SBIR-STTR Award

In this proposed SBIR program Test Devices, Inc, in conjunction with our industry partners Pratt & Whitney (see letter of support) and Mechanical Solutions, Inc., will leverage our experience in the domain of high temperature full component and subscale testing to develop a concept for an affordable Highly Simulative Subscale Testing (HSST) Facility capable of conducting tests that will measure components under more realistic service environments to include: High temperature (1500F), gradient capability (stretch goal 2000F rim temps) Centrifugal loading and thermal gradients to produce multiaxial stress states at high temperatures (stretch goal 100,000 rpm) Ability to test in controlled atmospheric conditions, primarily the creation of high local pressures and oxidizing environments We believe the USAF and engine OEMs would greatly benefit from the highly-realistic subscale test facility proposed for the HSST concept. We will leverage results from existing prototype work to produce a cost effective concept. The HSST will provide critical new information for the development and validation of coatings, hybrid microstructures, and other advanced material systems as well as support Integrated Computational Materials Engineering (ICME) activities and advances of component design and usage based lifing analysis. The primary deliverables for this project include: HSST Conceptual design including mechanical, instrument, control, and data acquisition Proposed concepts for test samples and associated analytical method to capture microstructural and mechanical behavior Bench Testing to validate microstructural and mechanical modeling Suitable test requirements and test plans for early spin testing Technical and cost trade studies of various methods and instrumentation

Benefit:
The development of a highly realistic, yet affordable test capability will help speed the development of new materials and coatings, and provide valuable risk reduction prior to full scale validation testing.

Keywords:
Subscale component,

In this proposal for SBIR program (phase-II), Test Devices, Inc, in conjunction with its industry partners Pratt & Whitney and Mechanical Solutions, Inc., will leverage its experience in the domain of high temperature full component and subscale testing to develop a prototype testing facility capable of conducting tests that will evaluate components under more realistic service environments to include: Centrifugal loading and thermal gradients to produce multiaxial stress states at high temperatures 2000F target test temperature capability with thermal gradient Up to 100,000rpm disk test speed Capability to test in vacuum and controlled partial atmospheric conditions Capability to test at pressures up to 50psi with gas species is considered as a part of stretch goals The HSST Phase-II project will be built on the successful result of phase-I work (AF141-175). The new temperature control system developed in the phase-I has successfully demonstrated its capability; it has generated a rim temperature of 2430F with a very steep thermal gradient (1100F/in) on a 5.0 (OD) disk. The result of phase-II work will culminate in a prototype subscale spin test capability with a thermal gradient, which is capable of generating an engine-like multi-axial stress field at realistic temperatures.

Benefit:
The USAF and engine OEMs will benefit from the highly-realistic subscale test facility proposed for the HSST concept in that it will provide critical data for the development and validation of coatings, hybrid microstructures, and other advanced material systems as well as support Integrated Computational Materials Engineering (ICME) activities and advances of component design and usage based lifing analysis. This will assist in speeding the development of new engines that are lighter, more fuel efficient and less polluting.