Physics Based Gear Health Prognosis via Modeling Coupled with Component Level Tests

Award Information
Agency: Department of Defense
Branch: Navy
Contract: N00014-07-M-0445
Agency Tracking Number: N074-010-0092
Amount: $69,862.00
Phase: Phase I
Program: STTR
Solicitation Topic Code: N07-T010
Solicitation Number: N/A
Solicitation Year: 2007
Award Year: 2007
Award Start Date (Proposal Award Date): 2007-07-20
Award End Date (Contract End Date): 2008-05-20
Small Business Information
1820 Ridge Avenue, Evanston, IL, 60201
DUNS: 088176961
HUBZone Owned: N
Woman Owned: N
Socially and Economically Disadvantaged: N
Principal Investigator
 Jason Sebastian
 Materials Design Engineer
 (847) 328-5800
Business Contact
 Raymond Genellie
Title: Vice President - Operations
Phone: (847) 425-8211
Research Institution
 Charlotte Newman
 633 Clark Street
Crown 2-502
Evanston, IL, 60208-1110
 (847) 467-1967
 Nonprofit college or university
A "smart steel" concept is proposed by QuesTek Innovations to enable a major advance in physics-based gear health prognosis. The concept is based around idea that the decay of stable austenite within the cases of gear steels during high-cycle fatigue (HCF) may provide a "state expressive" signature that can be used as input into physics-based predictions of remaining HCF life. Under a Phase I effort, the evolution of surface retained austenite under HCF conditions in existing high performance gear steels will be measured and modeled. The goal will be to assess the feasibility of achieving a sufficiently gradual transformation to serve as a desired "state signature" of fatigue lifetime. In parallel, the 3D characterization of nucleation sites and numerical mechanics modeling of nucleation under the ONR/DARPA "D3D" Digital 3D Structure consortium will be leveraged to assess feasibility of coupling the retained austenite state to the prediction of remaining HCF life. Due to the large difference in magnetic permeability between austenite and martensite, magnetic sensor approaches will be surveyed for continuous in-flight monitoring of case austenite contents. The cyclic testing and austenite measurements in Phase I will be conducted at Northwestern University (the institutional STTR partner).

* Information listed above is at the time of submission. *

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