AIM Tutorial
Rollie Dutton & Dennis M. Dimiduk
Materials and Manufacturing Directorate
Air Force Research Laboratory
Leo Christodoulou, Steve Wax
DARPA
25-Jun-03 1
AGENDA
• What is AIM?
– Rollie Dutton, AFRL/MLLM
• AIM for Solid Rocket Motors
– Lee Davis, ATK Thiokol Propulsion
• BREAK
• AIM for Liquid Fueled Rocket Engines
– Glenn Havskjold, Boeing-Rocketdyne
• AIM - the use of AIM to bound advanced rocket
engine TBC design
– Tony Evans, University of California - Santa Barbara
• Summary
– Rollie Dutton AFRL/MLLM
25-Jun-03 2
Aerospace Structural Materials
Development: How It Happened
• DoD materials transition opportunities
DKB (systems) have drastically reduced
• Material development time far exceeds
the modern short product cycle
– iterative, empirical development of
“Knowledge Base” is lengthy, data
intensive, and expensive
Adapted from Fraser, 1998; Wax, 1999
21st Century Reality Demands that the Paradigm Change!
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The Disconnect!
Major disconnect between Materials
Major disconnect between “Knowledge Base”
materials development &
materials development &
components/systems
components/systems DKB
engineering design
engineering design
•• Known alloy to reliable
Known alloy to reliable
part ~36 months
part ~36 months
•• Steels for navy landing
Steels for navy landing
gear 15+ yrs
gear 15+ yrs
•• Lightweight composites
Lightweight composites
for army vehicles 15+ yrs
for army vehicles 15+ yrs
•• Gamma titanium
Gamma titanium
aluminides ~30yrs and
aluminides ~30yrs and Materials Engineering Design
counting
counting Development • Materials Input from
•• Ceramics for engines - -
Ceramics for engines • Highly Empirical “Knowledge Base” of Data
30+++ ? yrs
30+++ ? yrs (Data Sheets, Graphs,
• Testing
Independent of Use Heuristics, Experience, etc.)
•• Evolutionary alloy
Evolutionary alloy • System/Sub-System Design
• Existing Models
changes (ship steels,
changes (ship steels, Unlinked is Heavily Computational
superalloys, etc) ~7-10
superalloys, etc) ~7-10 and Rapid
years
years • Well Established Testing
Protocols
25-Jun-03 Adapted from Wax, 1999 4
Integrating Materials & Processes
with Engine Design
Performance / Secondary
Flow Path Flow / Thermal
Materials /
Common 3-D Models,
Analysis Tools, Manufacturing
Processing
Database & Cost
Structural Design /
Assessments Geometry
Design “development cycle”: 95% CONFIDENCE OF 99% EXCEEDENCE)
X (AVERAGE) EXTRAPOLATED 1150F; integral
Simulations
400
1A6917
0.010
1B4902
0.005
1A8301 & 1B7801
FABRICATE 200 0.001
yield strength model
140 145 150 155 160 165 170 175 180 185 190
ALTERNATING PSEUDOSTRESS, 1000 PSI
COMPONENT 100
80
yield strength
60
40
GENERATE CURVES;
20
5 3 2 5 4 2 5 5 2 5 6
SYNTHESIZE MINIMA
10 10 10 10
CYCLES TO FAILURE, NF CLASS: 1
THE INFORMATION CONTAINED HEREON IS SOURCE SUPERSEDES CURVE NO.
6746,6747,6969,7139-7144,7343,
PROPRIETARY INFORMATION 7346,7244,7245,7373 D3659 D7361
PREPARED BY DATE APPROVED BY DATE ISSUE DATE PAGE
G. T. CASHMAN 20-JUN-96 Mark R. Brown 21-JUN-96 28-JUN-96 1 OF 2
CONVERGE REPRESENTATIONS 10 mm
CONVERGE
& MEASURED PROPERTIES
MEASURE PROPERTIES WITH
DATABASE
Evaluate other issues (cost, suppliers,
life), Certify Design Drawing Constitutive Relationships
25-Jun-03 Micro-Scale Mechanical Tests
31
Summary
• The time for structural materials development and use must be
shortened (time focus, not cost focus)
• Industrial M & P community demanding a quantum-leap in
relevant engineering simulation capability
• Accelerated Insertion of Materials is the long-term, strategically-
relevant, computational materials science & engineering vision
• Materials Science & Engineering community must produce
integrated predictive tools
• Accelerated insertion demands integration of engineering design
with M & P to achieve true systems engineering of materials
technologies
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