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Theme of IWSHM 2017:
Real-Time Material State Awareness and Data-Driven Safety Assurance
AFOSR Basic Research Spotlight
8:10 am - 8:40 am, September 12th, Hewlett Auditorium (Hewlett 200)
The Air Force Office of Scientific Research (AFOSR), is the organization responsible for discovering, shaping, and championing basic science, and furthering the frontiers of scientific knowledge and technology that profoundly impacts the future Air Force (AF). In a broad sense, AFOSR, in its motto “excellence in science and transformative capabilities for the AF”, accomplishes this mission by identifying the best fundamental research that and has relevance to the DoD and the AF, through funding and appropriate oversee of the research work conducted in universities, industry and government laboratories in the US and around the world, actively maintaining strong, productive alliances with such institutions to bring newly created scientific understanding and technology options from the scientific community and generate tremendous payoffs for the nation’s defense. For over sixty years, the accomplishments of AFOSR, ranging across a wide spectrum of sciences and technologies, have led to the creation of revolutionary new capabilities for the Air Force and significant discoveries for the benefit of mankind. This presentation will overview programmatic activities supporting basic research enabling science and technology advances, as well as STEM education and workforce creation.
Health Management: A Long View
8:40 am - 9:10 am, September 12th, Hewlett Auditorium (Hewlett 200)
Boeing Digital Aviation
John Maggiore leads the Maintenance and Leasing Solutions organization within Boeing Digital Aviation. Boeing Maintenance and Leasing Solutions provide a broad portfolio of information and analytics-powered capabilities to the aviation industry. These solutions are used in both daily operations and long-term planning by hundreds of airlines, lessors and MROs around the world to help customers save money, improve efficiency and minimize disruptions. His keynote address will examine the journey of aircraft health management as a discipline, and its impacts and promise.
Advancements on the Adoption of SHM Damage Detection Technologies into Embraer Aircraft Maintenance Procedures
9:10 am - 9:40 am, September 12th, Hewlett Auditorium (Hewlett 200)
Embraer - São José dos Campos
Structural Health Monitoring has the potential to revolutionize aircraft maintenance. Less complex and less time-consuming procedures – when compared to current non-destructive inspection (NDI) technologies – allowed by SHM can reduce the amount of time and burden of the inspection tasks and, consequently, reduce costs. Over the years Embraer has investigated different SHM technologies, and two of them were selected for a more in-depth investigation. After demonstrating strong results on ground tests and in an Embraer-190 flight test aircraft, Comparative Vacuum Monitoring (CVM) and Lamb Waves (LW) technologies were included in an effort to move SHM, in particular the concept of Scheduled Structural Health Monitoring (S-SHM), into routine use for aircraft maintenance procedures. Embraer teamed with the Airworthiness Assurance NDI Validation Center (AANC) at Sandia Labs and Azul Airlines in a joint effort with the Brazilian Civil Aviation Agency (ANAC) for the qualification of SHM technologies and to validate the performance of such systems in real-life operational environment. The work aimed to develop and carry out a qualification process for SHM damage detection systems, which includes laboratory tests for the assessment of detection capabilities in terms of Probability of Detection (POD) and tests with systems installed on a number of aircraft from Azul Airlines.
Structural Health Monitoring for Bridge Safety and Management
8:00 am - 8:30 am, September 13th, Hewlett Auditorium (Hewlett 200)
New York State Department of Transportation (NYSDOT)
Bridge infrastructure condition has been a hot topic of discussion due to increasing average age of bridges, many bridges nearing their design life, and lack of needed investments. This coupled with growing demands and changes in customer expectations, the role of the owner is a challenging endeavor. Structural health monitoring and nondestructive testing are being increasingly advocated to complement or replace the visual inspection of bridges and to assist in bridge management. This presentation will discuss structural health monitoring and its components, its current use in bridge management applications, and future trends.
Ultrasonics, Corrosion and SHM - The Story of Permasense Ltd
8:30 am - 9:00 am, September 13th, Hewlett Auditorium (Hewlett 200)
UK Research Centre in NDE, Imperial College London
The oil and gas sector produces fuels that meet more than 50% of the world’s energy demand. It handles unrefined fluids that come straight from a reservoir deep in the earth’s crust. The crude oil often is an unpredictable cocktail that constantly corrodes and erodes the plants that have been built to refine it.
While corrosion costs the world about 3% of GDP/annum, the oil and gas sector proportionally spends much more to guarantee integrity of its assets. Unexpected shut downs cost millions of dollars per day in lost production alone, however catastrophic failures can be even more costly.
Historically, to mitigate the risk of failures, refineries carry out wall thickness surveys at regular intervals by performing manual spot check ultrasonic thickness measurements. These infrequent measurements had poor repeatability.
Our research at Imperial College London resulted in the development of the first wireless, permanently installable ultrasonic thickness gauge, delivering precise on demand measurements. The spin-off company Permasense Ltd was formed to develop and commercialise the technology with the aim to make a complete SHM system available to industry. To date the company has supplied more than 15000 sensors to the O&G industry and more than 15 million wall thickness measurements have been made. In 2016 Permasense Ltd was acquired by Emerson, a multi-national corporation. This talk will describe how the system works and challenges we encountered when bringing the technology from the lab to the field. Finally, we will reflect on general lessons that can be learned from the process.
Materials Star in FHE Solutions for Structural Health Monitoring
9:00 am - 9:30 am, September 13th, Hewlett Auditorium (Hewlett 200)
Flexible Hybrid Electronics manufacturing techniques have advanced to allow for system level integration of cost effective, light-weight and scalable sensor systems that have the ability to combine multiple sensor data streams into a single MCU. NextFlex has, through efforts in its own labs as well as a series of funded projects, advanced these techniques to produce devices for market readiness, including: strain; temperature; moisture; vibration; chemical, and other sensing platforms. The speaker will identify a series of application areas still to be enabled by new manufacturing methods and what is needed to bring these products to market. He will highlight needs for data collection on manufacturing materials to be made available in a database for modelling and simulation of FHE systems, and new manufacturing developments for distributed sensor systems that provide form factor and cost advantages over previous approaches. The speaker will outline findings from several projects conducted at NextFlex related to mechanical failure modes and environmental degradation that impact interconnects and system functionality, and will provide a forward-looking view of the work NextFlex and the FHE community must do to move technology forward in devices for structural health monitoring.
SHM Challenges for Fixed-wing Military Aviation: Thoughts on Future AFRL R&D Projects
8:30 am - 9:00 am, September 14th, Hewlett Auditorium (Hewlett 200)
Air Force Research Laboratory
The US Air Force (USAF) and US Department of Defense has a long history of research and development in the exploration of on-board sensors being used for detection of damage in aircraft structures. Initial activities can be traced to the early 1980’s which led to an extensive on-aircraft assessment of acoustic emission based (i.e. “passive) sensor system. In the late 1990’s an effort was launched to revitalize the capability which cumulated in the “Hot Spots” program which explored the use of an ultrasonic guided wave (i.e. “active”) sensor system. Each of these programs encountered challenges that have hindered the use of these technologies on fixed-wing military aircraft. This paper briefly reviews these previous efforts, present current USAF Military Standards that define Structural Health Monitoring (SHM) for fixed wing aircraft, and provide a discussion of current and future concepts for research and development to resolve these challenges and enable eventual adaptation of SHM for fixed-wing applications. This will include a summary of current initiatives within the Materials and Manufacturing Directorate of AFRL and notional thoughts on potential projects for future developments required for this capability to be applied to fixed wing military aircraft
FAA SHM Research Program and the Challenges in Civil Aviation
9:00 am - 9:30 am, September 14th, Hewlett Auditorium (Hewlett 200)
Federal Aviation Administration
The FAA’s Structural Health Monitoring (SHM) research program began in 2011 and its primary focus was to determine the potential impact of introducing SHM on civil aircraft on FAA regulatory policy and guidance. The FAA funded investigators at the Sandia National Labs Airworthiness Assurance Nondestructive Inspection Validation Center (AANC) to assist the FAA in developing a research program based on the AANC’s past work experience in NDI validation for the FAA. The program included a survey of the aviation industry concerning SHM capability, a gap analysis of SHM research needs and to develop an SHM application that would clearly show the steps to possible approval. As part of the research project, a team consisting of Sandia National Labs AANC, the Boeing Corporation, Delta Air Lines, Structural Monitoring Systems, Anodyne Electronics Manufacturing Corporation were formed and selected the Comparative Vacuum Monitoring (CVM) system as the SHM test program on the B737 Center Wing Box Fitting. The team installed CVM sensors on several Delta Air Lines 737 aircraft, collected lab and flight test data sufficient to convince Boeing to approve this application and become the first successfully approved use of SHM in the civil aviation community. This presentation will discuss the challenges faced by this team and the FAA during its research program and as well as continuing hurdles still being faced for future SHM use on the civil aviation community.
Integrated Hybrid Structural Management System (IHSMS) Program
9:30 am - 10:00 am, September 14th, Hewlett Auditorium (Hewlett 200)
GM Impact Technologies
Sikorsky Aircraft Corporation
The Future Naval Capabilities Integrated Hybrid Structural Management System (FNC IHSMS) program developed intelligent rotor and airframe Structural Health Management (SHM) capabilities to enhance on-condition maintenance on the CH-53K Helicopter. The aircraft’s existing Integrated Vehicle Health Management System (IVHMS) provides drivetrain system diagnostics and health management capabilities; FNC IHSMS integrates rotor and airframe SHM with the existing CH-53K on-board health management system and ground-based maintenance support system to reduce both maintenance and operational cost. This keynote talk provides an overview of the FNC IHSMS program, including technical efforts and the execution strategy adopted by Sikorsky and US Navy to successfully develop a TRL 6 integrated rotor and airframe SHM system for future maturation and transition to the CH-53K Helicopter.
The IHSMS team is comprised of, Office of Naval Research (ONR), NAVAIR, the CH-53K Program Office (PMA-261), Sikorsky Aircraft, large and small commercial businesses, and one university. The program began in 2012 with a rigorous systems engineering evaluation of projected CH-53K maintenance drivers to identify candidate technologies to reduce operational cost associated with rotor and airframe components and subsystems. Technologies selected for incorporation into the FNC IHSMS program included loads monitoring, impact/damage detection and environmental monitoring. Selected technologies were incorporated into full scale CH-53K components and tested to validate their ability to detect and quantify degraded conditions. Software module were also developed and integrated into both the on-board and off board components of IVHMS to demonstrate FNC IHSMS integration into the existing CH-53K health management system.
The talk concludes with a summary of key findings, as well as the path forward for technology maturation on a flight test aircraft that serves as the next step along the path to transition to the CH-53K Helicopter.