N112-088 TITLE: Operational Engine-Inducted Sand and Dust Loading Rate Detector

TECHNOLOGY AREAS: Air Platform, Sensors

ACQUISITION PROGRAM: F-35, Joint Strike Fighter

OBJECTIVE: Develop innovative sensors (or an assembly of sensors) to be positioned in an aircraft engine’s gas path to measure particulate load rates, specifically for sand and dust.

DESCRIPTION: The majority of today’s military engagements are occurring in desert environments which present unique challenges for aircraft operation. Sand negatively impacts part durability, increasing compressor erosion and reducing turbine cooling flow. An innovative sensing capability is needed to measure sand and dust loading rates in an operationally deployed engine. Particle sensors in the aircraft engine’s main gas path at the inlet and exhaust and in the engine’s secondary flow path are needed to measure sand and dust flow through the engine and to detect and measure particle size distribution, mineralogy, and chemistry.

This integrated sensing capability will provide information to help manage the health and durability of the aircraft’s engine. The sensor’s first application would be to study durability impacts from sand and dust loading rates followed by engine repair and overhaul management of engines operating in sandy environments. Engine environment will constrain sensor design with inlet distortion, hot exhaust gas temperatures, and secondary air passage geometry.

PHASE I: Define and determine the feasibility of providing a dependable sensor (or an assembly of sensors) to measure particulate load rates given the constraints mentioned. Initiate the design to the conceptual level for one or several engine systems, such as the Joint Strike Fighter P&W F135 or GE/RR F136, Sikorsky SH60 GE T700, F/A18E/F GE F414, E-2C RR T56-427, or a similar future naval air systems platform. A prototype sensor assembly may be demonstrated in bench tests if feasible.

PHASE II: Produce a detailed design(s) and prototype the assembly (preferably via strong coordination with selected-engine OEM and/or multiple designated second-party partners, especially relating to the signal data bus transmission scheme, data acquisition and processing approach, and specific assembly interface to the engine case).

PHASE III: Finalize engine sensor assembly integration with major DOD end users and engine manufacturers and conduct the necessary qualification testing.

PRIVATE SECTOR COMMERCIAL POTENTIAL/DUAL-USE APPLICATIONS: These sensors will provide information to help manage engine health and durability of both military and commercial aircraft operating in sandy environments.

REFERENCES:
1. Intra, P., & Tippayawong, N. (2007). An overview of aerosol particle sensors for size distribution measurement. Maejo International Journal of Science and Technology, 1(2), 120-136. Retrieved from http://www.mijst.mju.ac.th/vol1/120-136.pdf

2. Simon, D. L., Gang, S., Hunter, G. W., Guo, T.-H., & Semega, K. J. (2004, June). Sensor needs for control and health management of intelligent aircraft engines. Paper presented at ASME Turbo Expo 2004, Vienna, Austria. Retrieved from http://gltrs.grc.nasa.gov/reports/2004/TM-2004-213202.pdf

3. Walsh, W. S., Thole, K. A., & Joe, C. (2006, May). Effects of sand ingestion on the blockage of film-cooling holes. Paper presented at the ASME Turbo Expo, Barcelona, Spain. Retrieved from http://www2.mne.psu.edu/psuexccl//p46.5.pdf

4. Land, C. C., Joe, C., & Thole, K. A. (2010). Considerations of a double-wall cooling design to reduce sand blockage. Journal of Turbomachinery,132. Retrieved from http://asmedl.aip.org/getpdf/servlet/GetPDFServlet?filetype=pdf&id=JOTUEI000132000003031011000001&idtype=cvips

5. Scala, S. M., Konrad, M., Mason, R. B., Semick, J., & Skelton, D. (2004, July). Sensor requirements to monitor the real time performance of a gas turbine engine undergoing compressor blade erosion. Paper presented at the 40th Joint Propulsion Conference and Exhibit, Fort Lauderdale, FL.

6. Powrie, H., & Novis, A. (2006, July). Gas path debris monitoring for F-35 Joint Strike Fighter propulsion system PHM. Paper presented at the IEEE Aerospace Conference, Big Sky, MT. Retrieved from http://ieeexplore.ieee.org/stamp/stamp.jsp?tp=&arnumber=1656114

7. McDonald, E., & Caldwell, T. (2004). Geochemical and physical characteristics of Iraqi dust and soil samples. U.S. Army Research Office, Final Project Report No. 6310-653-4560. Retrieved from http://www.defenseindustrydaily.com/files/Iraq_Dust_2004-10_DRI_Report.pdf

KEYWORDS: sand erosion; propulsion; desert operations; sensors; prognostics health management; particle sensor

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