Integrated Technology Development

Toward ASIP Corrosion Tools

Aircraft Structural Integrity Conference
San Antonio, Tx
2 Dec 2014

Douglas Dudis, Ph.D.

Corrosion Integrated Product Team Lead
Integrity  Service  Excellence
Materials & Manufacturing Directorate
AF Research AF Research Laboratory

DISTRIBUTION STATEMENT A. Approved for public release. 88ABW-2014-5563.

 Overview

• Recent AFRL/RX Corrosion Activities

– AFRL IPT Overview
– IPT Activities

• Some Technical Directions

Acknowledgements:
AFRL RX Corrosion IPT
60+ Participants in Many Organizations!

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DISTRIBUTION STATEMENT A. Approved for public release. 88ABW-2014-5563.
 AFRL Corrosion IPT
Interactions
AF, OSD, Navy, Army
Academia, Industry
Corrosion Community

Corrosion Core Team Aircraft Design and

AF Materials and Life Management
Manufacturing Research
Dr. Dudis- Lead
Dr. Hunter
Dr. Juzukonis Structures/Propulsion
ICMSE (modeling) IPT
Mr. Stimson (0.5)- Ctr
LOA IPT
Dr. Nick Wilson – Ctr AFMC
Faculty/Students  AF Life Cycle Management
Center
AFRL - CTIO - Integrity Programs
 AF Sustainment Center
AFRL Sustainment
Tech Trans

AF Corrosion
Program Office
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DISTRIBUTION STATEMENT A. Approved for public release. 88ABW-2014-5563.
 AFRL S&T Corrosion IPT Charter

• Lead for AFRL S&T corrosion response/activities

– Needs, Strategy, Planning, Issues, Advocacy, Status, etc.
• Quick response support to AF CCPE & AF Corrosion
Enterprise
• Provide corrosion M&P support to the AF
• Champion/conduct high priority S&T projects
• Enhanced interaction/collaboration
– DoD Corrosion Office
– Navy & Army corrosion activities
– Academia
– Industry
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DISTRIBUTION STATEMENT A. Approved for public release. 88ABW-2014-5563.
 AFRL RX Corrosion IPT Alignment
with OSD Corrosion S&T Roadmap
OSD AFRL RX IPT
Performance/Service Life Prediction
- Models
- Accelerated Testing Accelerated Test Protocols for Life
- Validation Prediction
- Design Tools
Real Time Condition Assessment
Probabilistic Modeling of Corrosion
- Mechanical Properties
Behavior
- Integrity
- Galvanic Interaction
- Degradation Mechanisms Determination of Bio-corrosion
Surface Engineering – Optimized Processes Inhibition by Non-Cr Coatings
- Mechanical
- Adhesion Promotion Stable Surrogate Material to Simulate
- Sacrificial Hidden Corrosion on Aircraft Structure
Cleanliness Requirements
- Logistics Non-Chrome Highly Flexible Primer
- Packaging/Storage Coating
- Shelf-Life
- Energy
- Maintenance DISTRIBUTION STATEMENT A. Approved for public release. 88ABW-2014-5563.
5
 Cost of Corrosion*

Preliminary Numbers for FY13: $6.0 B, 25% of total Maintenance

*David Robertson, “Developing an AF Long Term Corrosion Prevention and Control Strategic Plan,” ASIP 2012:
http://www.meetingdata.utcdayton.com/agenda/asip/2012/proceedings/presentations/P6280.pdf 6
DISTRIBUTION STATEMENT A. Approved for public release. 88ABW-2014-5563.
 AF Integrity Programs
• AF uses integrated Weapon System Integrity Programs to design
and maintain the integrity of systems and subsystems
throughout a weapon systems’ life cycle.
• Integrity programs encompass:
– Aircraft Structural Integrity Program (ASIP)
– Avionics Integrity Program (AVSIP)
– Propulsion Systems Integrity Program (PSIP), and
– Mechanical Equipment and Subsystems Integrity Program
(MECSIP).
• These Programs establish disciplined, time-phased tasks to be
accomplished during development, production, operation and
sustainment of weapon systems.
• There is a significant lack of validated corrosion-related Systems
Engineering (SE) tools and methods, applicable across the life
cycle, to implement the intent of these programs. 7
DISTRIBUTION STATEMENT A. Approved for public release. 88ABW-2014-5563.
 ASIP MIL-STD-1530C Requirements
(Corrosion Related Shown in Green)
Task I Task II
Design Analyses &
Design Information
Development Tests
Materials And Joint
ASIP Master Plan
Allowables
Design Service Life and
Load Analyses
Design Usage
Design Service Loads
Structural Design Criteria
Spectra
Durability & Damage
Design Chemical, Thermal &
Tolerance Control
Environment Spectra
Program
Corrosion Prevention and
Stress Analysis
Control Program
Nondestructive Inspection
Damage Tolerance Analysis
Program
Selection of Materials,
Processes, & Joining Durability Analysis
Methods
Corrosion Assessment
Sonic Fatigue Analysis
Vibration & Flutter Analyses
Mass Properties Analysis
Survivability Analysis
Design Development Tests
Initial Risk Analysis
DISTRIBUTION STATEMENT A. Approved for public release. 88ABW-2014-5563.
Task III Task IV Task V
Certification & Force
Force Management
Full-Scale Testing Management
Execution
Development
Individual Aircraft
Static Tests Certification Analyses
Tracking Program
Rotorcraft Dynamic
First Flight Verification Strength Summary &
Component Tracking
Ground Tests Operating Restrictions
Program
Force Structural Loads/Environment
Flight Tests
Maintenance Plan Spectra Survey
Loads/ Environment
Durability Tests Spectra Survey ASIP Manual
Development
Individual Aircraft
Aircraft Structural
Damage Tolerance Tests Tracking Program
Records
Development
Rotorcraft Dynamic
Force Management
Climatic Tests Component Tracking
Updates
Program Development
Interpretation &
Evaluation of Test Recertification
Results
8
 ASIP Corrosion Needs (1 of 2)

– Translation of system level corrosion req’mts into

measurable/certifiable metrics at subsystem, component
and supplier levels.
– Methods for decomposing aircraft loads/environments into
verifiable corrosion req’mts for specified design/service life
– Translation of corrosion req’mts into selection of materials,
finish systems, etc. to assure LC corrosion performance
– Test protocols representative of actual materials, processes,
design and manufacturing configurations
– Accelerated test methods that yield reliable accept/reject
criteria for LC corrosion evaluations
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DISTRIBUTION STATEMENT A. Approved for public release. 88ABW-2014-5563.
 ASIP Corrosion Needs (2 of 2)

– Quantitative corrosion information and models to support

design/material selection tradeoffs and the translation of
those trades into life cycle performance and cost estimates
– Availability of high performance M&P technologies and
corrosion predictive methods that deliver high confidence
in achieving corrosion prevention in new designs;
– Data for design and fleet management decision making
– Corrosion detection (particularly hidden corrosion), and
accurate quantification of detection results in the existing
fleet.

10
DISTRIBUTION STATEMENT A. Approved for public release. 88ABW-2014-5563.
 Corrosion S&T for Accelerated
Corrosion Modeling*

Environments Combined Effects Chambers Use & Integrity

Damage Program
Specimens Material Building Blocks Character- Corrosion
(Gen1: SCCS) ization Test and
Models
Numeric Galvanic & Probabilistic Modeling Design
Trade
Models Atmospheric Based Models Tools

Sensing Corrosion Sensors, CONOPS and Protocols Contractually

Enforceable
Specs & Stds

Materials Develop & Evaluate Coating Systems

*Modeling: Numerical and Experimental

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DISTRIBUTION STATEMENT A. Approved for public release. 88ABW-2014-5563.
 Corrosion S&T Impact
Design and Material Qualification Gap
B117
UV
old New
6 months to 1
year

3-6 years
coupons
gloss
Adhesion Spectral

All aspects of the systems Outdoor exposure in

Accelerated testing in
are usually included: various conditions
controlled conditions;
surface conditioning
Chemical resistance,
(material type and heat
strip-ability,
treatment anodize, clad,
environmental
cleaning, activation,
degradation, damage
thickness, application
tolerance etc.
technique, etc.)

Simply picks best for conditions tested: Cannot

predict time to failure, estimate cost, evaluate Flight test
3-10 years
risk, etc Limited number of
aircraft
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DISTRIBUTION STATEMENT A. Approved for public release. 88ABW-2014-5563.
 Corrosion S&T Impact
Design and Material Qualification Gap
B117
UV
old New
6 months to 1
year

3-6 years
coupons
gloss
Adhesion Spectral

All aspects of the systems Outdoor exposure in

Accelerated testing in
are usually included: various conditions
controlled conditions;
surface conditioning
Chemical resistance,
(material type and heat
strip-ability,
treatment anodize, clad,
environmental
cleaning, activation,
degradation, damage
thickness, application
tolerance etc.
technique, etc.)

Simply picks best for conditions tested: Cannot

predict time to failure, estimate cost, evaluate Flight test
3-10 years
risk, etc Limited number of
aircraft
13
DISTRIBUTION STATEMENT A. Approved for public release. 88ABW-2014-5563.
 Advanced Combined Effects for
Design & Sustainment
Prior FY14 FY15 FY16 FY17 FY18 FY19 FY20 FY21 FY22
SERDP
Transformation of DoD Best
SBIR Phase I & II
Practices for Corrosion Testing

SBIR P I Gen 1 Combined

4 Awds Effects Chamber

SBIR Phase 2 DoD/OEM/Industry

Acceptance/Commercialization
+Multi-Agency leveraging
Accelerated
Laboratory Simulation of Methodologies
Outdoor Environments &
Advanced Test
Laboratory Simulation of Methodologies for
Operational Environments Design Trade Tools

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DISTRIBUTION STATEMENT A. Approved for public release. 88ABW-2014-5563.
 Accelerated Aging
1 year
Long-term aging
Accelerated aging of an egg @ 80ºF
should not change
the target aging
mechanism! 21 days

Accelerated
aging @ 100ºF

8 min
Accelerated
aging @ 212ºF

15
Slide courtesy Dr. Greg Schoeppner DISTRIBUTION STATEMENT A. Approved for public release. 88ABW-2014-5563.
 Structural Component Corrosion Simulation (SCCS)
Building Block Test Development
Technology Problem/Approach
Problem: Airframe structures consist of combinations of
materials/coating systems that undergo fatigue loading cycles,
variable environments, moisture entrapment, etc.
Approach: Test methodology development leading to Joint Test
Protocols (JTPs)
• Expose representative airframe structural elements to
operational environments.
• Compare the results with the conditions of in-service aircraft
to ensure testing can reproduce similar damage.
• Results will allow for prediction models to be incorporated into
ASIP risk assessment tools.
DISTRIBUTION STATEMENT A. Approved for public release. 88ABW-2014-5563.
Project Status
• Baseline study: representative large airframe legacy
aircraft materials selected; “worst case” condition
• Bare 7075-T6 skin, stiffener, splice plate
• Cd-plated steel fasteners
• Dry-installed fasteners; no fay surface sealants or CPCs
• Chromated and non-chromated coating systems
• Specimens subjected to alternating ASTM B117 salt
fog, axial cyclic loading with temp. cycling to -60F
• All relevant control groups (64 total specimens)
• NDI during testing with complete teardown analysis
Customer Support Plan
• ASIP Corrosion Gaps (per Chuck Babish, USAF Technical Advisor for ASIP)
 Ability to translate top-level service life (hours and years in service) and
sustainment requirements into selection of materials, finish systems, etc.
that withstands competing pressures during design
 Well defined and agreed-to accelerated test methods and accept/reject
criteria for corrosion evaluation for a range of environments and service life
requirements
 Knowledge and data to enable credible & convincible business case and
Life Cycle Cost (LCC) analysis for any trade studies involving corrosion
prevention & control
• Addressing needs by providing mid-level building block testing to assist in
bridging the gaps in corrosion data for ASIP design and risk analyses.
POC: Mr. Steve Thompson AFRL/RXS
Steven.thompson.21@us.af.mil 16
 Building Block Approaches for
More Realistic Materials Evaluations

??

Protocols for Future

Test Specimens

SCCS Gen 1
test specimen”

Coated
Corrosion test specimen

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DISTRIBUTION STATEMENT A. Approved for public release. 88ABW-2014-5563.
 Building Block Approaches for
More Realistic Materials Evaluations

??

Protocols for Future

Test Specimens

SCCS Gen 1
test specimen”

Coated
Corrosion test specimen

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DISTRIBUTION STATEMENT A. Approved for public release. 88ABW-2014-5563.
 Probabilistic Modeling
Of Corrosion For Life Prediction
Objectives
• Develop deterministic and probabilistic
models for predicting the beginning and
growth of corrosion as a function of time
• Evaluate how variables affect the outcome
of the prediction of corrosion initiation and
propagation
• Explore how the model(s) may impact the
management of corrosion in the field
DISTRIBUTION STATEMENT A. Approved for public release. 88ABW-2014-5563.
Problem
• Current models of corrosion in
aircraft structures are inadequate
• No tangible corrosion metric is
currently possible
Benefits/Payoffs
• Realistic time-based corrosion models
• Improved component life prediction
• Integrate corrosion into ASIP
• Provide basis for fleet management
POC: Dr. Kumar Jata, AFRL/RXC
kumar.jata@wpafb.af.mil 19
 Environmental Severity Index
ESI (Location) x Time at Location = Corrosion Cost

Discrepancies limits effectiveness MX vs. Eng Data:

Additional work required Additional analysis required
Inaccurate Data:
Has been/can be addressed
Path forward:
• ESI is AVERAGE for Location (all factors rolled into ESI)

• Maturation Effort for C5 Individual Aircraft Tracking

Even for this relatively simple case, it is not as easy

as it looks…
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DISTRIBUTION STATEMENT A. Approved for public release. 88ABW-2014-5563.
 Environmental Severity Index
ESI (Location) x Time at Location = Corrosion Cost

Discrepancies limits effectiveness MX vs. Eng Data:

Additional work required Additional analysis required
Inaccurate Data:
Has been/can be addressed
Path forward:
• ESI is AVERAGE for Location (all factors rolled into ESI)

• Maturation Effort for C5 Individual Aircraft Tracking

Even for this relatively simple case, it is not as easy

as it looks…
21
DISTRIBUTION STATEMENT A. Approved for public release. 88ABW-2014-5563.
 Next Gen: Cumulative Damage Model for
Prediction of Atmospheric Corrosion

Form based on Eyring equation

describing the variance of the rate of a
chemical reaction with temperature

Material
Reactivity
(kinetics)
Chloride Reaction Sulfur Dioxide Reaction Contains Relevant
• Chemistry
 H 
K i  exp [ ACLT f Cl T , RH  f T , Cl   ASO2T
CL SO2
f SO2 T , RH  f T , SO2   • Environment
 kT 
AO3T O3 f O3 T , RH  f T , O3  • Time (by hour)

Ozone Reaction

David Rose, University of Dayton PhD Dissertation, 2014 22

DISTRIBUTION STATEMENT A. Approved for public release. 88ABW-2014-5563.
 AFRL SERDP – Outdoor Test Site Locations

Calibration/Validation Sites
• Data from four different locations with diverse conditions was used to initially calibrate
candidate models… later reduced to three sites
• Candidates were validated by applying them to independent proxy data for locations not
used for calibration
– Final model was validated using data from seven different sites in four different climate
zones

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David Rose, University of Dayton PhD Dissertation, 2014
DISTRIBUTION STATEMENT A. Approved for public release. 88ABW-2014-5563.
 AFRL SERDP Project
Cumulative Damage Model Results
40000
y = 1.0702x + 2502.7
35000 R² = 0.8628
Predictions (mg/cm2)

30000
25000
20000
15000
10000
5000
0
0 5000 10000 15000 20000 25000 30000 35000
Test Results (mg/cm2)

R2 value of 0.86 is higher than any published atmospheric corrosion rate prediction
model intended for application at locations with diverse environmental conditions
David Rose, University of Dayton PhD Dissertation, 2014 24
DISTRIBUTION STATEMENT A. Approved for public release. 88ABW-2014-5563.
 Summary

• Corrosion issues receiving increased attention within the AF

• AF study has identified key areas where S&T can provide
solutions to AF corrosion issues
• IPT has identified several areas for emphasis to support ASIP
• Proposed research areas are aligned with OSD priorities
• Leveraging other services, industry, academia
• Approaches becoming more sophisticated/realistic/applicable

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DISTRIBUTION STATEMENT A. Approved for public release. 88ABW-2014-5563.