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Damage precursor detection to outsmarting fatigue
- 1. UNCLASSIFIED UNCLASSIFIED The Nation’s Premier Laboratory for Land ForcesUNCLASSIFIED 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 ed.m.habtour.civ@mail.mil
- 2. 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
- 3. 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
- 4. UNCLASSIFIED UNCLASSIFIED The Nation’s Premier Laboratory for Land Forces Current State: Data Collection Materiel Instrumentation Data Collection Systemic Issues Root Causes Mi1ga1ng Correc1ve Measures 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
- 5. 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
- 6. 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
- 7. 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 Response(mm) 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
- 8. UNCLASSIFIED 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 𝑚𝑦̈ + 𝑐𝑦̇ + 𝑘𝑦 = 𝐹 𝑚 = inertia, 𝑐 = Damping, 𝑘 = Structural stiffness Nonlinear system: 𝑚 𝑒𝑓𝑓 𝑦̈ + 𝑐𝑦̇ + 𝑘 𝑒𝑓𝑓 𝑦 + 𝑁𝑖(𝑦2 𝑦̈ + 𝑦𝑦̇ 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
- 9. UNCLASSIFIED 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
- 10. UNCLASSIFIED 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
- 11. UNCLASSIFIED UNCLASSIFIED The Nation’s Premier Laboratory for Land Forces Damage Precursor: Micromechanics Model ρ ∂2 ui ∂t2 = ∂2 uk ∂xj ∂xl Cijkl + ∂um ∂xn Cijklmn +δkm Cijnl +δik Cjlmn +δim Cjknl( ) ⎡ ⎣ ⎢ ⎤ ⎦ ⎥ Quadratic Nonlinearity Term u a( )= u1 cos ka −ωt( )−u2 sin2 ka −ωt( )+... where ( ) 22 2 1 8 a ku uβ= → β ≡ Quadratic Nonlinearity Parameter ( ) 2 2 1 8u a ku β = Second-harmonic amplitude gives an experimental parameter measured lattice damage β 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
- 12. UNCLASSIFIED 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
- 13. 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 d 4 ijkl ijklC Cw π χ φ χ φ π − 〈 〉 = ∫ ∫ ( ) 2 1 0 1 1 , d d 4 ijklmn ijklmnC Cw π χ φ χ φ π − 〈 〉 = ∫ ∫ ( )0 ˆ ˆ ˆ ˆ ˆ ˆ ˆ 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 u n n u C C C u δ δ δ β 〈 〉 + + +〈 〉 〈 〉 〈 〉 〈 〉 = − 2z 3z 4z 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
- 14. UNCLASSIFIED 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 1 3 3.5 4 4.5 5 5.5 6 x 10 -5 N/Nf compliance,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 FailureStress,MPa FailureStrain,% Failure Displacement, µm 28 mm 12.5mm gage length adhesivefiber gripped region load (mm/N) Elastic Modulus Map Conductivity Map
- 15. 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
- 16. 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
- 17. UNCLASSIFIED 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
- 18. UNCLASSIFIED 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
- 19. UNCLASSIFIED 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
- 20. UNCLASSIFIED UNCLASSIFIED The Nation’s Premier Laboratory for Land Forces US Army Research Laboratory: • Nano- & Micromechanics Characterization: Dr. Daniel Cole, daniel.p.cole.civ@mail.mil • Composites DP Detection: Dr. Robert Haynes, robert.a.haynes43.civ@mail.mil • Composites Micromechanics Modeling: Dr. Todd Henry: todd.c.henry2.civ@mail.mil • NDE & Materials Constituents Modeling: Dr. Christopher Kube, christopher.m.kube.ctr@mail.mil • SHM-Based Adaptive Controls: Mr. Brent Mills, brent.t.mills.civ@mail.mil • System Identification & Fault Detection: Dr. Ed Habtour: ed.m.habtour.civ@mail.mil Collaborators: US Army Aviation and Missile Research, Development, and Engineering Center: Aviation Structures Durability: Mark Robeson, mark.e.robeson.civ@mail.mil Center for Advanced Life Cycle Engineering, University of Maryland: Experimental and Computation Mechanics: Dr. Abhijit Dasgupta, dasgupta@umd.edu Damage Precursor: Efforts Leads