UNCLASSIFIED: Distribution Statement A. Approved for public release; distribution is unlimited

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Lenard Gibbs
5 years ago
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1 Topics v Accelerated Corrosion Expert Simulator v Why the Army is Developing this Tool v ACES Small Business Innovation Research v How ACES Works v Future Work 1

2 ACES IS v Modeling & Simulation tool for predicting corrosion initiation and growth over time v Currently developing for ground vehicles and equipment v Effort was started in 2008 and is ongoing v Potential use by other industries 2

3 Why Develop ACES v Army ground and aviation corrosion costs estimated ~$3.5 billion per year v Some Army systems are over 40 years old v Army equipment service life targets are rising 3

Source: Lt. Steve Gozzo, USN http://www.defenseimagery.

4 Why Develop ACES v Our equipment tends to be deployed in harsh environments Sandstorm in Iraq Kuwait Oil Field Fires Public Domain Source: Lt. Steve Gozzo, USN Public Domain Source: DoD photo by Corporal Alicia M. Garcia, U.S. Marine Corps. (Released) 4

mil/photos/picture.php?/778/category/ 174https://www.army.mil/article/166113.

5 Why Develop ACES MV Cape Texas Roll-On-Roll-Off Ship Army Landing Craft Air Cushion Public Domain Source: Military Sealift Command, https:// Public Domain Source: Military Sealift Command,

6 Why Develop ACES v Even if the environment isn t harsh, we make it harsh Paladin Firing Round Condensation Inside Truck Public Domain Source: Spc. Gregory Gieske 6

7 Why Develop ACES v Cyclic corrosion testing is effective but - lengthy, costly, and cannot cover all environmental exposure 7

8 Why Develop ACES v Army equipment does corrode over time Frame rail with poultice Paint too thin over rough metal surface 8

9 Why Develop ACES Stitch welds with rust jacking between welds Metal deformed, gaps sealed Welds 9

10 Why Develop ACES v Army equipment shares common corrosion mechanisms General Corrosion Crossmember Perforation Corrosion 10

11 Why Develop ACES v Contractors design and build Army systems Ø Army writes contract requirements Ø Requirements are performance-based Ø Contractor typically owns most of the CAD data v Army needs to assess contractor designs and design changes 11

12 Why Develop ACES v Improve availability, reliability, and durability of equipment v Reduce cost of corrosion Ø Reduce initial cost Ø Reduce maintenance costs materials & labor hours v Reduce life cycle corrosion testing v Assist in improving corrosion tests v Retain corrosion knowledge 12

13 Why Develop ACES v These incentives overlap with automotive, off-highway, shipping/transportation, and many other industries v Modeling and simulation tool would be useful to many industries v Consequently, Army selected the Small Business Innovation Research (SBIR) to fund ACES development 13

Small Business Innovation Research (SBIR) v SBIR is a government program directed toward small business to develop products for government and industry use v Multi-phased

14 Small Business Innovation Research (SBIR) v SBIR is a government program directed toward small business to develop products for government and industry use v Multi-phased program co-funded by government and industry partners v Industry partners can provide in-kind funding = time, facilities, testing v ACES SBIR project started in 2008 and is ongoing 14

15 SBIR Team Members Collaborative Team TARDEC Materials/Corrosion GCAS, software developer U.S. Marine Corp (Navy) Oshkosh Defense Naval Air Systems Command (NAVAIR) Elzly Corporation TARDEC Simulation & Modeling University of Akron U.S. Air Force General Motors Past participants included: Dr. Robert (Bob) Baboian, corrosion consultant, author, lecturer, Ford Motor Government Stakeholders TARDEC Materials/Corrosion TARDEC Simulation & Modeling Navy - US Marine Corp Navy NAVAIR 15

ACES Output v Predicts type of corrosion risk Ø Uniform corrosion Ø Galvanic corrosion Ø Crevice corrosion Ø Pitting corrosion* Ø Stress corrosion

16 ACES Output v Predicts type of corrosion risk Ø Uniform corrosion Ø Galvanic corrosion Ø Crevice corrosion Ø Pitting corrosion* Ø Stress corrosion cracking* v Predicts rate of degradation due to corrosion v Recommends alternative materials/coatings *Models developed, but not yet implemented in code 16

17 ACES SBIR Project PHASE YEARS ACTIVITIES I (10 months) II / II Enhancement (2 years) III (4 years) 2008 Developed preliminary model for galvanic corrosion Demonstrated model on multi-material latch Approved for Phase II funding 2009 to to Added General Corrosion model Added Crevice Corrosion model Improved ease of use Ported software to desktop computer Tested on subset of one vehicle Approved for Phase III Added character recognition of 2D CAD drawings for importing material and coatings data Added Pitting Corrosion model Added geometry recognition 17

18 How ACES Works Prepare CAD Model Add External Conditions Reasoning Module Y = f(x i ) Explanation Module I/O 18

19 How ACES Works v Prepare the 3-D CAD Model Materials Vehicle Geometry CAD STEP Fomat CAD Integrity Geometry Analyzer Coatings Ancillary Info 19

20 Analyze Geometry, Materials Through Hole Pocket / Cup Stitch Welds Blind Hole Lap Joint Bolt, Nut, Washer, Crevices 20

21 How Aces Works v Incorporate External Conditions Environment Profile Maintenance Profile Mission Profile Produce Combined Data X i I/O 21

22 How ACES Works v Execute Reasoning Module Ø Combines Electrochemistry and statistical-based Artificial Intelligence methods to predict various forms of corrosion Knowledge Base Reasoning Module GPU Physics fk User Interface (I/O): Image with risks Types of corrosion Alternatives X i Y = f(xi) 22

23 Uses for ACES v Acquisition of New Vehicles Ø Upfront design optimization Ø Assess compliance of final design to contract Ø Aid in setting maintenance intervals v Existing Fielded Vehicles Ø Evaluate engineering changes Ø Guide material/component selection Ø Model corrosion maintenance issues Ø Enhance understanding of the effects of maintenance on corrosion 23

24 Corrosion Risk Mapping All Photos are Public Domain 24

25 Future Domains? Aerospace Mother Nature? Buildings All Photos are Public Domain 25

2017 AIR FORCE CORROSION CONFERENCE Corrosion Policy, Oversight, & Processes

2017 AIR FORCE CORROSION CONFERENCE Corrosion Policy, Oversight, & Processes Rich Hays Photo Credit USAFA CAStLE Deputy Director, Corrosion Policy and Oversight Office OUSD(Acquisition, Technology and