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“ ABL Smart Piping System for Containment and Control of Highly Corrosive and Hazardous Chemicals ” SBIR Phase II Contract: HQ0006-05-C-7254 Status Meeting 1 May, 2006 Air Force Program Manager Brandon Arritt, AFRL/VSSV Odyssian Technology Barton Bennett Paul Ditsler Ben Smith.

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  1. “ABL Smart Piping System for Containment and Control of Highly Corrosive and Hazardous Chemicals ”SBIR Phase II Contract: HQ0006-05-C-7254Status Meeting1 May, 2006Air Force Program ManagerBrandon Arritt, AFRL/VSSVOdyssian TechnologyBarton BennettPaul DitslerBen Smith DISCLAIMER STATEMENT The views, opinions, and findings contained in this report are those of the author(s) and should not be construed as an official Department of Defense position, policy, or decision. DISTRIBUTION SBIR Data Rights. Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.

  2. HQ0006-05-C-7254 ODYSSIANTECHNOLOGY AGENDA • Overview • Recent Program Accomplishments • Design and Analysis • Sensor Development and Evaluation • Process Development • Plans for Next Quarter • Open Technical Discussion • AF/MDA Related Work • Closing Session • Financial Overview • Related Federal Appropriation Request • Lab Tour – Overview of Other Technology

  3. ODYSSIANTECHNOLOGY Smart Piping Systems Integrated Leak Detection Sensors e-Board Multifunctional Thin Film Igniters Deposition of Conductive Material Sporting Goods Multifunctional Structure Small UAV Multifunctional Structure

  4. HQ0006-05-C-7254 ODYSSIANTECHNOLOGY Program Status Overview Recent Accomplishments • Smart Pipe Designs • Flanged Fitting • Compression Fitting • Integrated Sensor Circuitry • Sensor Research and Development (non-SBIR funded) • Pressure Sensor • Process Development • Straight and Curved Composite Dual Wall Pipe • Electrical Tracings Proprietary or Confidential Data Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.

  5. ODYSSIANTECHNOLOGY CY2005 CY2006 CY2007 Q1 Q2 Q3 Q1 Q2 Q3 Q4 Q4 TASKS Aug 2 –Nov 1 Nov 2 –Feb 1 Feb 2 –May 1 May 2 –Aug 1 Aug 2 –Nov 1 Nov 2 –Feb 1 Feb 2 –May 1 May 2 –Aug 1 Rqts & Criteria Definition – Task I – Task II Sensor & Controls Dev Design & Modeling – Task III – Process Dev. and Fabr Task IV Task V – Testing, Evaluation Task VI – Program Mgt. & Reporting Kick-off Mtg @ MDA Mtg @ Odyssian Mtg @ Odyssian Mtg @ MDA > < May 1, 2006

  6. ODYSSIANTECHNOLOGY Phase II Team • Odyssian Technology Contribution: Overall program responsibility. System design, development, fabrication, and evaluation. • Boeing ABL and Phantom Works Contribution: Requirements and criteria definition and general program oversight. • Dr. Lieberman (University of Notre Dame) Contribution: Consultation and research on chemical sensors and chemical exposure testing. Facilities and experience for handling hazardous chemicals. • Dr. Corona (University of Notre Dame) Contribution: Structural analysis modeling and mechanical testing of smart piping system. Facilities for mechanical testing. • Dr. Lee (Purdue University) Contribution: Chemical sensor testing. Facilities and experience for handling hazardous chemicals. Proprietary or Confidential Data Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.

  7. HQ0006-05-C-7254 ODYSSIANTECHNOLOGY AGENDA • Overview • Recent Program Accomplishments • Design and Analysis • Sensor Development and Evaluation • Process Development • Plans for Next Quarter • Open Technical Discussion • AF/MDA Related Work • Closing Session • Financial Overview • Related Federal Appropriation Request • Lab Tour – Overview of Other Technology

  8. HQ0006-05-C-7254 Positive Electrical Pin (for shown circuit) Positive Electrical Pin (for circuit on other side of seal) Copper foil conductor Secondary O-ring Primary O-ring Chlorine Sensor (Tin Fuse) Common Ground ODYSSIANTECHNOLOGY ABL SMART PIPING SYSTEM Task III: Design and Modeling Threaded Pipe Design Proprietary or Confidential Data Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.

  9. HQ0006-05-C-7254 ODYSSIANTECHNOLOGY ABL SMART PIPING SYSTEM Task III: Design and Modeling Flanged Pipe Design Proprietary or Confidential Data Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.

  10. HQ0006-05-C-7254 ODYSSIANTECHNOLOGY ABL SMART PIPING SYSTEM Task III: Designand Modeling Proprietary or Confidential Data Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.

  11. HQ0006-05-C-7254 ODYSSIANTECHNOLOGY ABL SMART PIPING SYSTEM Task III: Designand Modeling Proprietary or Confidential Data Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.

  12. Flange Design Based on ANSI B16.5 Standard Estimated 50% Weight Savings Over Hastelloy Baseline Smart Pipe Design Made of Aluminum with PVDF Insert HQ0006-05-C-7254 ODYSSIANTECHNOLOGY ABL SMART PIPING SYSTEM Task III: Designand Modeling Baseline Smart Pipe Design Proprietary or Confidential Data Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.

  13. Curved Pipe Braided or Wound Mates to other Smart Pipe Fittings Lighter Weight than Elbow Joints HQ0006-05-C-7254 ODYSSIANTECHNOLOGY ABL SMART PIPING SYSTEM Task III: Designand Modeling Proprietary or Confidential Data Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.

  14. HQ0006-05-C-7254 ODYSSIANTECHNOLOGY ABL SMART PIPING SYSTEM Task III: Design and Modeling Proprietary or Confidential Data Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.

  15. Smart Collar Usable on pre-existing piping systems Large array of commercial uses Developed under 21st Century Fund cost match HQ0006-05-C-7254 ODYSSIANTECHNOLOGY ABL SMART PIPING SYSTEM Task III: Designand Modeling Proprietary or Confidential Data Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.

  16. Tubing Materials Composite Material System, Toray T700G 12K / #2510 Unidirectional Carbon/Epoxy Prepreg Toughened Matrix / Intermediate Modulus Fiber Boeing Certified 250F Degree Oven Cure Toray T800HB / Cytec CYCOM 823 VaRTM Material System 12K Intermediate Modulus Fiber 250 Degree Cure VaRTM Resin Room Temperature Injection Chemical Resistant Liners (to be explored), PVDF Sleeve – Straight Pipe FEP or PVDF Heat Shrink – Curved Pipe HQ0006-05-C-7254 ODYSSIANTECHNOLOGY ABL SMART PIPING SYSTEM Task III: Design and Modeling Proprietary or Confidential Data Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.

  17. Flanged Fitting Materials Aluminum 6061 T6 Bolted Region PVDF Insert Bonded Region Bolts Carbon Steel, ANSI Standard Flared Fitting Materials Hasteloy C276 (Chlorine) Inconel 625 or Stainless Steel 316L (BHP) Seal Materials PVDF body with Viton O-rings (Threaded and Flanged) SAE AS1098 teflon ring seal (flared) To be explored Copper Tracing / Gold Plated Electrical Contacts HQ0006-05-C-7254 ODYSSIANTECHNOLOGY Proprietary or Confidential Data Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.

  18. FEA Analysis NEi/Nastran Complex Models Created Multiple Loading/Boundary Conditions Considered Verified Correlation between FEA Models and Classical Hand Analysis HQ0006-05-C-7254 ODYSSIANTECHNOLOGY ABL SMART PIPING SYSTEM Task III: Designand Modeling Proprietary or Confidential Data Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.

  19. HQ0006-05-C-7254 ODYSSIANTECHNOLOGY AGENDA • Overview • Recent Program Accomplishments • Design and Analysis • Sensor Development and Evaluation • Process Development • Plans for Next Quarter • Open Technical Discussion • AF/MDA Related Work • Closing Session • Financial Overview • Related Federal Appropriation Request • Lab Tour – Overview of Other Technology

  20. Ultra Wide Band (UWB) Newer Technology Low Power Consumption Rate Zigbee Mature Technology On-Off Keyed (OOK) Very low power Sensor networking Simple Signals Development Kits and Chipsets Identified HQ0006-05-C-7254 ODYSSIANTECHNOLOGY ABL SMART PIPING SYSTEM Task II: Sensors and Controls Proprietary or Confidential Data Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.

  21. Features Small size 300 psi operating range 1500 psi burst Must be mounted and encapsulated Suppliers / Cost Silicon Microstructures, Memstech $5 each (bare die) 500 piece minimum purchase HQ0006-05-C-7254 ODYSSIANTECHNOLOGY ABL SMART PIPING SYSTEM MEMS Pressure Sensors Proprietary or Confidential Data Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.

  22. Features Small size 500 psi operating range 1000 psi burst -40o F to 250o F operating temp Mounting and packaging options Supplier / Cost Measurement Specialties (Entran) $475 each Custom features at additional cost HQ0006-05-C-7254 ODYSSIANTECHNOLOGY ABL SMART PIPING SYSTEM Sub-Miniature Pressure Transducers Proprietary or Confidential Data Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.

  23. Activates at 75 psi 2-3 cycles before failure Simple design and materials HQ0006-05-C-7254 ODYSSIANTECHNOLOGY ABL SMART PIPING SYSTEM Prototype Pressure Transducers Diaphragm Concept Spring Contact Concept • Activates at 30 psi • Unknown failure • Simple design and materials Proprietary or Confidential Data Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.

  24. Activates at 40 psi 3 cycles before failure May be susceptible to vibration HQ0006-05-C-7254 ODYSSIANTECHNOLOGY ABL SMART PIPING SYSTEM Prototype Pressure Transducers Developed under non-SBIR Funds Proprietary or Confidential Data Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.

  25. Activates at 35 psi 6-8 cycles before failure Eliminates failure due to vibration Eliminates fatigue of spring conductor HQ0006-05-C-7254 ODYSSIANTECHNOLOGY ABL SMART PIPING SYSTEM Prototype Pressure Transducers Developed Under non-SBIR Funds Proprietary or Confidential Data Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.

  26. HQ0006-05-C-7254 ODYSSIANTECHNOLOGY ABL SMART PIPING SYSTEM Pressure Vessel Used for Testing Pressure Sensors Proprietary or Confidential Data Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.

  27. HQ0006-05-C-7254 ODYSSIANTECHNOLOGY AGENDA • Overview • Recent Program Accomplishments • Design and Analysis • Sensor Development and Evaluation • Process Development • Plans for Next Quarter • Open Technical Discussion • AF/MDA Related Work • Closing Session • Financial Overview • Related Federal Appropriation Request • Lab Tour – Overview of Other Technology

  28. Table Rolling Oven Curing Inexpensive, Re-usable Tooling High Quality Parts Compaction Pressure from Heat Shrink HQ0006-05-C-7254 ODYSSIANTECHNOLOGY ABL SMART PIPING SYSTEM Task IV: Process and Fabrication Proprietary or Confidential Data Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.

  29. HQ0006-05-C-7254 ODYSSIANTECHNOLOGY ABL SMART PIPING SYSTEM Table Rolling Process Proprietary or Confidential Data Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.

  30. Bias plies increase waste and production cost FEA analysis indicates that bias plies are unnecessary 20% Weight savings HQ0006-05-C-7254 ODYSSIANTECHNOLOGY ABL SMART PIPING SYSTEM Task IV: Process and Fabrication No Bias Plies Bias Plies Proprietary or Confidential Data Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.

  31. HQ0006-05-C-7254 ODYSSIANTECHNOLOGY ABL SMART PIPING SYSTEM Wash-out Mandrel For Use in Fabricating Curved Pipe Proprietary or Confidential Data Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.

  32. HQ0006-05-C-7254 ODYSSIANTECHNOLOGY ABL SMART PIPING SYSTEM Curved Pipe Process Proprietary or Confidential Data Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.

  33. Flat Flexible Cable Expensive Crimped Terminations Easily installed Conductive Polymer Silver Filled Expensive Can be Printed Flexible Pattern Could be Copper Electroplated Must be Insulated from Pipe Copper Foil Solderable Must be Insulated from Pipe High conductivity HQ0006-05-C-7254 ODYSSIANTECHNOLOGY ABL SMART PIPING SYSTEM Task IV: Process and Fabrication Proprietary or Confidential Data Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.

  34. HQ0006-05-C-7254 ODYSSIANTECHNOLOGY AGENDA • Overview • Recent Program Accomplishments • Design and Analysis • Sensor Development and Evaluation • Process Development • Plans for Next Quarter • Open Technical Discussion • AF/MDA Related Work • Closing Session • Financial Overview • Related Federal Appropriation Request • Lab Tour – Overview of Other Technology

  35. HQ0006-05-C-7254 ODYSSIANTECHNOLOGY ABL SMART PIPING SYSTEM Plans for Next Quarter • Achieve Better Definition of Current ABL Piping • Flange Design • Seal Design • Cost • Complete Design and Analysis (Task III) • Pipe, fitting, seals • Phase II Demo • Continue Sensor Development • Determine Feasibility of COTS Sensors • MEMS • Subminiature Transducers • Develop BHP Reactive Sensor Concepts • Develop Additional Pressure Sensor Concepts • Conduct Chemical Compatibility Testing • Complete Process Dev/Eval of Curved Pipe • Braided VaRTM Curved Pipe • Wound Prepreg Curved Pipe • Develop initial sensor circuit design Proprietary or Confidential Data Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.

  36. HQ0006-05-C-7254 ODYSSIANTECHNOLOGY AGENDA • Overview • Recent Program Accomplishments • Design and Analysis • Sensor Development and Evaluation • Process Development • Plans for Next Quarter • Open Technical Discussion • AF/MDA Related Work • Closing Session • Financial Overview • Related Federal Appropriation Request • Lab Tour – Overview of Other Technology

  37. Input from Shery Welsh 3-17-2006 (Current ABL Pipe, Flange and Seal Design Details) Clarification on requirements (geometry); ¼” to 1” flared, 1.25”-12” flanged AF SPO Approval for ABL Specifications Lightweight NASA Flange Designs SAE Seal Ring AS1098 Female Boss Fitting Design Requirements Definition Purchase of Test Equipment in Lieu of Boeing Subcontract Testing Purchase of Test Equipment in Lieu of ND Testing Add Braided and Wound Pipe Vibration Pressure Burst Increased Strain Requirement 0.41% vs 0.15% Composite allowable strain 2% Curve Shape Definition Use of Pre-shaped Pipe Segments? On-site Bending? Flexible Tooling Needed? Phase II Demonstration More Straight Piping Circulation/pressurized Meeting Setup with U of I HQ0006-05-C-7254 ODYSSIANTECHNOLOGY Issues / Discussion Topics Proprietary or Confidential Data Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.

  38. Phase II Test Matrix Proprietary or Confidential Data Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.

  39. HQ0006-05-C-7254 ODYSSIANTECHNOLOGY AGENDA • Overview • Recent Program Accomplishments • Design and Analysis • Sensor Development and Evaluation • Process Development • Open Technical Discussion • AF/MDA Related Work • Closing Session • Financial Overview • Related Federal Appropriation Request • Lab Tour – Overview of Other Technology

  40. HQ0006-05-C-7254 ODYSSIANTECHNOLOGY

  41. Backup Slides

  42. HQ0006-05-C-7254 Phase II Piping Requirements • Geometry, • Type A Pipe • inside tube diameter, 1.00 to 1.25 inches (chlorine only) • fitting, bolted flange joint. • Lengths range from 6 to 110 inches long for 1.0” diameter and 30 to 110 inches for 1.25” diameter. • Type B Pipe • inside tube diameter, .75 inches • fitting, Threaded compression fitting • Lengths range from 6 to 110 inches long for 1.0” diameter and 30 to 110 inches for 1.25” diameter. • Temperature, • operating, 40F to 80F • survival, -65F to 160F • Dynamic, • acceleration, 9g in all 3 axis, followed by leak test at MEOP • vibration, 3-axis random vibration, 0.04g2/Hz, 6.1grms, duration 90 minutes each axis, analysis requires an uncertainty factor of four (4). • Operating Force Loads, (chlorine only) • Type A • axial, 628-982 lbs. (P x A x 2) • torsion, 60 in-lbs. (5 ft-lbs) • pressure, 400 psia (MEOP) • Type B • axial, 353 lbs. (P x A x 2) • torsion, 60 in-lbs. (5 ft-lbs) • pressure, 400 psia (MEOP) Proprietary or Confidential Data Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.

  43. HQ0006-05-C-7254 Phase II Piping Requirements(continued) • Design Ultimate Loads (static), (chlorine only) • Type A • axial, 1570 - 2,450lbs. (P x A x 2) • torsion, 90 in-lbs. (7.5 ft-lbs) • pressure, 1000 psia • abuse, 500 lbs over 4 inch footprint • Type B • axial, 663 lbs. (P x A x 2) • torsion, 90 in-lbs. (7.5 ft-lbs) • pressure, 1000 psia • abuse, 500 lbs over 4 inch footprint • Impact damage degradation, 100 ft-lbs using a 1.0 inch diameter tip (must be able to operate under burst pressure after impact) • Leak detection sensitivity, 3 PPM max • Duty cycles up to MEOP, 2,000 cycles • Strain of 0.41% • Design per MIL-STD-1522A • Includes: design burst pressure of 2.5 times MEOP • Includes: proof test pressure of 1.5 times MEOP • 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 MEOP – Maximum estimated operating pressure Proprietary or Confidential Data Disseminate IAW DODD 5230.24, DODD 5230.25. Distr. Authorized to U.S. Government Agencies Only. Export is restricted.

  44. Phase II SBIR Program

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