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UNCLASSIFIED
UNCLASSIFIED The Nation’s Premier Laboratory for Land Forces UNCLASSIFIED The Nation’s Premier Laboratory for Land Forces
UNCLASSIFIED
Damage Precursor Index Methodology for Aviation Structures
Ed Habtour1, Daniel Cole1, Christopher Kube1, Adam Svensken1, Mark Robeson2, and Abhijit Dasgupta3
1 U. S. Army Research Laboratory, APG, MD 21005 USA 2US Army Aviation and Missile Research, Development, and Engineering Center, Ft. Eustis, VA 23604 USA
3Center for Advanced Life Cycle Engineering, University of Maryland, MD 20742 USA
Ed Habtour, Ph.D., P.E., Team Lead Prognostics & Diagnostics, Vehicle Technology Directorate at ARL [email protected]
UNCLASSIFIED
UNCLASSIFIED The Nation’s Premier Laboratory for Land Forces
Objective 1) Understand materials evolution 2) Incorporate precursors into models 3) Track changes in nonlinear dynamics
Damage Precursor: Aviation
Challenges 1) Characterize Precursors:
i. classes of materials ii. loading profiles iii. environmental Conditions
2) Nonlinearity: i. manifestation of health ii. parameters sensitivity iii. multiaxial loading
Army Impact
1) Prolong the life of critical components to achieve “Fatigue-Free”
2) Provide fast, relevant health information
UNCLASSIFIED
UNCLASSIFIED The Nation’s Premier Laboratory for Land Forces
The Why: FY16 Army Budget
1 FY2016 Army Budget Overview, Deputy Assistant Secretary of the Army (DASA) for Budget , 2015 2 Bureau of Labor Statistics, U.S. Department of Labor, Occupational Outlook Handbook, 2014-15 Edition, Military Career
Operations and Maintenance $45B, 36%
Military Personnel $56B, 44%
Other, $2B, 2%
Procurement & RDTE,
$23B, 18%
Battle Damage Assessment and Repair is not a driving
maintenance factor
OCO Request1 O&M $12B (55%)
FY16 Army Request1
Base: $126B OCO: $ 22B
~ 27% of Army personnel2 are in sustainment functions
UNCLASSIFIED
UNCLASSIFIED The Nation’s Premier Laboratory for Land Forces
Current State: Data Collection
Materiel Instrumentation Data Collection Systemic
Issues RootCauses Mi1ga1ng Correc1veMeasures
Deploy field analysts
Increase number of field data collectors world wide
Analyze field data
Utilize Physics of Failure capabilities
Increase LSS Green & Black Belt
Update training, manuals and requirements and integrate solutions
“… none are connected and provide a coherent description of what failed and why,…. Hence, there is no realistic, formal way to track successes, analyze failures… from past acquisition programs.” Final Report of the 2011 Army Acquisition Review
UNCLASSIFIED
UNCLASSIFIED The Nation’s Premier Laboratory for Land Forces
Shigley, Mechanical Engineering Design (2001)
Fatigue Loading in Shafts and Axles:
!!!32 = ! !!
!! + !!!!!!
!+ !!
!! +!!"!!!!
!!!
d = diameter !! = alternating moment !! = mean moment
!!= alternating torque !! = mean torque !! = yield strength ! = safety factor !! = fatigue strength reduction factor !!" = fatigue strength reduction factor for shear !! = fatigue limit !! = !!!!!!!!!!!!! !! = Surface Factor !! = ! !!"! !! = Load Factor (Bending, Torsion, …) !! = Size Factor !! = Temperature Factor !! = Miscellaneous Effects Factor
Current State: Design
UNCLASSIFIED
UNCLASSIFIED The Nation’s Premier Laboratory for Land Forces
Detect Precursors
Structural Mechanics
Micro- mechanics
Nonlinear Dynamics
Damage Sensors Repair
Open-loop Monitoring Integrated State Awareness & Control
Current State of the Art ARL
ARL: Future State of the Art
UNCLASSIFIED
UNCLASSIFIED The Nation’s Premier Laboratory for Land Forces
Approach
Project 1: Metal Alloys • Steel 1095 • Al 7075
Project 2: Composite • Glass/epoxy • IM7/8552 • IM10 Project 3: Composite Constituents • Individual IM7 • 8552 • Fiber/Matrix
Future Materials • 3-D Printed • Hybrid Alloys Select Aviation
Materials
Local Materials Characterization (e.g. SEM, AFM, EBSD, Nanoindentation)
Identify Precursors
Create State Awareness Models
Global Sensing (e.g. UT, Electrical, Optic, IR, EMI)
Detect Precursors – COTS sensors
Conventional & Multifunctional Sensors:
Performance, Sustainment & Survivability
Engineering Models
• Connect Micro to Macro-Mechanics
• Apply Nonlinear Dynamics
0
1
2
3
4
5
6
46.4 46.6 46.8 47 47.2 47.4 47.6 47.8 48
Res
pons
e (m
m)
Freq. (Hz)
Translation Base Excitation 0.3g, Ramp up 30s, Dwell 20s, 5in beam, AR=8
Test 1
Test 2
Test 3
Test 4
Test 5
Model 1
Model 2
Model 3
Model 4
Model 5
Dynamic Loading • Structural • Rotating • Tension-Tension • 3- Point Bend
Environmental Loading
• Thermal Cycling
Excite Structure – Laboratory testing
Mechanical Properties
• Tension • Bending • Shear
Control Loads
20 µm
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UNCLASSIFIED The Nation’s Premier Laboratory for Land Forces
Damage Precursor in Alloys: Identification
Research Results
E. Habtour, D. Cole, M. Robeson et al., Str Ctrl & Health Monitoring, 2016 E. Habtour, D. Cole., Int. J. of Nonlinear Mechanics, 2016
𝑚�̈� + 𝑐�̇� + 𝑘𝑦 = 𝐹 𝑚 = inertia, 𝑐 = Damping, 𝑘 = Structural stiffness Nonlinear system:
𝑚𝑒𝑓𝑓 �̈� + 𝑐�̇� + 𝑘𝑒𝑓𝑓 𝑦 + 𝑁𝑖(𝑦2�̈� + 𝑦�̇�𝟐) + 𝑁𝑔 𝑦3 = 𝐹 𝑁𝑖 = Nonlinear inertia, 𝑁𝑔 = Nonlinear stiffness, 𝐹 = Base excitation
• Detected precursors with COTS sensors • Nonlinear detection models for transverse rotational Vibration
Accomplishments
a)
b) c) After
20 µm
Fatigued Beam Free Surface
Alloy Cantilever under Harmonic Oscillation
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UNCLASSIFIED The Nation’s Premier Laboratory for Land Forces
Damage Precursor in Alloys: Verification
Research Results
Control 75K cycles 150K cycles BCC
Ferrite
Fe3C Cementite D. Cole, E. Habtour, et al., to be
submitted to Experimental Mechanics, 2016
• Changes in local micro-mechanical properties prior to crack initiation
• Confirmed precursors using novel techniques • Nano-indentation • AFM, EBSD
Accomplishments/Advancements
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UNCLASSIFIED The Nation’s Premier Laboratory for Land Forces
Damage Precursor: Global Model
Equation of motion for nonlinear system is: !!""! + 2!!!""!!! + !!""! + !!"#$ !!! + !!! + !!"#$!! = !!!!
Nonlinear inertial coefficient including tip rotary inertia is:
!!"#$ = ! !!"!"!
!
!
!"!
!+! !!"!"
!
!
!
!!!+ !!!" !!!
Effective stiffness and nonlinear geometric stiffness coefficients:
!!"" = !" !!!"!"!
! !!"#$ = 2 !" !!!!! !!"
!
!
!! =1+ 3!
!
4!!"#$!!""
1+ !!
2!!"#$!!""
Equation of motion for linear system is: !!""! + 2!!!""!!! + !!""! = !!!!
E. Habtour, et al., to be submitted to Mech Sys & Sig Pro, 2016
UNCLASSIFIED
UNCLASSIFIED The Nation’s Premier Laboratory for Land Forces
Damage Precursor: Micromechanics Model
ρ∂2ui∂t2
=∂2uk∂x j∂xl
Cijkl +∂um∂xn
Cijklmn +δkmCijnl +δikC jlmn +δimC jknl( )⎡
⎣⎢
⎤
⎦⎥
Quadratic Nonlinearity Term
u a( ) = u1 cos ka−ωt( )−u2 sin 2 ka−ωt( )+ ...
where ( )222 1
8a ku uβ= →
β ≡ Quadratic Nonlinearity Parameter
( )22
1
8ua ku
β =
Second-harmonic amplitude gives an experimental parameter
measured lattice damageβ β β+=
C. Kube and J. Turner, J. Acoust. Soc. Am., 2015
C. Kube and J. Turner, J. of Elasticity, 2015
Damage Quantification from Harmonic Generation
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UNCLASSIFIED The Nation’s Premier Laboratory for Land Forces
Damage Precursor: bridging the scales
Example of 3-Dimensional Distribution of Material Nonlinearity for Titanium Single Crystals
• Nonlinearity is directionally dependent • Nonlinear response depends on dilational or shear wave displacement
UNCLASSIFIED
UNCLASSIFIED The Nation’s Premier Laboratory for Land Forces
C. Kube and J. Turner, J. Acoust. Soc. Am., 2015
C. Kube and J. Turner, J. of Elasticity, 2015
Effective elastic moduli needed to define requires averaging over all orientations of the grains
β
( )2 1
0 1
1 , d d4ijkl ijklC Cw
πχ φ χ φ
π −〈 〉 = ∫ ∫
( )2 1
0 1
1 , d d4ijklmn ijklmnC Cw
πχ φ χ φ
π −〈 〉 = ∫ ∫
( )0 ˆ ˆ ˆ ˆ ˆ ˆˆ ˆ ˆ ˆ
ijklmn ijnl jlmn jkm ik im j l n i k m
j l i
knl
j ki kl
n n n u uC C un n u
C CC u
δ δ δβ
〈 〉 + + +〈 〉 〈 〉 〈 〉
〈 〉= −
2z 3z4z
5z
4x
5x
2x
3x1z
1x 1y
4y 5y
2y
3y1z
1x 1y
Single Grain Elastic Modulus
Aggregate Elastic Modulus
ijklC
〈Cijkl 〉
Damage Precursor: bridging the scales
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UNCLASSIFIED The Nation’s Premier Laboratory for Land Forces
Characterizing: Induce Damage Precursors in Composites
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 13
3.5
4
4.5
5
5.5
6x 10-5
N/Nf
com
plia
nce,
s
Bulk Composite – Compliance Effect Measured during 3-pt Bend Test
Microtensile Testing for Individual Microfibers
0
1000
2000
3000
4000
5000
6000
0.0
0.5
1.0
1.5
2.0
2.5
3.0
50 100 150 200
Failu
re S
tress
, MPa
Failu
re S
train
, %
Failure Displacement, µm
28 mm
12.5
mm
gage lengthadhesivefiber
gripped region
load(m
m/N
)
Elastic Modulus Map Conductivity Map
UNCLASSIFIED
UNCLASSIFIED The Nation’s Premier Laboratory for Land Forces Habtour, et al. Shock and Vibration (In Preparation)
Damage Precursor: Nonlinearity vs. Control
!!""! + 2!!!""!!! + !!"" − !!!!!! − ℎ!!!! ! + !!"#Ω!!!!+!!"#$ !!! + !!! + !!"#$ − ℎ!!!! !! = !!Ω! + !!!!
E. Habtour, et al., to be submitted to Mech Sys & Sig Pro, 2016
UNCLASSIFIED
UNCLASSIFIED The Nation’s Premier Laboratory for Land Forces
Sense Evolution: • Ultrasonics • Electric Impedance • Thermocouple • Accelerometer • Fiber optic
Material Evolution: • Fibril stiffness • Cavitation • Deformation/Stress • Debonding • Compliance • Micro-structure
Sense Precursors
Precursors Models (MRC)
Uncertainty Quantification
(ISC/CSC)
Provide Current State
Adapt Control
• Reduce damaging flight loads
• Maintain Capabilities • Optimize • Relearn
Sensor/Data Fusion
Operational Loads
Risk Assessment (ISC/CSC)
RUL Models (ISC/CSC)
Survivability Models
(ISC/CSC)
Forecast Future State
Material Degradation
Sensor Data
Current State
Projected Capabilities
Proposed Solution
Propeller System: • Propellers • Bearings • Controllers
Materials System:
• Composite • Alloys
State Information
Integrated State-Awareness & Control
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UNCLASSIFIED The Nation’s Premier Laboratory for Land Forces
Update Health State
Micromechanics and Structural Testing Facilities
Adaptive Controls
ARL Computational Facilities
Reliability & State Awareness Facilities
Integrated State-Awareness & Control
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UNCLASSIFIED The Nation’s Premier Laboratory for Land Forces
Transonic Experimental Facility
Rodman Materials Research Laboratory
Rotorcraft Survivability Assessment Facility
Pulse Power Facility
Access to Partner Facilities
Zahl Physical Sciences Laboratory Shooter Performance Facility
DSRC & Scientific Visualization Facility
Robotics Research Facility
Vertical Impulse Measurement
Facility
Environment for Auditory Research
Fuel Reformation Laboratory
Novel Energetics Research Facility
Electromagnetic Vulnerability Assessment
Facility
Microsystem Indoor Testing Grounds
Specialty Electronic Materials and Sensors Cleanroom
Vehicle Research Laboratory
ARL Technical Infrastructure
Academia Industry
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UNCLASSIFIED The Nation’s Premier Laboratory for Land Forces
C. Kube and J. Turner, J. of Aco Soc of Am, 2015 C. Kube and J. Turner, J. of Elasticity, 2015 D. Cole, E. Habtour, et al., ASME SMASIS, Colorado Springs, CO, Sept 21-23, 2015 E. Habtour, D. Cole, M. Robeson et al., Structural Control & Health Monitoring, 2016 E. Habtour, D. Cole., Int. J. of Nonlinear Mech, 2016 D. Cole, E. Habtour, et al., to be submitted to Exp Mech, 2016 E. Habtour, et al., to be submitted to Mech Sys & Sig Pro, 2016 Additional References: FY2016 Army Budget Overview, Deputy Assistant Secretary of the Army (DASA) for Budget , 2015 Bureau of Labor Statistics, U.S. Department of Labor, Occupational Outlook Handbook, 2014-15 Edition, Military Career Shigley, Mechanical Engineering Design (2001)
Publications
E. Habtour, et al., to be submitted to Mech Sys & Sig Pro, 2016
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UNCLASSIFIED The Nation’s Premier Laboratory for Land Forces
US Army Research Laboratory: • Nano- & Micromechanics Characterization: Dr. Daniel Cole, [email protected] • Composites DP Detection: Dr. Robert Haynes, [email protected] • Composites Micromechanics Modeling: Dr. Todd Henry: [email protected] • NDE & Materials Constituents Modeling: Dr. Christopher Kube, [email protected] • SHM-Based Adaptive Controls: Mr. Brent Mills, [email protected] • System Identification & Fault Detection: Dr. Ed Habtour: [email protected] Collaborators: US Army Aviation and Missile Research, Development, and Engineering Center: Aviation Structures Durability: Mark Robeson, [email protected]
Center for Advanced Life Cycle Engineering, University of Maryland: Experimental and Computation Mechanics: Dr. Abhijit Dasgupta, [email protected]
Damage Precursor: Efforts Leads