A Novel Sensor for Pitting Corrosion Monitoring and Load Distribution Measurements Navy SBIR FY2011.2 Sol No.: Navy SBIR FY2011.2 Topic No.: N112-120 Topic Title: A Novel Sensor for Pitting Corrosion Monitoring and Load Distribution Measurements Proposal No.: N112-120-0496 Firm: AlphaSense, Inc. 470 Century Blvd. Wilmington, Delaware 19808 Contact: Pengcheng Lv Phone: (302) 468-0980 Web Site: www.alphasense.net Abstract: In this proposal, AlphaSense, Inc. details the development of a novel sensor for pitting corrosion monitoring and load distribution measurements. The key innovations of this proposal include the following: a) corrosion and load distribution measurements based on the electrical impedance measurements, b) the application of electrical impedance tomography technique to efficiently image the impedance distributions, c) a novel force-sensitive conductive polymer for accurate load distribution measurements, and d) the implementation of compact, low cost and handheld sensor readout electronics using a microcontroller. With such innovations, the merits of the proposed sensor include the following: a) Compact and low cost, b) High sensitivity and large dynamic range, c) High spatial resolution with a small number of sensor elements, d) Minimal interference with the testing articles, e) Physically and chemically robust under the operating environment, and f) High throughput. Benefits: The outcome of this research is coupled to a very clear commercialization path. The proposed sensor technology can be used in a wide variety of military and civilian applications. Nowadays, magnesium alloys are widely used in the military aircrafts and helicopters as engine and gear box casings. The proposed sensor allows quick assessments of corrosion build- up and pressure/load distributions in those critical components without disassembling the parts. The sensor enables condition based maintenance (CBM) rather than maintenances at pre-defined intervals. Consequently, substantial time and cost savings can be obtained from the applications of the proposed sensor in the field. Additionally, the sensor will significantly reduce the down time and increase the mission readiness of critical military assets. Therefore, the proposed sensor can be add values to many DoD programs, including the Prognostics and Health Management for JSF program, NAVAIR rotorcraft programs (e.g. PMA-299 H-60 multi-mission helicopter program and PMA-261 H-53 heavy lift helicopter program) and the Air Force's Common Vertical Lift Support Platform (CVLSP) program. Besides the military applications, magnesium alloys are also widely used in the automotive, construction and power generation industries. Therefore, the proposed sensor can also be used in those market sectors for condition based maintenance. By no means is the sensor only limited to the corrosion detection and load measurements in magnesium alloys. It shall also find applications in other materials and alloy systems for structural health monitoring. For example, it can be used to detect cracks, corrosions and even leaks in liquid- carrying pipelines. It may also be used as an efficient industrial process control tool for real- time monitoring of the mixing process inside a large mixing vessels. Furthermore, the EIT technique has already been used as a simple, low-cost medical imaging tool. The sensor system developed under the current program may also be well suited for the medical applications. Potential end users may include the military system integrators (e.g. Boeing, Sikorsky, and Pratt&Whitney), automaker (General Motor), and commercial helicopter manufacturer (Bell Helicopter) etc. We estimate that the total market size in the above-mentioned market sectors can easily exceed $20 M/year. Return