New BAE Systems’ corrosion sensor wins JSF contract

Posted on: Jul. 17th, 2006 || Source: baesystems.com | E-mail Article | Print Article

New BAE Systems’ corrosion sensor wins JSF contract

Farnborough, United Kingdom. - A new corrosion monitoring system developed by BAE Systems has been down selected by the F-35 JSF programme team.

The F-35 JSF team concluded that the Sentinel system, a cooperative progamme between BAE Systems’ Advanced Technology Centre (ATC)and the Company’s Australian operation, best satisfied its requirement, with the technology offered far in advance of other competing systems. Sentinel is mature enough to be developed for the F-35 JSF within the systems development and demonstration (SDD) phase to support implementation in the JSF programme.

The down selection followed a trade study by BAE Systems, which looked at identifying corrosion sensor types and modelling technique. The study also identified suitable locations for corrosion sensors and most importantly established the clear cost benefits of a corrosion monitoring system.

“It is estimated that the US Department of Defense spends $40billion per a year on corrosion related issues and the US Air Force over $1.5billion”, said Dr Steven Harris, Materials Group Leader at BAE Systems’ Advanced Technology Centre. “In an aircraft it is vital to get to any possible corrosion damage before it actually happens. If you do you can repaint and add protection rather than go to the very expensive stage of repairing an airframe.”

The Sentinel system monitors the loss of corrosion inhibitor in the paint and indicates when the current paint will be exhausted and needs replacing. The low cost of the sensors means they can be placed in different areas on an aircraft, on different types of aircraft and at different locations.

A key challenge in the design of these sensors was ensuring they reacted to the atmosphere in the same way as materials being tested, as well as being robust enough to provide accurate data in changeable atmospheric conditions.

More complex systems are also being developed by BAE Systems including sensors, which measure temperature, humidity, salinity, PH levels and heat conductivity. Other future developments include an environmental degradation model, which calculates a microclimate and predicts the failure of protective schemes leading to the onset and growth of pitting corrosion. This output is presented as a life prediction for several sections of the airframe and the data can be used for asset management, inspection planning and materials selection and design.

“Corrosion protection is increasingly recognised as a key issue”, adds Dr Harris. “Aircraft have to be painted. If they are not corrosion becomes a problem. Small blisters in the paint may fatigue and crack. Both metal and composites need coating to stop the rain, sun and constant expanding and contracting due to temperature changes. Indeed on some military aircraft types corrosion maintenance hours are known to outstrip flight hours.”

Corrosion sensors can be applied across all sorts of platforms. BAE Systems is currently looking at a version for protecting the Concorde aircraft currently on display and there is also a possibility of applying them to helicopters, tanks and ships. Sensors have already been used in support of large civil passenger aircraft programmes.

About BAE SYSTEMS
BAE Systems is the premier transatlantic defence and aerospace company delivering a full range of products and services for air, land and naval forces, as well as advanced electronics, information technology solutions and customer support services. With more than 100,000 employees worldwide, BAE Systems’ sales exceeded GB £15.4 billion (US$28 billion) in 2005.
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