Corrdesa currently primes a number of DoD SBIRs and partners on several more contracts that leverage our corrosion analysis and simulation technology.
ONR Sea-Based Aviation (SBA) program
Innovative approaches for Predicting Galvanic Effects of Dissimilar Material Interfaces: The long term aim of the SBA program is to develop computational methods for analyzing combinations of stress and corrosion. NAVAIR has determined that more than 80% of structural failures initiated from corrosion pits, while the majority of severe corrosion pitting in Naval aircraft results from galvanic corrosion between the aluminum airframe and cathodic materials such as carbon fiber composite skins, stainless steel bushings, etc. Understanding and developing computational methods to model the interaction of stress fields with corrosion pits will give us a way to predict and therefore minimize stress corrosion cracking and corrosion fatigue. Corrdesa is currently working on a Phase 2.5 SBIR Program:
- Demonstrate and validate existing CAE computational methods
- Develop and validate a new user-friendly galvanic corrosion tool (Corrosion Djinn™) for use by Design and M&P engineers
- Develop with the SBA Team a Best Practices document for taking polarization data
- Assemble all of the Team’s data into an online database – a “Corrosion MMPDS” – that is required to bring computational corrosion into the mainstream as an engineering analysis method.
US Air Force
Galvanic Corrosion Prediction for Aircraft Structures: The US Air Force Corrosion Office at Wright-Patterson Air Force Base is developing the capability for computational corrosion modeling. Corrdesa is in Phase 2 of an SBIR program to develop a toolset that can be used by USAF engineers to analyze and predict galvanic corrosion driven by coupling between and aluminum air frames.
Although CAE and FEA methods are available for corrosion analysis, they are very complicated to use and require specialist training. The toolset that Corrdesa is developing will is make it possible for M&P engineers to more easily understand and predict corrosion from mixed material aircraft structures, especially in Remotely Piloted Aircraft (RPA’s) such as the General Atomics Reaper, and in modern aircraft such as the Lockheed-Martin F-35 Lightning II. The toolset will include both CAE and Corrosion Djinn™ approaches – the Corrosion Djinn™ approach being used primarily for interface evaluations and scoping, while the CAE approaches will be used for detailed analysis.
Corrdesa is working on this project with the USAF Corrosion Office and UDRI.
NAVAIR Selective Electroplating Technology Improvement (SETI) program: Depot sustainment of Naval aircraft frequently requires touching up and replacing electroplated coatings on-aircraft, which is traditionally done by the process of selective electroplating (brush plating/stylus plating). This is a rather crude electroplating process in which the plating “brush” is used rather like a paint brush, frequently dipping it into open containers of toxic plating chemicals such as cadmium and hexavalent chromium, and electroplating it onto the aircraft.
This process exposes the maintainer to toxic chemicals, dripping and spilling them onto clothing, into the aircraft, and onto the hangar floor or the flightline. Corrdesa will modify, demonstrate, validate and transition the computer-controlled non-drip Dalistick electroplating technology developed by Dalic in France. Processes will be developed for on-aircraft depot plating and anodizing, including validating brush zinc-nickel to replace toxic cadmium/hexavalent chromium. The outcome of this work will be a greatly improved selective electroplating process that will produce more consistent coatings while avoiding OSHA citations for worker exposure to toxic chemicals. This technology, once fully qualified and Americanized, will be transitioned into all three FRCs and probably most other DoD maintenance depots.
Corrdesa is working on this project with Fleet Readiness Center SE, Jacksonville, and Dalic, France.
US Army Project on Electorchemical Machining (ECM): ECM is a non-contact machining process that uses a tool and a corrosion solution such as NaCl to machine complex holes and grooves in metals that are very hard to machine mechanically such as Ti alloys, Ni-based superalloys, W alloys. The problem with the method is that, unlike a standard cutter, the hole made by an ECM tool does not exactly match the shape of the tool, but depends on the tool shape, current, tool sink rate, electrolyte flow, temperature, and other factors. Tools are therefore currently made by the Edisonian approach of make-test-make. Corrdesa is modeling the process in order to develop an understanding of the most critical parameters, and developing an approach that the tool designer can use to design the tool and process correctly the first time.
Corrdesa is working on this project with CD-adapco and ExtrudeHone, who manufacture ECM machines.