final...

PHASE I CONTRACT NO.: F29601-03-M-0294

PHASE I SBIR

FINAL TECHNICAL REPORT - DRAFT 04/04/04

S E P T 5 T H , 2 0 0 3 - MARCH 5 T H , 2 0 0 4

Multifunctional Structures with Structurally Integrated Circuitry

For Use on the Airborne Laser (ABL)

Prepared by: Barton Bennett

Odyssian Technology, LLC 3740 Edison Lakes Parkway Mishawaka, Indiana 46545 (574) 257-7555 - Office (574) 850-4060 - Mobile

Report Date: 04 April, 2004

Submitted to: Capt. Russell Burks, AFRL/VSSV

Jim Guerrero, AFRL/VSSV Jan Mosher, AFRL/VSIR

DISTRIBUTION Distribution authorized to U.S. Government Agencies only, Proprietary Information, 04 April, 2004. 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

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REPORT DOCUMENTATION PAGE Form Approved

OMB No. 0704-0188 Public reporting burden for this col lection of information is estimated to average 1 hour per response, including the time for reviewing instructions, searching existing data sources, gathering and maintaining the data needed, and completing and reviewing this collection of information. Send comments regarding this burden estimate or any other aspect of this collection of information, including suggestions for reducing this burden to Department of Defense, Washington Headquarters Services, Directorate for Information Operations and Reports (0704-0188), 1215 Jefferson Davis Highway, Suite 1204, Arlington, VA 22202-4302. Respondents should be aware that notwithstanding any other provision of law, no person shall be subject to any penalty for failing to comply with a collection of information if it does not display a currently valid OMB control number. PLEASE DO NOT RETURN YOUR FORM TO THE ABOVE ADDRESS.

1. REPORT DATE (DD-MM-YYYY) 04-04-2004

2. REPORT TYPE Final Technical Report

3. DATES COVERED (From - To) 05-09-2003 to 05-03-2004

4. TITLE AND SUBTITLE

5a. CONTRACT NUMBER F29601-03-M-0294 5b. GRANT NUMBER Multifunctional Structures with Structurally Integrated Circuitry For Use on the Airborne

Laser (ABL)

5c. PROGRAM ELEMENT NUMBER 65502C

6. AUTHOR(S)

5d. PROJECT NUMBER 1601 5e. TASK NUMBER MV

Barton Bennett, President & Sr. Program Manager

5f. WORK UNIT NUMBER GB 7. PERFORMING ORGANIZATION NAME(S) AND ADDRESS(ES)

8. PERFORMING ORGANIZATION REPORT NUMBER

Odyssian Technology, LLC 3740 Edison Lakes Pwy, Suite 201 Mishawaka, Indiana 46545

The Boeing Company (subcontractor) 9-90.2 Building M/S 45-82 9725 East Marginal Way Seattle, WA 98108

9. SPONSORING / MONITORING AGENCY NAME(S) AND ADDRESS(ES) 10. SPONSOR/MONITOR’S ACRONYM(S) Sponsoring Agency: Monitoring Agency: Missile Defense Agency Air Force Research Lab (AFRL/VSSV) 3550 Aberdeen Avenue, SE 11. SPONSOR/MONITOR’S REPORT Kirtland AFB, NM 87117-5776 NUMBER(S) AFRL-VS-PS-TR-2004-1067 12. DISTRIBUTION / AVAILABILITY STATEMENT Distribution authorized to U.S. Government Agencies only, Proprietary Information, 04 April, 2004. Other requests for this document shall be referred to the Air Force Research Laboratory/VSSV, 3550 Aberdeen Avenue SE, Kirtland AFB NM 87117-5776. Data rights IAW DFAR 252.227-7018. Limited Data Rights for pages 16-20, 24-28, 31, 37. SBIR Data Rights for remaining pages. 13. SUPPLEMENTARY NOTES 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. Violators are subject to severe criminal penalties. 14. ABSTRACT

This phase I SBIR program developed a smart piping system for the Airborne Laser (ABL) with integrated leak detection sensors. Under separate leveraged funding (non-Federal), a smart seal ring was developed that is useable with the phase I smart piping system and which provides integrated leak detection capability. Both the ABL smart piping system and smart seal ring provide redundancy that allows the detection of leak progression prior to leakage to the outside environment. Lightweight material are used to reduce the weight of the piping system. A baseline comparison shows the smart pipe (with redundant containment structure) to be approximately 32% lighter over Hasteloy metallic pipe.

15. SUBJECT TERMS Composites, smart structure, multifunctional structure, smart pipe, smart seal

16. SECURITY CLASSIFICATION OF: Not classified

17. LIMITATION OF ABSTRACT

18. NUMBER OF PAGES

19a. NAME OF RESPONSIBLE PERSON Capt. Russell Burks

a. REPORT Unclas

b. ABSTRACT Unclas

c. THIS PAGE Unclas

SAR

41

19b. TELEPHONE NUMBER (include area code) 505-853-1502 Standard Form 298 (Rev. 8-98)

Prescribed by ANSI Std. 239.18

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DATA RIGHTS

LIMITED RIGHTS

The Smart Seal Ring Technology reported herein is subject to Limited Data Rights IAW DFAR 252.227-7018.

Contract No. F29601-03-M-0294

Contractor Name Odyssian Technology

Contractor Address 3740 Edison Lakes Parkway Mishawaka, Indiana 46545

Pages subject to Limited Data Rights: pages 16-20, 24-28, 31, 37 The Government's rights to use, modify, reproduce, release, perform, display, or disclose these technical data are restricted by paragraph (b)(2) of the Rights in Noncommercial Technical Data and Computer Software--Small Business Innovative Research (SBIR) Program clause contained in the above identified contract. Any reproduction of technical data or portions thereof marked with this legend must also reproduce the markings. Any person, other than the Government, who has been provided access to such data must promptly notify the above named Contractor.

The balance of the technology reported herein (other than the Smart Seal Technology) is subject to the SBIR Data Rights IAW DFAR 252.227-7018.

SBIR DATA RIGHTS Contract No. F29601-03-M-0294

Contractor Name Odyssian Technology

Contractor Address

3740 Edison Lakes Parkway

Mishawaka, Indiana 46545

Expiration of SBIR Data Rights Period 04 April, 2009

The Government's rights to use, modify, reproduce, release, perform, display, or disclose technical data or computer software marked with this legend are restricted during the period shown as provided in paragraph (b)(4) of the Rights in Noncommercial Technical Data and Computer Software--Small Business Innovative Research (SBIR) Program clause contained in the above identified contract. No restrictions apply after the expiration date shown above. Any reproduction of technical data, computer software, or portions thereof marked with this legend must also reproduce the markings.

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TABLE OF CONTENTS

1.0 PROGRAM INTRODUCTION .........................................................................................................................1

2.0 PROGRAM OBJECTIVES..................................................................................................................................2

3.0 PROGRAM ACCOMPLISHMENTS AND RESULTS ..................................................................................2

3.1 SCHEDULE AND BUDGET PERFORMANCE ........................................................................................2

3.2 TECHNICAL ACCOMPLISHMENTS........................................................................................................4

PROBLEM AND OPPORTUNITY DEFINITION .............................................................4

PHASE I CONCEPTUAL DESIGN STUDY .................................................................. 10

PHASE I DEMONSTRATION................................................................................... 21

PHASE II PROOF OF CONCEPT DESIGN .................................................................. 37

4.0 FEASIBILITY AND ABL BENEFIT ..............................................................................................................41

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LIST OF FIGURES

Figure 1: Updated Program Schedule…………………………………………………………… 3

Figure 2: Smart Pipe - Dual Walled with Foam Filled Core…………………………….……… 13

Figure 3: Smart Pipe - Dual Walled with Reinforcement Ring………………………………… 14

Figure 4: Smart Pipe – Dual Walled with Hollow Core and Sensor Coils…………….............. 14

Figure 5: Smart Pipe – Dual Walled with Leak Detection Bladder…………………………….. 15

Figure 6: Smart Pipe – Single Walled with Embedded Sensor Film……………………………. 15

Figure 7: Smart Seal Ring – Channel Design Concept…………………………………………. 17

Figure 8: Smart Seal Ring – Surface Deposition Concept………………………………………. 18

Figure 9: Smart Seal Ring – Tapered Compression Seal…………………………………………19

Figure 10: Smart Seal Ring – Autonomous Sandwich Concept ………………………............... 20

Figure 11: Smart Pipe: Solid Model Design of Phase I Demonstration Component……………. 22

Figure 12: Smart Pipe: Cross-sectional Views of Fitting and Electrical Leads…………………. 23

Figure 13: Smart Seal Ring – Solid Model Design of Phase I Demo Component………………. 24

Figure 14: Photograph of Phase I Smart Pipe and Seal Prior to Sensor Integration…………….. 25

Figure 15: Photograph of Phase I Smart Pipe and Seal Components…………………………… 26

Figure 16: Photograph of Phase I Smart Pipe and Seal after Sensor Integration……………….. 27

Figure 17: Photograph of Smart Seal………………………………………………………….…. 28

Figure 18: Photograph of Initial Phase I Test Set-up…………………………………………..… 29

Figure 19: Design and photograph of Sensor Circuit……………………………………….….... 30

Figure 20: Photograph of Smart Pipe with Sensor Circuitry………………………………...…... 31

Figure 21: Photograph of Preliminary Detection Test Set-up……………………………….…… 32

Figure 22: Solid Model Design of Phase II Demo Component………………………………....... 38

Figure 23: Solid Model Design of Phase II Test Articles…………………………………………. 39

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LIST OF TABLES

Table 1: Effects of Chlorine Gas on Unprotected Persons…………………………..……….… 5

Table 2: Effects of Chlorine Gas on Unprotected Materials.…………………………………… 7

Table 3: Materials and Methods Commonly Used in Chemical Industry for Chlorine………… 8

Table 4: Preliminary Application Requirements from Boeing………………….……………... 9

Table 5: Summary of Phase I Sensor Research…………………………..…………………….. 11

Table 6: Preliminary Test Data of Chlorine Detection Sensor……………………….………… 34

Table 7: Comparison of Weight of Baseline Tubing (Hasteloy) to Composite Tubing………... 36

Table 8: Preliminary Phase II Requirements from Boeing……………………………..……… 40

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1.0 PROGRAM INTRODUCTION

This phase I SBIR program developed multifunctional structure (MFS) technology for use on the Airborne Laser (ABL). Boeing, the ABL Prime Contractor, was 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, had overall program responsibility and developed conceptual designs using 3D solid modeling, fabricated and evaluated a proof-of-concept demonstration article, and 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. The ABL high energy laser is a chemical laser which efficiently converts energy from chemical bonds and reactions to laser photons. These laser devices are typically used for applications that require high-power, lightweight, and self-contained sources of laser radiation. Public literature shows that there are currently two classes of chemical lasers, which are known as hydrogen fluoride (HF) lasers and chemical oxygen-iodine lasers (COIL). COIL and HF technologies have been developed to the point where multi-kilowatt devices can be routinely constructed. The high energy laser system being deployed on the ABL is a COIL laser. Although very efficient, the COIL lasers generally require the use of highly toxic and explosive chemicals including basic hydrogen peroxide (BHP) and chlorine.

In phase I, Odyssian Technology developed a lightweight smart piping system for containment and monitoring of the chlorine gas used in the COIL laser. This ABL smart piping system has a lightweight dual walled design with integrated sensors that provides redundancy in containment structure to allow for the detection of a chemical leak prior to leakage to the outside environment. This is accomplished using lightweight composite and polymer materials to reduce the weight of the Smart ABL Piping System over the metallic Hasteloy baseline. Carbon fiber reinforced polymer composite materials are used to reduce weight and improve specific strength over conventional gas piping materials. Lightweight thermoplastic material (Kynar) which is compatible with a variety of corrosive gases is used in conjunction with anodized Aluminum to achieve low density fittings. The multifunctional design uses lightweight and advanced materials in conjunction with integrated sensors and circuitry to achieve an advanced lightweight piping system that detects leak progression of toxic and corrosive chemicals prior to leakage to the outside environment (ABL cabin).

Under Odyssian cost share a Smart Seal Ring was developed that like the ABL smart pipe detects a leak prior to leakage to the outside environment. This technology is patent pending and provides uniqueness by offering redundant sealing capability with sensors integrated between each seal to allow for the detection of leak progression.

Benefits anticipated by Boeing and validated in phase I include weight savings and leak progression detection of corrosive and toxic gas that ultimately results in improved personnel safety, reduced operational maintenance cost, and improved mission performance (improved mission duration and range from weight savings). During phase II, SBIR funding and Odyssian Technology cost share funding will be used to further develop and test the MDA Smart Piping System and smart seal ring. Sensor technology will be explored for detection of other corrosive and toxic chemicals that are used in the ABL high energy laser.

The official start date of this program was September 5, 2003 with completion of technical tasks occurring six (6) months after start date on March 5, 2004).

2.0 PROGRAM OBJECTIVES

This Phase I SBIR program was designed to demonstrate the feasibility of using multifunctional structure with integrated electrical circuitry for use of the ABL.

As part of this initial task, Boeing ABL engineers made an assessment to identify potential high pay-off applications for the use of multifunctional structure technology on the ABL. The piping system of the ABL high energy laser was selected and the objective was established to develop and demonstrate a smart piping system for use with the laser’s chlorine gas. In addition, Odyssian Technology established the objective of developing and demonstrating under cost share funding a smart seal ring that could be used with the smart piping system. The seal, like the smart pipe, was to provide containment and leak progression detection capability for chlorine gas.

3.0 PROGRAM ACCOMPLISHMENTS AND RESULTS

The program performance and technical accomplishments of phase I are discussed and summarized in this section of the final report. The original phase I work plan called for the design and fabrication of a simple flat laminate structure with integrated electrical circuitry. After selection of the COIL piping system for demonstrating MFS technology, it was apparent that the scope of technical activity would have to surpass the phase I proposal to provide a good demonstration to the ABL program. This was accomplished through Odyssian Technology cost share and voluntary uncompensated overtime of select Odyssian personnel.

3.1 – SCHEDULE AND BUDGET PERFORMANCE

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.

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

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.

Task I (Application Definition) and Task IV (Technology Impact Analysis) were the

primary tasks requiring Boeing input. Task I was extended due to a delay in getting Boeing under contract. This delay was due to Boeing’s requirement of having Odyssian registered with the U.S. State Department for export control prior to starting contracting activity. Task IV was delayed until the results of Task III (Proof-of-Concept Demo) were known. Task III (Proof-of-Concept Demo) was started earlier than originally scheduled to provide results in time for the phase II proposal.

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

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

TASK

Task – Application

Task

– Conceptual Design

Task

– Proof-of-Concept Demo

Task IV – Impact

Task V – Program Mgt. &

Kick-off & Tech. Coordination Teleconference

Sept Oct Nov Dec Jan Feb

Tech Coord. Meeting

3.2 – TECHNICAL ACCOMPLISHMENTS

The Boeing ABL program identified four applications for multifunctional structure technology for possible development under this SBIR. These included;

1. Lightweight smart piping system with integrated leak detection capability for use on the high energy laser system.

2. Lightweight smart belly skin with integrated thermal and structural monitoring.

3. Smart laser containment structure with integrated monitoring.

4. Integration of vibration control circuitry and electrical interconnects into laser support structure.

The first application listed above, the smart piping system, was selected for further consideration and development because of its relative high payoff potential. It was rationalized that a smart piping system for the ABL high energy laser would reduce operational maintenance and support costs by reducing the possibility of chemical corrosion of the ABL aircraft structure, would reduce personnel safety hazard by reducing the likelihood of exposure to toxic chemicals, and would improve mission performance by improving the control and reliability of the laser’s chemical containment system.

The scope of phase I was limited to the development of a smart piping system with containment structure and leak progression detection for Chlorine gas. This chemical piping system was selected due to its potentially harmful effects to the ABL structure, systems, and personnel.

Problem and Opportunity Definition

Health Hazard of Laser Chemicals

During phase I, research was conducted to understand the effects of chlorine exposure on ABL personnel. Table 1 summarizes of the effects of chlorine gas on humans. As shown, small traces of chlorine gas in concentrations over 0.004% can be dangerous to human health when exposure occurs for 30 minutes to an hour. Exposure to concentrations over 0.1% will result in death after a few breaths.

Effects of Chlorine Gas on Unprotected Persons

Concentration of Chlorine Gas Effect / Symptoms

1 ppm Nose, throat, conjunctiva irritation after several hours of exposure

1.3 ppm Coughing, labored breathing

3.5 ppm Noticeable odor

4.0 ppm Highest concentration for 1 hour without serious damage

40 – 60 ppm Dangerous if exposed 30 minutes to 1 hour

1000 ppm Death after a few breaths

Table 1: This table shows that chlorine gas is a serious health hazard to unprotected persons. Chlorine is highly toxic and poses serious human hazards. Human exposure to chlorine gas at concentrations as low as 40-60 ppm (0.004% to 0.006%) is very dangerous. Exposure at concentrations of 1000 ppm (0.1%) will cause death after a few breaths.

Other corrosive and potentially hazardous chemicals used in the ABL high energy laser include ammonia, hydrogen peroxide, base hydrogen peroxide, and iodine. Although phase I was limited in scope to consideration of chlorine, limited research on ammonia gas found that ammonia is corrosive, a health hazard, and may be explosion under the right conditions. Ammonia is generally not considered a serious fire or explosion hazard because ammonia-air mixtures are difficult to ignite and a relatively high concentration of the gas is required. However, a large and intense energy source such as lightning strike may cause ignition and/or an explosion. The flammable/explosion concentration range has been reported in various sources to be 15 to 28%. In addition, an ammonia gas leak could be a health hazard to exposed ABL crew members. Contact with the skin causes burns and blistering. Ammonia gas causes irritation of the eyes and respiratory tract. Higher concentrations cause conjunctivitis, laryngitis, and pulmonary edema. Pulmonary edema is the most frequent cause of death in humans exposed to ammonia gas. Chlorine Reaction with ABL Structure and Various Materials

Research was conducted on the reaction of chlorine gas with various materials believed to be present on the ABL, as well as, for materials being considered for use in the smart piping system. Table 2 provides a summary of the effects of chlorine gas exposure on unprotected materials. As shown, unprotected aluminum and titanium react when exposed to chlorine gas. Aluminum undergoes greater attack when exposed to moisture ridden (wet) chlorine gas and Titanium undergoes greater attack when exposed to dry chlorine gas. When exposed to sufficiently wet chlorine gas, Titanium is perfectly passive. When exposed to chlorine gas under dry conditions, Titanium undergoes a spontaneous explosive reaction. The corrosion and

spontaneous combustion of Aluminum and Titanium, respectively, is significant because of their pervasive use in primary aircraft structure. Table 2 also shows that chlorine may have an accumulated effect on the corrosion of exposed ABL electronics including copper, tin, or gold conductive tracings and associated tin alloy solder. These risks to weapon system performance in conjunction with the serious health hazards, makes the need for reliable chemical containment and leak progression detection of paramount importance.

Table 2 was also used to assess sensor concepts and the material considerations for the smart piping system. Original smart pipe and smart seal ring concepts and designs, developed under separate cost share funding, relied on the detection of chlorine gas using sensing elements that react to chlorine gas causing a corresponding change in electrical readings. This can be achieved by using electrically conducting metals that corrode in the presence of chlorine gas or particulate polymer composites that expand in the presence of chlorine gas. Table 2 identifies metals that could be effective as chlorine sensing elements under various conditions. This data also identifies materials that are inert to chlorine gas, therefore allowing their use for containment structure or sealing material.

Some of the original concepts for the smart seal ring and smart pipe sensor circuitry included conductive and sensor tracings that would be fabricated using chemical etch or electroplating processes common to conventional circuit board manufacture. The metals listed in Table 2 that have asterisks next to their name are those metals used for conductive tracings in conventional circuit boards. Early smart seal ring design concepts included the use of rigid multilayer PCB substrates with embedded circuit tracings to support multiple sensor rings.

Effects of Chlorine Gas on Unprotected Materials

Material Effect / Symptoms

Aluminum More readily attacked by wet than by dry chlorine at room temperature. At temperatures above 265°F (130°C) moisture greatly reduces corrosion.

Titanium

With sufficient water, is perfectly passive up to 345°F (175°C). The amount of moisture required to maintain passivity depends on chlorine pressure, temperature, flow rate, purity, and degree of surface abrasion of the titanium. In dry conditions, a spontaneous explosive exothermic reaction occurs.

Carbon Steel Moisture greatly accelerates corrosion and is known to ignite near 483°F (251°C). Ignition occurs at lower temperatures with higher alloy content.

Stainless Steel Moisture has a significant effect on corrosion of type 304 and type 316. Tests conducted in chlorine containing 0.4% water showed rates of approximately 30.5 mm/yr at 105°F (40°C).

Nickel Alloys Are adversely effected by the presence of moisture in chlorine up to their maximum use temperature and can increase the reaction rate from 2 to 20 times.

Copper Alloys Water vapor at room temperature was shown to accelerate the attack on copper and copper alloys.

Magnesium The presence of a small amount of water results in a pronounced attack by chlorine at room temperature

Lead Has been found to be resistant to corrosion in dry flowing chlorine at temperatures up to 525°F (275°C).

Tin* Tin is readily attacked by chlorine at room temperature.

Gold* Reacts with chlorine. If needed, will be further characterized in phase II.

Silver* Silver is resistant to both dry and moist chlorine.

Teflon Stable and resistant to chlorine gas.

Kynar Stable and resistant to chlorine gas.

Epoxy Negligible to no reaction with fluorinated polymers.

Carbon fiber No known reaction. To be research further in phase II.

Glass fiber Wet chlorine is handled under pressure using fiberglass reinforced plastics.

Table 2: Shown are the effects of chlorine gas on unprotected materials. Typical high performance aircraft use both Aluminum and Titanium extensively for primary structure, support racks, brackets enclosures, and sometimes for fasteners, clips, and hinge or pivot hardware. As shown, moist chlorine aggressively corrodes Aluminum at room temperature and dry chlorine explosively reacts with Titanium. Also, it is shown that chlorine could have a corrosive effect on exposed electronic circuitry.

Chemical Industry Chlorine Handling Practices

Research was conducted to identify materials commonly used by the chemical industry in containing and handling chlorine gas. Odyssian Technology also hired a contract employee with experience in handling and transferring chlorine gas at a large chemical corporation. This research and experience identified the materials listed in Table 3 as the materials commonly used for industrial handling and transfer of chlorine gas.

Use Material

Pipe Schedule 80 carbon steel pipe, stainless steel pipe, copper transfer tubing, Kynar transfer tubing and pipe liner, Monel flex transfer hose.

Fittings Brass, nickel plated brass

Seals Lead washers

Pipe Liner (corrosion) Kynar (PVDF), Halar (ECTFE), FEP

Gas leak sensors Relatively large industrial gas sensors. Variety of proprietary sensors. Limited supplier information shows some to be electrochemical

Table 3: Materials and methods that are commonly used by the chemical industry to handle, transfer, and sense chlorine gas. This information was useful in determining proven chemical resistant polymers that were used as liners and to fabricate lightweight fittings for the smart piping system.

This research and information was useful in identifying proven materials, methods, and hazards associated with the handling of chlorine gas. Industrial gas facilities commonly use schedule 80 carbon steel piping, Kynar plastic piping, copper tubing, and Monel flex hose for the bulk transfer of chlorine gas. Lead compression seal rings as well as brass compression fittings are used to achieve leak free connections. Kynar is most commonly used not only as a lightweight transfer pipe, but is also commonly used to line steel pipe for added corrosion protection. Kynar is a thermoplastic that is highly resistant to a variety of corrosive gases.

Research into industrial sensing devices showed the use of relatively large units that are offered by a multitude of suppliers. Due to the proprietary nature of these systems, determining the exact active mechanism behind their operation was difficult to achieve. Limited vendor input indicated that electrochemical sensors are a common means for detection in industrial sensors.

Application Requirements

Odyssian Technology compiled a preliminary list of application requirements and targets near the beginning of the program (see Table 4), which were later reviewed by Boeing. Boeing input provided temperature and pressure requirements for other COIL chemicals, provided a higher chlorine pressure requirement (from 800 psia to 1000 psia), and defined the chlorine phase composition to include both gas and liquid. The increased pressure requirement from 800 psia to 1000 psia had little impact on the previously designed phase I proof-of-concept component, due to the fact that the inner composite smart pipe is sized to handle 3500 psia and outer composite smart pipe is sized to handle 6000 psia.

Table 4: Preliminary Application Requirements and Targets. During phase II, the application requirements and targets will be expanded upon and used to drive the smart pipe designs and test plans.

REQUIREMENTS Revised 12-19-03

Functionality and Utility

Phase I: 1. Containment of chlorine gas and liquid (dry) 2. Leak progression detection of chlorine gas and liquid (dry & wet). Detection prior to leakage

outside containment structure.

Phase II: 1. Containment of Chlorine, Ammonia, Base Hydrogen Peroxide, and Iodine gases (dry) 2. Leak progression detection of Chlorine, Ammonia, Base Hydrogen Peroxide, and Iodine gases (dry &

wet). Detection prior to leakage outside containment structure.

Basic Generic Requirements (for Phase I Feasibility Demonstration)

1. Geometry, a. inside tube diameter, 0.75 inches b. fitting, ¾ dia.”, coarse, compression (size, thread, type)

2. Operating Temperature, 40F to 80F

3. Operating Force Loads, a. axial, 20 lbs. b. torsion, 60 in-lbs. (5 ft-lbs) c. pressure, 400 psia

4. Design Ultimate Loads (static), a. axial, 30 lbs. b. torsion, 90 in-lbs. (7.5 ft-lbs) c. pressure, 1000 psia

5. Leak detection sensitivity, 3 PPM max

6. Design per MIL-STD-1522A

7. 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

Improvement Targets (for Phase I Feasibility Demonstration) 1. Multifunctional leak detection design with integrated sensors and wireless communication

a. Chlorine gas leak detection b. Wireless communication (demonstrated in phase II)

2. 5% to 15% weight reduction over conventional plumbing system (when considering the weight of separate bulk leak detection systems)

3. 5% - 10% increase in system acquisition cost with 30% - 40% reduction in associated life cycle costs.

Phase I Conceptual Design Study

During phase I, a conceptual design study was conducted during which multiple concept designs were created and considered. 3D solid models were created for different design concepts for the smart pipe and smart seal ring. Common elements of the designs include leak detection sensors embedded between redundant containment structure and redundant seals. The redundant containment and sealing is provided to allow the sensing of leak progression prior to leakage to the outside environment.

Early Conceptualization and Research

It became apparent early in the program that there is very little space available within the smart pipe and smart seal ring for placement of the sensors. This led to the initial conceptualization of using small electrically conductive films or elements to detect the presence of chlorine. It was postulated that chlorine would cause corrosion of certain electrically conductive sensors causing a corresponding change in electrical readings. This change in readings would be used to sense the presence of chlorine. This concept for sensing was reinforced by the research summarized in Table 2. As shown, several metallic conductive materials including Aluminum, Titanium, Tin, Gold, and Copper undergo corrosion in the presence of chlorine gas. Originally, it was conceptualized that this corrosion event would occur over time at a rate adequate enough to provide chlorine detection within a reasonable period of time. As shown in Table 2, the reaction rate of the various metallic conductors with chlorine gas is highly dependant upon temperature and moisture content. In addition, it was leaned through discussions with Professors at Purdue University and the University of Notre Dame that naturally occurring oxidation coatings can significantly inhibit initial reaction rates.

Research was conducted on the type of sensors available for possible use in the smart piping and smart seal ring. Table 5 provides a summary of the type of sensors researched during phase I. Due to the time and financial constraints of phase I and the vastness of sensor technology, this research was conducted to provide a high level understanding of various sensor technologies available. As shown in page 1 of 2 of Table 5, the original sensor concept described above is often referred to as a Reactive Conductor Sensor. Other sensors listed in Table 5 that were incorporated into phase I conceptual designs include thick film and conductive sensors. The thick film concept included the use of porous conductive polymers filled with reactive conductive particulates that would corrode in the presence of chlorine to cause a change in electrical readings. Other thick film sensor technology involves the use of conductive polymers whose polymer matrix reacts in the presences of a gas causing an expansion or contraction of the matrix and a corresponding change in electrical readings. The conductive sensor technology used included the use of a conductive elastomer bladder that would expand in the presence of a leak causing a change in electrical reading. Other sensor technologies with great potential for the smart pipe and seal application include capacitive, inductive and fiber optic sensors. These technologies will be further explored during phase II.

Sensor Technology Description Advantages Disadvantages

Reactive Conductor sensor

Sensor reacts or corrodes in the presence of chemical, activating or breaking electronic circuit.

Small, Simple, low cost One time use

Cermet sensor Ceramic metallic gas sensor Small, Rugged, Multi-gas Readiness level, Availability

Nose sensor An electronic nose is chemical sensing and a pattern recognition system.

Sensitive to multi levels and types of gas uses neural net

Expensive, Complex, Readiness Level

Ion Mobility sensor

Ionized gas, timing velocity to detector Moderate cost

Surface Acoustic Wave sensor

Detects change in acoustic wave velocity and frequency across chemical selective material.

Low Cost

Ultrasound sensor

Uses ultrasonic to measure particle concentration, size and type in channel

Low cost

Microwave Cavity sensor

Compares data of enclosed and exposed cavities with microwaves

High sensitivity

Piezoelectric quartz crystal microbalance sensors

Change in mass of deposited chemical changes frequency of oscillator

Vapor and liquid detection

Photonic gas sensor

IR Gas absorption spectral variation High accuracy and fast response time, reliable.

Expensive, Complex

Photo-acoustic gas sensor

Pressure variation in cavity, by selective absorption of IR

Table 5(page 1 of 2): Shown is a summary of various types of sensors that were researched during phase I. As shown, there are multiple sensor technologies that will be further considered and researched during phase II. The first sensor listed (reactive conductor sensor) was developed and demonstrated in phase I due to its simplicity, small size, and low cost.

Sensor Technology Description Advantages Disadvantages

Thick film sensors

Sensors based on low cost thick film technology Robust, compact inexpensive

Ceramic sensors Ceramic, change in electrical conductivity High Temp, Pressure and corrosive environments

Optical sensor IR gas spectral tuning Photonic band gap Gas Specific sensing, reliable

Acoustic sensor Gas sound measurement Robust, corrosive environment

Conductive sensor

Variation in potential or resistance Low cost, simple

Cantilever beam sensor

Cantilever beam polymer reacts with gas and bends Sensitive, small, self powered

Ultrasonic sensor

Measures ultrasonic vibration variation Robust

Capacitive sensor

Measures change in capacitance Clean, remote

Inductive sensor Measures change in inductance Rugged

Photo-electric sensor

Light beam interruption non specific gas

Fiber-Optic Optical properties change when polymer coating reacts low cost, small, simple

Table 5(page 2 of 2): Shown is page 2 of the summary of the sensors researched during phase I. These sensor technologies that will be further considered and researched during phase II. Sensor technology listed here on the second page that are of particular interest include thick film sensors, conductive sensors, capacitive sensors, inductive sensors, and fiber optic sensors.

Multifunctional (Smart) Pipe Concept Designs

The following is a list of the smart pipe concepts that were explored during phase I. Most of these smart pipe concepts have redundant containment structure in the form of dual walls. The final concept listed (number 5) is single walled with integrated sensors. In this concept the single wall is oversized to provide adequate strength beyond the points or depth of sensing.

Smart Pipe Concepts,

1. Dual walled pipe having foam filled inter-core with electrically conductive reaction sensors that detect the presence of specific corrosive chemicals.

2. Dual walled pipe having ring reinforced inter-core with electrically conductive reaction sensors that detect the presence of specific corrosive chemicals.

3. Dual walled pipe having a hollow inter-core with electrically conductive reaction sensors coiled around the inner pipe that detect the presence of specific corrosive chemicals.

4. Dual walled pipe having a hollow or ring reinforced inter-core with conductive particulate filled bladder wrapped over the inner tube. Leaks are detected when the leaking chemical causes the bladder to expand which results in a corresponding change in electrical readings. This concept is not specific to a particular gas.

5. Single walled pipe with embedded thick film sensors that detects the presence of a leak. This concept includes multiple approaches to the sensor film.

3D solid model designs of these concepts were developed and are illustrated in Figures 2 through 6. All of these concepts provide chlorine leak progression detection using sensors that react or change in the event of a leak causing a corresponding change in electrical readings.

Concepts 1 through 5 listed above involve the use of dual walled or redundant containment structure. If chlorine gas begins to leak from the inner pipe, it enters the cavity area between the walls of inner and outer pipes (core area). The outer pipe acts to prevent dilution of the corrosive gas to achieve optimum sensor

response and to provide an additional barrier from further leakage. With the exception of the bladder concept (listed as concept 4 above and illustrated in Figure 5), the exposure of the

Figure 2: Dual walled pipe having foam filled inter-core with integrated electrically conductive reaction sensors that detect the presence of specific corrosive chemicals. This concept offers the added benefit of foam filling the space between the inner and outer pipes to improve impact tolerance.

Foam Core

sensor to chlorine causes a corrosion reaction to occur resulting in a reduction in the sensor element’s cross-sectional area and an increase in electrical resistance. This change in electrical

response would cause the transmission of a uniquely modulated signal that identifies the leaking pipe segment within the smart piping system. This concept assumes the use of metallic sensing elements that aggressively react with chlorine to cause an increase in electrical resistance.

Figure 2 shows a smart pipe concept that includes foam core in the core region. The metallic conductors and sensors are places in hat shaped cavities within the foam. The advantage of the foam core is the potential for improve impact tolerance. Figure 3 shows the same smart pipe configuration except that support rings are used in place of the foam core. This offers the advantage of eliminating the use of foam cores that are specific to pipe lengths and curves. The support rings will be universal to a multitude of pipe lengths. The electric conductors and sensors can be attached to the inner tube, outer tube or the support rings. The attachment to the support rings would allow for the conductors to be loosely suspended isolating the conductors/sensors from thermally or mechanically induces strain.

Figure 4 shows a smart pipe concept in which two sensing conductors are wrapped around the outside of the inner tube. One of the sensing conductors contains a metallic element (Titanium) that

Figure 3: Dual walled pipe having ring reinforced inter-core with electrically conductive reaction sensors that detect the presence of specific corrosive chemicals. Unlike the foam core, the support rings in this concept are common across multiple pipe lengths, resulting in potential reduction in manufacturing cost.

Support ring

Figure 4: Dual walled pipe having a hollow inter-core with electrically conductive reaction sensors coiled around the inner pipe that detect the presence of specific corrosive chemicals. This concept has the advantage of being less susceptible to circuit failure caused by exceeding strain limits because the compliantly coiled conductors are not aligned with the path of longitudinal strain and have opposing torsion strain directions.

Compliant Coils

corrodes rapidly when exposed to dry chlorine gas and the other sensing conductor contains a metallic element (Aluminum) that corrodes rapidly when exposed to wet chlorine gas. This

approach provides sensing conductors that collectively would work in both wet and dry chlorine gas. This concept has the advantage of being less susceptible to circuit failure caused by exceeding strain limits because the compliantly coiled conductors are not aligned with the path of longitudinal strain and have opposing torsion strain directions.

The advantage of the reactive conductor sensors is that the sensing is specific to chlorine gas, thus greatly reducing the potential for interference. The disadvantage is that it is specific to chlorine gas and can not be used as a universal sensor for detecting leaks. A concept was developed for providing universal leak detection within the smart pipe. This concept, illustrated in Figure 5, uses an electrically conductive bladder which is placed over the outside of the inner composite tube. In the event of a leak, the bladder expands which causes the distance between conducting particulates to increase resulting a corresponding increase in electrical resistance across the bladder. The electrical bladder is created by filling or coating an elastomer material with conductive particles.

Figure 6 provides a cross sectional view of a single walled pipe with embedded leak detection sensors. In this concept the core space is reduced and is occupied by only the sensor film. The sensor film

is a reactive polymer electrical conductor whose resistance increases when exposed to chlorine.

Figure 5: Dual walled pipe having a hollow or ring reinforced inter-core with conductive particulate filled bladder wrapped over the inner tube. Leaks are detected when the leaking chemical causes the bladder to expand which results in a corresponding change in electrical readings. This concept has the advantage of being useful for sensing the leak of any gas or fluid (not specific to a particular chemical).

Electrically conductive elastomer bladder

Figure 6: Cross section of a single walled pipe with embedded sensor film that detects the presence of a leak. This concept offers the advantage of smaller outer diameter pipe and potentially lower cost manufacturing.

Sensor film and dispersion media

This increase in resistance occurs when the electrical polymer conductor undergoes a corrosive reaction with chlorine.

Multifunctional (Smart) Seal Ring Concept Designs

Under separate funding, design concepts were developed for multifunctional (smart) seal rings with seal and leak progression detection capability. Figures 7 through 10 show multiple smart seal ring concepts having integrated sensors capable of detecting chemical leak progression. The smart seals include multiple concentric sensing rings that corrode in the presence of the corrosive chemical causing a change its electrical response. If chemical breaks the first seal and travels to the first and inner concentric sensor ring, corrosion occurs causing an increase in electrical resistance and which then triggers the transmission of a unique modulated signal indicating the beginning of a leak at the specified fitting. The multiple concentric sensor rings allow for the identification of chemical leak propagation which senses the breakdown of a seal and the potential for a leak before the leak occurs. The use of microprocessors to transmit RF signals will be demonstrated in phase II.

Figure 7 shows a conceptual design for a smart seal ring in which the surface of the ring is malleable enough to seal the fitting (such as lead or a relatively soft polymer). The three sensor rings shown are recessed in channels. In the event that a leak begins to propagate through the first seal surface, the corrosive chemical reacts with the ring sensor causing a shift in electrical readings. The sensor causes the control circuitry to initiate the transmission of a signal to the COIL operator that shows the seal is beginning to break down and leak progression has occurred. A cross sectional view of this seal ring concept is shown in Figures 4 and 5. These figures more clearly show the recessed channels that hold the sensor rings. As shown, the flat surface of the ring provides sealing much like a conventional lead or nylon washer seal.

Figure 7: Exploded view of a Smart Seal Ring with integrated leak detection sensors. This concept includes sensor rings or electrically conductive rings with reactive conductor elements. As with the smart pipe, the sensor ring reactive conductor corrodes when exposed to chlorine causing a change in resistance. In this concept there are three sensor rings in channels that detect leak progression. The flat surface of the ring provides sealing much like a conventional lead washer seal. The center layer of the exploded view shows the embedded circuit tracings. The back layer of the exploded view is similar to the front layer, but without the IC.

A similar concept is shown in Figure 8. The difference is that the sensor rings and the seals are on the surface of the seal ring. This type of smart seal ring could be fabricated using low cost printed circuit board fabrication techniques. Reactive conductor tracings (sensor ring) would be chem. etched or electroplated as currently done with printed circuit boards (PCB). The seal ring could be a soft metallic tracing such as silver that is resistant to chlorine and has adequate hardness to provide a good seal. A cross sectional view of this seal ring concept is shown in Figures 2 and 3. These figures more clearly show the raised sensor and seal rings.

Channel Sensor Rings

Embedded Circuit Tracings

Integrated Chip Set

Channel Sensor Rings (not shown)

SMART SEAL RING – CHANNEL CONCEPT

In addition, concepts were formulated for development of tapered compression fittings with

integrated leak detection sensors. Figure 9 shows a conceptual design of a smart compression fitting. The three sensor rings are recessed into channels and the seal is provided by the tapered surface. In this concept space for circuitry and electronic components would be even more limited. Consideration has been given to locating sealed surface mounted components inside the inner tube or core area of the smart pipe.

Figure 8: Exploded view of a Smart Seal Ring with integrated leak detection sensors. In this concept there are three sensor rings on the surface (instead of in channels) that detect leak progression. The adjacent rings are seal rings and are on the surface of the ring. The sensor rings are similar to the conductive tracings on a printed circuit board and are either deposited or chem. etched. The adjacent seal rings are made of either a soft metal or elastomer. As with the smart pipe and the previous smart seal ring concept, the sensor rings have a reactive conductor that corrodes when exposed to chlorine causing a change in resistance. The seal is provided by the soft metal or elastomer seal rings. The center layer of the exploded view shows the embedded circuit tracings. The back layer of the exploded view is similar to the front layer, but without the IC.

Surface Deposited Sensor Rings (red)

Embedded Circuit Tracings Integrated Chip Set Surface Deposited Rings (not shown)

SMART SEAL RING – SURFACE DEPOSITION CONCEPT

Surface Deposited Seal Rings (beige)

Under separate match funding, design concepts were developed for a sandwich smart seal ring with integrated power circuitry and power source. Previous conceptual designs and the phase I demo design rely on external power and control circuitry. Odyssian Technology has interest in developing an autonomous multifunctional smart seal ring that can detect leaks of various substances. It is believed that such a smart seal ring (or family of rings) would have wide application in the military and commercial market place for use in detecting fluids and gases such as Freon, petroleum, natural gas, corrosive gases, etc.. Concepts continue to be formulated and partnerships explored for further development during phase II. Work being conducted by the University of Notre Dame on hydrocarbon micro-sensors have been discussed and will be considered for use in phase II and/or phase III.

Figure 9: Tapered Smart Seal Ring for compression fitting having integrated leak detection sensors. In this concept there are three sensor rings that are recessed into channels that detect leak progression. The seal is provided by the surface of the tapered compression fitting.

Recessed Sensor Rings (red)

SMART TAPERED COMPRESSION SEAL

Figure 10 shows a 3D solid model design of a Sandwich Smart Seal Ring concept. As shown, redundant sealing is provided by two o-rings and leak detection is provided by a single sensor ring. This concept is similar to the design used for the phase I proof-of-concept demonstration. In this concept a core is used to provide compressive strength and to protect the electronics and power source located within the core. This concept is believed to have significant potential for multiple market applications. This smart seal ring is self contained or autonomous. In the event of a seal leak, a modulated RF or induction signal would be transmitted to a receiver/display module attached to an ID collar adjacent to the fitting.

Figure 10: Exploded view of a Sandwich Smart Seal Ring. In this concept the seal has sandwich construction with the power and control circuitry integrated into the center or core area. Unlike the previous concepts, this smart seal is fully autonomous with onboard power and control circuitry

O-ring seals

AUTONOMOUS SANDWICH SMART SEAL RING

Reactive Conductor Sensor Ring

Battery Core

Encapsulated Electronic Components (encapsulate not shown)

Phase I Demonstration

Proof of Concept Design

The phase I proof-of-concept design is shown in Figures 11 through 14. This design is a derivative of the multiple concept designs previously reported. The design achieves chlorine leak detection using electrical conducting elements that react with chlorine gas under dry and moist conditions. The smart pipe tubing is made of carbon reinforced epoxy. Unlike previous concept designs, this phase I demo design does not have any support structure in the inter-tubular space (such as foam or support rings). Instead the support is provided at the ends by the custom designed fittings. This was considered adequate due to the relatively short length (18 inches) of the demo component. The conducting elements consist of copper foil with white tin fuse or sensor elements. Tin reacts rapidly with dry and wet chlorine gas to produce tin chloride (SNCl2 and SNCl4). This reaction will result in a fusing of the electrical sensing circuit (loss of electrical continuity). Upon such an event, the electronic control chip (via comparator circuitry) will send out a signal either via RF or modulated signal along the power conductors that indicates the sensing of a chemical leak. Each smart seal ring and smart tube stock section will have a unique digital address that identifies which seal or tube is leaking. As previously described, the pipe is made up of two concentric composite tubes that are each sized to carry full pressure loads. In the event that the inner tube leaks, the gas is contained by the outer tube. The reactive conductor sensing elements are located within this inter-tubular space, which alert the operator that leak progression has occurred.

The smart seal ring, which is being developed under separate funding, uses the same principal. The ring has redundant seals with conductive sensing rings positioned between the seals. If the inner seal fails the sensing ring electrical reading changes and sends a signal alerting the operator of the problem. The outer redundant seal prevents leakage to the outside atmosphere; thus allowing the detection of leak progression. The fitting is designed to be made of anodized aluminum with Kynar spacers. Electrical pin terminations located in the fitting transfer signal from one pipe section to the adjacent section. A single (or multiple) power source provides electrical current which travels through each tube and fitting of the piping system. The phase I demo component shows the electronic control components located outside the tube near the male fitting. In phase II, consideration will be given to integrating electronic components into each seal ring and tube stock.

Figures 11 thru 14 show designs for the phase I proof of concept component. Figure 11A provides a perspective of the smart pipe that shows the male fitting, while Figure 11B provides a view from the female fitting. As illustrated in Figure 11A, power connection is provided using electrical pins. These pins are military standard gold plated electrical pins, as commonly seen in military connectors. The outer set of pins provides the positive and negative voltage leads to the adjacent pipe segment, while the inner set of pins (two inner top pins) provides positive voltage leads to the seal ring (one to each side of the seal ring). The bottom inner pin provides a common ground lead to both sides of the seal ring.

A comparison of the Boeing ABL baseline chlorine gas tubing (Hasteloy C-276) to the phase I tubing (dual walled carbon/epoxy composite tubing) shows a 32% savings in running weight of the tube. This assessment compares Hasteloy tubing to composite tubes with 0.030” thick walls capable of holding up to 6000 psi in the inner tube (0.75”ID) and 3500 psi in the redundant outer tube (1.25”ID) compared to 800 psi in the single walled Hasteloy tube. In summary, the MDA smart piping system achieves a 32% savings in running weight (of the tube) while improving the tube pressure capacity by a factor of 4+.

Figure 11: Multifunctional Pipe Design – The smart or multifunctional ABL pipe uses a control circuit on each pipe segment to monitor leak progression within its tube and female fitting connection. In the event of a leak a signal is sent to the operator with a unique address indicating that leak progression has occurred. LEDs are placed at each fitting near the control circuit to provide visual identification of a leaking seal or tube. The relayed address (identifier) of the leaking component is checked against the scribed part number on the pipe segment prior to repair.

A

B

Control Circuit (chip set)

Male Fitting

Female Fitting

Figure 12A thru 12C provide cross-section views that show the electrical pins and drilled holes for the electrical leads. These figures illustrate the location of the various electrical leads that support the power and leak detection circuitry. Figure 12A shows the pin and drilled hole for one of the two electrical connections that provide power to the adjacent pipe segment. Figure 12B shows the pin and drilled hole for one of the two positive voltage connections that provide power to the multifunctional/smart seal ring. As shown, this lead comes from the sensor circuit board or chip set located on the outside of the outer tube.

Figure 12C shows the pin and drilled hole used for the common ground lead to the sensor circuits. This ground is common to both sensor circuits located on each side of the seal ring, as well as, to the sensor circuit located within the inter-tubular space. As shown, this lead comes from a location outside the outer tube that is 180 degrees from the sensor circuit board. A foil copper conductor wraps around half of the outer pipe to connect this lead with the sensor control circuitry. Also shown in 12C is the

drilled hole for the positive voltage lead of the sensor circuit located between the tubes.

Figure 12: Cross-section Views of ABL Smart Pipe – Electrical leads using MIL-STD electrical pins transfer power to adjacent pipe segments and to the seal ring and tube sensor circuits. The multifunctional capacity of the smart pipe requires couplings that are a hybrid of electrical connectors and mechanical fittings. Also shown, are the inner liner and dual composite tube walls.

A

B

C

The design of the phase I smart seal ring, which was developed under separate funding, is shown in Figure 13. This design shows that redundant sealing is provided through the use of two elastomer o- rings. A sensor circuit located between the two seals has two tin sensors that detect the presence of chlorine gas. In the event that the inner primary o-ring leaks, the tin sensors or fuse plugs react spontaneously with the chlorine gas causing a loose of electrical conductivity and signal to be sent to the operator indicating the progression of a leak. The o-rings are standard seals made from chemical resistant Viton. The primary o-ring is PTFE-encapsulated for added long term chemical resistance. The body of the smart seal ring shown in Figure 13 is made of Kynar, which is a chemical resistant thermoplastic. Kynar is commonly used in industry for lining chlorine gas pipes.

Figure 13: Multifunctional Seal Ring Design – Redundant sealing is provided through the use of two elastomer o-rings. The sensor ring circuit located between the two o-rings detects the presence of chlorine gas if the inner primary seal is broken. The outer secondary ring holds the leaked gas while the sensor detects the chlorine and the operator is informed of the leak progression event. The three female electrical pins provide the electrical connections to both sides of the smart seal ring. Two tin sensors or fuse plugs are shown on the sensor ring at the 3 and 9 o’clock positions.

Proof of Concept Demonstration

Fabrication of the composite concentric tubing was done by a company in Ogden Utah

named Gold Tip Incorporated. The carbon reinforced epoxy tubing was fabricated using TR50/NCP301 material system from Newport Adhesives & Composites Incorporated. This is a 250F cure system that should be adequate for the phase I demonstration article. During phase II, a material system will be selected that satisfies ABL structural performance and program requirements.

Figure 14 shows a photograph of the assembled components prior to integration of the

circuitry and bonding of the components. The fittings are made of anodized aluminum and Kynar to minimize weight. The composite tubing is made of unidirectional carbon reinforced epoxy. The composite tubes were shrink wrapped and oven cured. This is a low cost process commonly used to fabricate commodity composite products (i.e., arrow shafts, etc.). Shrink wrap processing is low cost and provides better dimensional control for thin walled tubing when compared to conventional winding. During phase II, materials and processes will be researched and developed to assure low cost, high quality, and reliable products.

Figure 14: Multifunctional Pipe – The smart or multifunctional ABL pipe is shown with fabricated components loosely assembled. As shown, the tube is made of carbon reinforced plastic and the fitting/seal assembly is made of Aluminum and Kynar. This photograph was taken prior to sensor and circuitry integration.

Figure 15 shows a photograph of the smart pipe components. This photograph shows

the two tubes which provide redundant containment structure (tube within a tube). Also shown is the smart seal ring which has two o-rings that provide redundant sealing. As shown, the fitting assembly is made of anodized aluminum with Kynar inserts to minimize weight. As with Figure 14, this photograph was taken prior to sensor and circuitry integration.

Figure 16 shows photographs of the ABL smart pipe. As shown, copper foil electrical

interconnects are adhered to the outside of the outer pipe. The control circuit board is mounted to the socket shown at the male end of the pipe. MIL-STD gold plated electrical pins are shown at the male fitting. These pins provide termination to the adjacent pipe and the smart seal ring. The smart seal ring is shown in place in the photograph in the lower right corner of Figure 16.

The phase I ABL smart pipe was fabricated to allow for ease of demonstration. The foil

interconnects were visibly mounted to the outside of the smart pipe to allow viewing and demonstration of the integrated electrical interconnect circuitry. It is anticipated that the phase II and phase III smart piping will have the electrical interconnects integrated out-of-view into the composite laminate structure.

Figure 15: Multifunctional Pipe – The smart or multifunctional ABL pipe is shown with fabricated components. As shown, the composite tube is made of two tubes (tube within a tube) to provide redundant containment structure. The seal ring has two o-rings to provide redundant sealing. The fitting assembly is made of anodized Aluminum and Kynar to minimize weight. This photograph was taken prior to sensor and circuitry integration.

Figure 17 provides a photograph of the phase I smart seal ring that was developed under separate cost share funding. As shown, copper foil tracing is used for the circuit that carries current from the positive electrical female pin through the tin fuse and on to the common ground female pin. As previously reported, the tin fuse acts as a chlorine gas detection sensor. When exposed to wet or dry chlorine, the tin and chlorine completely react to form tin tetrachloride gas, causing a fusing event. The smart seal ring has two o-rings. If the inner primary seal leaks, chlorine enters the inter-seal region and reacts with the tin while still contained by the outer secondary seal. The other side of the seal ring (not shown) has a similar circuit that runs from the other positively charged female pin to the common ground pin. This other pin can be seen in Figure 17 (upper right pin).

Figure 18 shows a photograph of the initial test set-up used to test and demonstrate the ABL smart pipe. As shown, a 3 volt DC battery power source, simple breadboard LED circuit, and digital electronic meter were used to test and demonstrate the smart pipe power and sensor circuitry. The LED circuit provided a visual indication of a detected leak. In the event of

Figure 16: Phase I Demo Component (ABL Multifunctional Pipe)– Photographs of the phase I ABL multifunctional pipe are shown. Copper foil electrical interconnects can be seen attached to the outside of the outer pipe. Electrical male pins are shown in the male fittings. Also shown is the smart seal ring placed in the male fitting of the pipe.

a leak the chlorine would react with the tin causing electrical discontinuity and the LEDs to stop illuminating. Once this basic concept was demonstrated, a more complex breadboard circuit was designed and assembled that included a comparator circuit for each of the three sensor circuits (the pipe and each side of the seal ring). The comparator circuits identify a change in electrical reading that results from a sensed chlorine leak (spent tin fuse). Once this circuit was successfully demonstrated, a circuit was designed that includes an RF encoder, transmitter, and receiver in addition to the visual LED display. This circuit design is shown in the schematic of Figure 19A.

Figure 19 shows the design and a photograph of the ABL smart pipe sensor circuit. The circuit design includes the schematic previously mentioned and shown in Figure 19A and the circuit component layout shown in Figure 19B. As shown in the

schematic the sensor circuit has three comparators circuits and three transistors that provide the switching between green and red light emitting diodes (LED) when the chlorine leak is sensed (tin fuse spent). Also shown is an encoder and RF transmitter that transmits an encoded digital signal to a remote RF receiver (not shown). In the event of a chlorine leak the tin fuse is spent and the circuit causes the LEDs to go from green to red and the transmitter to transmit an encoded signal to a remote receiver indicating which seal or tube is leaking.

The physical layout of Figure 19B shows the position of the thru-hole components. Figure 19C shows the circuit components that drive the LED switching. The RF components currently have not been assembled into the sensor card. It is anticipated that the remainder of the circuitry (RF related components) will be assembled onto this experimental card as part of phase II or phase II cost share. It is also anticipated that IC, surface mount, and polymer film electronics will be explored during phase II to significantly reduce the size and improve the integration of the sensor circuitry.

Figure 17 Smart Seal Ring – A photograph of the smart or multifunctional seal ring is shown. As can be seen, copper foil tracing is used to conduct electricity through the tin fuse. The tin fuse reacts with wet and dry chlorine gas to provide a chlorine leak detection sensor.

Positive Electrical Pin (for shown circuit)

Common Ground Chlorine Sensor (Tin Fuse)

Copper foil conductor Secondary

O-ring

Positive Electrical Pin (for circuit on other side of seal)

Primary O-ring

Figure 18: Initial Test Setup for ABL Smart Pipe – A simple breadboard circuit was fabricated and used in conjunction with a digital electronic meter to test the circuitry and to provide an initial demonstration of the concept. This simple circuit included LED’s that illuminated with a complete circuit; thus providing a visual indication of a chlorine leak (spent tin fuse).

Figure 19: ABL Smart Pipe Sensor Circuit Design – A schematic of the smart pipe sensor circuit is shown in Figure 19A. Figure 19B shows the physical layout design of the sensor circuit using thru-hole components on an experimental board. Figure 19C is a photograph of the phase I proof-of-concept sensor circuitry made with thru-hole components and an experimental rigid substrate. This board measures approximately 4.5 cm x 4.5 cm. During phase II, the use of ICs and surface mounted components will significantly reduce the size of the sensor circuitry.

A B

C

Figure 20 shows photographs of the male end of the smart pipe. Figure 20A shows the socket termination that provides connection to the sensor card. Figures 20B through 20D show the pipe with the sensor circuitry attached. In Figure 20C the green LEDS are illuminated because of circuit continuity. In Figure 20D, the seal ring is removed and discontinuity exists causing the red LED to illuminate.

Dr. Lieberman of the University of Notre Dame assisted Odyssian Technology in performing preliminary chlorine gas exposure testing on tin, copper, and aluminum. This test was done to provide a preliminary assessment of the feasibility of using tin as a chlorine gas sensor and to assess the immediate effects that chlorine gas may have on the smart pipe copper interconnects and aluminum fittings. The test set-up and apparatus are shown in the photographs of Figure 21. As shown, a chemical vapor hood was used in performing the experiment (Figure 21A). Dry chlorine gas from a twenty pound tank was transferred to glass testing vials that contained electrical leads soldered to metallic test elements (Figure 21C). A simple breadboard

Figure 20: Multifunctional Pipe with Sensor Circuit – The smart or multifunctional ABL pipe is shown with the sensor circuitry attached. In Figures 20C and 20D the LEDs are illuminated green and red indicating a no-leak and leak condition, respectively. Three LEDs are used to visually relay the sensor output of the two sensors on each side of the smart seal ring and the sensor in the inter-tubular space.

A B

C D

circuit was made (Figure 21B) to provide a visual indication of circuit continuity or discontinuity through the metallic elements. In the event of a spontaneous and complete reaction of the metallic element with chlorine gas, the element would fuse causing the circuit to be broken and an LED to stop illuminating. The visual test circuit used two AA batteries (not shown) that provided 3 Volts of DC power. This circuit was used in conjunction with a stop watch and a multimeter, which were used to measure time and electrical resistance.

Table 6 shows a summary of the preliminary test data. Test results for test coupons # 2, 3,

and 4 shows that tin does react near spontaneously with dry chlorine gas, thus making it a useful material for sensing the presence of chlorine gas. Additional testing in phase II will be needed to accurately characterize the reaction of tin with chlorine gas. The preliminary data suggests that an electrical current through the tin may slightly delay the fusing event. During phase II, testing will be conducted to determine appropriate tin thickness necessary to provide a fuse or sensor with desired sensitivity and response time. Prior to testing coupon #1 a large water deposit was placed into the vial. The electrical leads to the tin were wrapped due to prior solder connection breakage. The test data shows that coupon#1 did not undergo rapid corrosion as seen in the other tin tests. It is speculated that this may have been due to the consumption of chlorine gas during its reaction with water to form HCl. Further testing during phase II will assess the effects

Figure 21: Preliminary Testing Setup - A preliminary test was conducted to test the reaction of various electrical conductors with chlorine gas. Testing was conducted at the University of Notre Dame Chemistry Department by Odyssian Technology and a UND faculty advisor. Small glass containers were filled with dry chlorine gas to test metallic elements.

A C

B

of moisture on the reaction of chlorine gas with tin. As previously reported, literature suggests that tin spontaneously reacts with both dry and wet (moist) chlorine gas.

Table 6 also shows that copper and aluminum did not readily react with dry chlorine gas.

During phase II, testing will be conducted with more precise instrumentation to characterize the effect of chlorine gas exposure on electrical resistance. The electrical measurement instrumentation used during this preliminary testing did not have the precision necessary to measure the change in electrical resistance resulting from the corrosive action of the chlorine gas.

Electrical Resistance

(Ohms) Test Coupon Number

Sensor (fuse)

Element Material

Approx. Dimensions of

Conductive Element (T x W x L) Test Conditions

Exposure Time

(min:sec) Initial Final Test Results Observations

1 Tin 0.002 x 0.020 x 0.5 Moist Cl2, 3 VDC 3:32 0.5 0.4

Did not fuse. Poor clip connection gave temporary discontinuity reading, causing the test to be ended.

Large droplets of water placed in glass container. White layer formed on surface of tin.

2 Tin 0.002 x 0.012 x 0.37 Dry Cl2, 0 VDC :39 0.6 0.6 Fused. Lost electrical continuity

Fused. Lost electrical continuity after 39 sec of exposure to chlorine gas.

3 Tin 0.002 x 0.15 x 0.44 Dry Cl2, 3 VDC 1:08 0.6 0.6 Fused. Lost electrical continuity.

Fused. Lost electrical continuity.

4 Tin 0.002 x 0.15 x 0.52 Dry Cl2, 0 VDC :41 0.5 0.4 Fused. Lost electrical continuity.

Fused. Lost electrical continuity after 41 sec.

6 Copper 0.002 x 0.09 x 0.54 Dry Cl2, 0 VDC 10:00 0.4 0.4 Did not fuse. Discoloration of solder

7 Copper 0.005 x 0.015 x 0.38 Dry Cl2, 3 VDC 5:00 0.4 0.4 Did not fuse. Discoloration of solder

8 Aluminum 0.002 x 0.97 x 0.56 Dry Cl2, 0 VDC 2:00 1.5 1.5 Did not fuse. Discoloration of solder Notes: 1. Temperature and Pressure were at ambient conditions 2. Exact concentration of chlorine gas was not measured. Glass test containers were filled from 100% Cl2 dry gas tank. Subtle change in color used to determine when glass

containers were filled. 3. Electrical resistance measurements were taken with low precision equipment incapable of measuring minute changes in electrical resistance. In future tests, electrical resistance

will be measured using equipment capable of measuring very small changes in resistance. 4. Test sample #5 not tested

Table 6: Preliminary Testing Data - Early test data suggests that the use of tin as a sensor or fuse material for detection of chlorine gas is feasible. Additional testing is required to adequately characterize the reaction under a range of conditions. Under phase II, more accurate and extensive testing will be conducted.

Table 7 shows a comparison of Hasteloy to composite tubing. The relationships shown at the bottom of the table were used to calculate the pipe thickness required to contain various internal gas pressures. In addition, the far right column shows the running weight of each tube. The composite pipe thicknesses required to hold 800 psi are much lower than the amount of material that would be required to fabricate a robust pipe (each ply is 0.005” thick). Pipes with six plies (three 0° , three 90°) of material with total thickness of 0.0030” would be capable of holding 6000 psi pressure with a 0.75” inside diameter (ID), 3500 psi with a 1.25” ID, and 3000 psi with a 1.50” ID. The phase I demo design is using two concentric pipes; the inner pipe ID of 0.75” and the outer pipe ID of 1.25”. This table shows that if the composite pipes are made at 0.030” thickness, the combined running weight (considering both concentric pipes) would be 0.125 lbs/ft. This compares to 0.165 lbs/ft for Hasteloy, which is about 32% higher over the carbon epoxy dual walled pipe.

TABLE 7: COMPARISON OF HASTELOY TO CARBON EPOXY COMPOSITES TUBES

Material

Material Strength

ksi

Fiber in Hoop

Direction %

Fiber in Axial

Direction %

Material Factor

Safety Factor

Allowable Hoop

Stress (St) ksi

Allowable Axial

Stress (Sa) ksi

Gas Pressur

e (p) psi

Inside Diamete

r (D) inches

Thickness Required for Hoop Loads (tt) inches*

Thickness Required for Axial

Loads (ta) inches**

Material

Density lbf/in3

Running Weight

lbf/ft

480 60% 40% 1.3 3 74 49 800 0.75 0.004 0.003 0.054 0.006

480 60% 40% 1.3 3 74 49 800 1.25 0.007 0.005 0.054 0.017

Carbon Epoxy Compos ite

Tube TR50/NCT301

, 60%vf (800 psi) 480 60% 40% 1.3 3 74 49 800 1.5 0.008 0.006 0.054 0.025

480 60% 40% 1.3 3 74 49 6000 0.75 0.030 0.023 0.054 0.046

480 60% 40% 1.3 3 74 49 3500 1.25 0.030 0.022 0.054 0.075

Carbon Epoxy Composite

TR50/NCT301, 60%vf

(0.030" thick) 480 60% 40% 1.3 3 74 49 3000 1.5 0.030 0.023 0.054 0.093

52.9 - - 1.05 3 17 17 800 0.75 0.018 0.009 0.321 0.162

52.9 - - 1.05 3 17 17 800 1.25 0.030 0.015 0.321 0.450 Hasteloy

C-276

52.9 - - 1.05 3 17 17 800 1.5 0.036 0.018 0.321 0.648

* Thickness required to carry hoop loads: tt=pD/2S t ** Thickness required to carry hoop loads: ta=pd/4Sa

Phase II Proof of Concept Design

Conceptual designs were created of the proposed phase II demonstration and test components. Figures 22 shows a solid model concept design of the proposed phase II demonstration component and Figure 23 shows a concept design of phase II test articles. As shown, the phase II component includes the development of curved smart pipe and smart flange fittings. The test articles shown in Figure 22 will be fabricated to explore and demonstrate fabrication approaches for manufacturing the smart pipe with curvature. Boeing provided a preliminary set of requirements and guidelines for use during phase II. These requirements are listed in Table 8. Near the beginning of phase II, these requirements will be expanded upon to provide definition of phase II design priority.

Phase II will demonstrate a multifunctional (smart) piping system with curvature for use on the ABL. This multifunctional piping system will provide both containment and leak detection of the corrosive gases used in the Chemical Oxygen Iodine Laser (COIL). As demonstrated in phase I, the phase II system will provide containment redundancy to allow for leak progression detection; the detection of a leak before leakage occurs to the outside environment. The tube stock of the pipes segments will have dual concentric containment walls with sensors located in the inter-tubular space. In the event of a leak, the gas will enter the inter-tubular space causing corrosion of the sensor element and a corresponding shift in electrical sensor readings. Low power (non-interference) distributed RF control signals or modulated signals along the power conductor will alert a central leak detection controller that leak progression has occurred in an identified (addressed) pipe segment. The outer tube of the dual walled containment system will be designed to provide containment of the gas under full pressure. Thus, containment redundancy will be provided to allow for leak detection before the gas enters the outer atmosphere.

Under separate cost leverage funding, multifunctional or smart seal rings will be further developed during phase II that offer containment redundancy and gas sensing capability. As demonstrated during phase I, the phase II smart seal rings will have multiple seals per ring with conducting sensor rings located between each seal. Similar to the tube of the piping system, leak progression will is detected in the event that the inner seal is broken and gas enters the inter-seal region. Redundant outer seals will prevent leakage to the outside environment.

Figure 22: Phase II Demonstration Component – Shown is the proposed phase II demonstration component that includes curved smart piping and smart flange fittings.

Figure 23 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.

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 discontinuities shall be assessed. c. Metal welding, if used, shall be Class A, full penetration butt-type per MIL-STD-2219.

MEOP – Maximum estimated operating pressure

Table 8: Preliminary Phase II Requirements. Shown are a set of preliminary phase II requirements that have been provided by Boeing. Near the beginning of phase II these requirements and guidelines will be further considered and expanded upon.

4.0 FEASIBILITY AND ABL BENEFIT

Phase I demonstrated the feasibility of integrating leak detection sensors into lightweight piping. The feasibility and effectiveness of the phase I reactive conductive tin sensor for detecting chlorine was demonstrated. Multiple designs were developed that demonstrated the feasibility of integrating electrical interconnects and circuitry to support the smart piping and smart seal systems.

Early in the program, research was conducted that found that the ABL will benefit from the smart piping system by protecting ABL personnel from the highly toxic and hazardous COIL chemicals. Also, it was found that the smart piping system will provide benefit by reducing the likelihood of the COIL chemicals corroding the aircraft structure, electronic circuitry, fastening systems, etc.. During a meeting with the Boeing ABL program, their interest was expressed in developing a multifunctional piping system that minimized the likelihood of the corrosive gases ever leaking from the COIL system. During phase I designs were developed with redundant containment and sealing that satisfied this expressed need for leak detection prior to leakage. While Boeing has developed flush and mitigation plans for use in the event of a COIL chemical leak, Boeing expressed concern over the potential of corrosive gas elements accumulating in hard to reach fine fatigue cracks within the paint; thus exposing the aluminum and titanium structure to the corrosive COIL chemicals. Such fatigue cracks would be difficult if not impossible to clean, resulting in the accumulation of corrosive elements in structurally critical areas. The smart piping and seal technology demonstrated in phase I will be further developed during phase II to prevent such accumulation of corrosive chemicals and will ultimately benefit the ABL by significantly reducing operational maintenance costs and improving personnel safety.

PHASE I SBIR FINAL TECHNICAL REPORT - DRAFT 04/04/04odyssian.com/MDA/MDA/files/Phase I/Final...

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