N04-256
TITLE: Wireless Sensors with Advanced Detection and Prognostic Capabilities for
Corrosion Health Management
TECHNOLOGY AREAS: Air Platform
ACQUISITION PROGRAM: Joint Strike Fighter
OBJECTIVE: Develop, integrate, and demonstrate wireless corrosion sensors and algorithms capable of
detecting, monitoring, and predicting the corrosion health (damage) of aircraft.
DESCRIPTION: The JSF Corrosion and Control Plan seeks to minimize life-cycle costs due to
environmental degradation, including deterioration of nonmetallic materials as well as corrosion of metals.
The development and demonstration of the latest wireless and sensing technology and smart systems for
corrosion detection and prediction will support the effective implementation of structural prognostics and
health monitoring (SPHM) and the autonomic logistic information system (ALIS) within the JSF. The
capability of thin-film devices to measure in-situ galvanic activity has been demonstrated. This SBIR
primarily addresses the need to develop a robust and affordable wireless version of similar capability. The
next step is to develop appropriate algorithms and models to relate the galvanic activity to the actual in-situ
corrosion damage.
PHASE I: Develop and report on an overall strategy to develop wireless corrosion sensors and algorithms
or smart systems for corrosion detection and prediction. Determine the feasibility of the proposed
technology to detect and measure corrosion.
PHASE II: Develop and demonstrate a prototype of the preferred wireless sensor system, both hardware
and software, for an agreed aircraft component/subsystem. Develop and validate processes, algorithms,
and models to relate measured corrosion activity to in-situ corrosion damage.
PHASE III: Finalize the development of the wireless sensor system with a major aircraft and/or engine
manufacturer.
PRIVATE SECTOR COMMERCIAL POTENTIAL: Corrosion is a major life-cycle cost to both military
and commercial aircraft fleets and so the successful development of a lightweight, durable, and affordable
wireless corrosion sensor capable of monitoring, detecting, and predicting corrosion damage, particularly in
hard to inspect or hidden areas, would have huge commercial potential and payback.
REFERENCES:
1. MIL-HDBK-1568, Material and Processes for Corrosion Prevention and Control in Aerospace Weapons
Systems, dated 18 July 1996.
2. Henley, S., Currer, R., Sheuren, B., Hess, A., and Goodman, G. “Autonomic Logistics—The Support
Concept for the 21st Century.” IEEE Proceedings, Track 11, paper zf11_0701.
3. Byer, B., Hess, A., and Fila, L. “Writing a Convincing Cost Benefit Analysis to Substantiate Autonomic
Logistics.” Aerospace Conference 2001, IEEE Proceedings, Vol. 6, pp. 3095-3103.
4.
SAE
E-32
Committee
http://forums.sae.org/access/dispatch.cgi/TEAE32_pf/showFolder/100001/
def/def/3f4f
Documents.
5. IEEE Aerospace Conference Proceedings for 2001 and 2002 Track 11 PHM.
KEYWORDS: Condition Based Maintenance; Corrosion, Wireless Sensors; Prognostics; Health
Management; Logistics