Concurrent Technologies Corporation Research Articles

Alternatives to dichromate sealer in anodizing operations

Ogden Air Logistics Center (OO-ALC) is the primary facility within the United States Air Force for maintaining and overhauling aircraft landing gear. Aluminum landing gear components are anodized at OO-ALC to provide enhanced corrosion resistance, paint adhesion, and wear resistance; a sodium dichromate sealing operation usually completes the anodizing process. During sealing, the pores of the anodized (oxide) layer are hydrated, which fills the pores and provides improved corrosion resistance. However, this sealer contains hexavalent chromium, which is listed on the Environmental Protection Agency's list of industrial toxic chemicals that are targeted for voluntary reduction or elimination. The specification that outlines the sodium dichromate sealing process delineates three alternative processes that are approved for use: 1) boiling de-ionized water, 2) cobalt acetate, and 3) nickel acetate. While some research to support the use of these and other sealing processes has been gathered under past efforts, additional work must be conducted to fully integrate non-chromate sealers into OO-ALC's anodizing operations. To meet this need, the Air Force Research Laboratory tasked Concurrent Technologies Corporation to identify viable alternatives to the sodium dichromate sealer, conduct testing on these alternatives, and recommend the most promising sealer(s) for implementation based on the test results. This paper will describe the requirements for anodizing and sealing operations within OO-ALC, as well as the sealing technologies that are available and a path forward to demonstrate/validate the most promising alternatives for the specific needs and applications of OO-ALC.

Molten carbonate fuel cell operation with dual fuel flexibility

The ability to operate highly efficient, pollution-free, distributed-generation power plants on either natural gas or HD-5 grade propane is of interest to the U.S. Army and the U.S. Department of Homeland Security as secure power for critical power operations. To address this interest, Concurrent Technologies Corporation (CTC) teamed with FuelCell Energy (FCE) to test an internally reforming 250 kW carbonate fuel cell using HD-5 propane. This fuel cell power plant, originally designed to operate on pipeline natural gas or digester gas, was modified for dual fuel operation (natural gas and propane). Fuel cell operation using HD-5 propane was demonstrated for over 3900 h and achieved high-electrical efficiency (45.7–47.1% lower heating value (LHV)) over a broad range of power outputs. In addition, instantaneous and on-load fuel switching from natural gas to propane and back was demonstrated without loss of power. This dual fuel power plant operates efficiently on either fuel and provides the U.S. Army and other power users with a viable technology solution for critical power operations.

Carbonate Direct Fuel Cell Operation on Dual Fuel

The ability to operate highly-ef ficient, pollution-free, distributed-generation power plants on either natural gas or HD-5 grade propaneis of interest to the U.S. Army and the U.S Department of HomelandSecurity as secure power source for critical power operations. The abil-ity to operate continuously on HD-5 propane also provides a valuableproposition to islands, remote sites, national parks, data centers, militarybases, hotels, and hospitals. HD-5 propane, as opposed to other gradesof propane, was selected as the back-up fuel of choice because of itsavailability (even in remote areas), cost, and ease of processing in thefuel cell power plant. Although natural gas distribution through utilitypipelines is convenient, it is vulnerable to natural disaster, threats ofterrorism, and simple repair outages. Propane, however, is routinelytransported and stored as a liquid at ambient temperatures and offersa convenient and secure option for fuel cell operations. An adequatequantity of propane can be stored on site to sustain operations for sev-eral days in a variety of weather climates.In response to the interest for a fuel flexible power plant, Concur-rent Technologies Corporation (CTC), under contract to the U.S. ArmyEngineer Research and Development Center’s Construction EngineeringResearch Laboratory (ERDC-CERL), is working with FuelCell Energy(FCE) to test an internally reforming 250 kW carbonate fuel cell. Previousto the demonstration at CTC, FCE operated a 250 kW carbonate directfuel cell for 1500 hours, which generated 300,000 kilowatt-hours (kWh)net AC electricity using HD-5 propane as fuel. Among the challengesaddressed, lessons learned by FCE during initial operation on HD-5propane included: 1) avoiding carbon deposition during pre-reformingof propane into a methane rich gas, 2) metering and controlling propane flow to account for variations in fuel composition, 3) removing sulfurfrom the propane, and 4) increasing the steam required for operationon propane. Peripheral issues that required additional investigationincluded identifying the number and volume of propane tanks and avaporization system to deliver the required rate and quantity of fuel.

The National Centers for System of Systems Engineering: A Case Study on Shifting the Paradigm for System of Systems

Introduction Based on literature and interest encountered in practice, there is a clear and consistent increase in System of Systems Engineering (SOSE). SOSE is being used in organizations such as Lockheed Martin, Concurrent Technologies Corporation, and the Joint Forces Command, all providing a service or solution for complex, distributed problems. However, a quick scan of literature, publications, and websites show that the approaches being presented do not necessarily subscribe to a common theme or methodology for solving, or defi ning SOS type problems. For example:  Lockheed Martin (CIAD 2006) proposes a unifi ed discipline methodology that integrates the practitioners needed to provide SOS solutions.  Concurrent Technologies Corporation (www.sosece. org), that operates the System of Systems Center of Excellence, suggests that System of Systems Engineering is an emergent condition of Systems Engineering and builds on current techniques.  Joint Forces Command, Standing Joint Task Force (MECS report 2006) focus on System of System Analysis, which is used to defi ne service capabilities in the process of providing for a Joint Force capability.

Development of Fabrication Guidelines for Cold Bending of Plates

To avoid plate cracking during cold bending, it is necessary to use a suitable minimum inside bend radius, which typically varies with plate thickness and grade. However, because of the addition of new plate grades over the years, it was felt that the limits that had been given in ASTM A6 until recently, had not been developed on a consistent basis. Also, those limits were intended for material acceptance purposes using small specimen tests, and did not directly reflect fabrication limits. Therefore, a program was initiated by AISI about 1996 to develop rational limits directly applicable to plate fabrication. In the initial study, conducted by Concurrent Technologies Corporation, small specimens of various grades and thicknesses were cold formed using different bend radii and evaluated. In subsequent work, the present study was made to review that information, review historical forming limits, and develop a rational set of consistent limits for fabrication guidelines. It was concluded that radius-to-thickness limits from idealized bending limit diagrams developed from specimen tests could be used to establish fabrication limits, if appropriate allowances were made for conditions in fabrication that differ from those in the tests. This includes adjustments to account for plate properties that approach minimum specified values rather than the typical properties of the test material, thicknesses greater than those tested, and edge or surface imperfections that may be present in typical fabrication. After making such adjustments, a table of suggested limits was developed and subsequently adopted in ASTM A6. The adopted values were generally more liberal (allowed tighter bends) than those that had been given in the AISC Manual, thus providing greater flexibility in fabrication in most cases.

PTFE coating vs. impregnation: Analyzing what works best for anodized aluminum

Ogden Air Logistics Center (OO-ALC) is the primary facility within the United States Air Force for maintaining and overhauling aircraft landing gear. Aluminum landing gear components are anodized at OO-ALC to provide enhanced corrosion resistance, paint adhesion, and wear resistance; a sodium dichromate sealing operation usually completes the anodizing process. During sealing, the pores of the anodized (oxide) layer are hydrated, which fills the pores and provides improved corrosion resistance. However, this sealer contains hexavalent chromium, which is listed on the Environmental Protection Agency's list of industrial toxic chemicals that are targeted for voluntary reduction or elimination. The specification that outlines the sodium dichromate sealing process delineates three alternative processes that are approved for use: 1) boiling de-ionized water, 2) cobalt acetate, and 3) nickel acetate. While some research to support the use of these and other sealing processes has been gathered under past efforts, additional work must be conducted to fully integrate non-chromate sealers into OO-ALC's anodizing operations. To meet this need, the Air Force Research Laboratory tasked Concurrent Technologies Corporation to identify viable alternatives to the sodium dichromate sealer, conduct testing on these alternatives, and recommend the most promising sealer(s) for implementation based on the test results. This paper will describe the requirements for anodizing and sealing operations within OO-ALC, as well as the sealing technologies that are available and a path forward to demonstrate/validate the most promising alternatives for the specific needs and applications of OO-ALC.

The near-net-shape manufacturing of affordable titanium components for the M777 lightweight howitzer

The U.S. Marines’ and U.S. Army’s next-generation, titanium-intensive M777 howitzer offers reduced weight, increased mobility, and improved survivability over its aging, M198 steel-based predecessor. The National Center for Excellence in Metalworking Technology (NCEMT), operated by Concurrent Technologies Corporation, is helping to meet M777 program goals for cost, performance, and production schedule by developing near-net-shape manufacturing routes for traditionally machined and welded components. Under two projects sponsored by the Navy Manufacturing Technology Program, the NCEMT has developed investment cast spade and saddle components as well as flowformed tubes and forged bell housings. This paper summarizes the results of the two ongoing projects.

Turning research into results: A guide to selecting the right performance solutions

Performance ImprovementVolume 43, Issue 1 p. 44-46 Book Review Turning research into results: A guide to selecting the right performance solutions Richard E. Clark, Richard E. Clark Richard E. Clark is currently a professor of Educational Psychology and Technology at the University of Southern California. He also serves as president of Atlantic Training, Inc., an international consulting company. He has published more than 150 books, book chapters, articles, and monographs. In 2002, he was the recipient of the prestigious Thomas F. Gilbert Distinguished Professional Achievement Award.Search for more papers by this authorFred Estes, Fred Estes Fred Estes has worked for several years managing training and performance improvement projects for large companies, including Hewlett-Packard and Bank of America. He has worked as an internal performance consultant, an instructional designer, and an educational program manager. In addition, he has contributed to several professional journals and books.Search for more papers by this authorRebecca Helminen Middlebrook, Rebecca Helminen Middlebrook Rebecca Helminen Middlebrook is a May 2003 graduate of the Instructional Systems Technology MS program at Indiana University. She is currently pursuing doctoral study in the field of Texts and Technology at the University of Central Florida in Orlando. Rebecca's current research interests include ethical and usability issues surrounding the use of persuasive technology in college writing/learning centers. She may be reached at rmiddleb@mail.ucf.edu.Search for more papers by this authorAngela Palchesko, Angela Palchesko Angela Palchesko is an Associate Instructional Designer for Concurrent Technologies Corporation (CTC), where she assists government and industry in the development of training solutions to improve productivity and effectiveness. She has a master's in Instructional Systems Technology from Indiana University, and her current interests include knowledge management and SCORM conformant content development. Angela may be reached at apalch esko@yahoo.com.Search for more papers by this author Richard E. Clark, Richard E. Clark Richard E. Clark is currently a professor of Educational Psychology and Technology at the University of Southern California. He also serves as president of Atlantic Training, Inc., an international consulting company. He has published more than 150 books, book chapters, articles, and monographs. In 2002, he was the recipient of the prestigious Thomas F. Gilbert Distinguished Professional Achievement Award.Search for more papers by this authorFred Estes, Fred Estes Fred Estes has worked for several years managing training and performance improvement projects for large companies, including Hewlett-Packard and Bank of America. He has worked as an internal performance consultant, an instructional designer, and an educational program manager. In addition, he has contributed to several professional journals and books.Search for more papers by this authorRebecca Helminen Middlebrook, Rebecca Helminen Middlebrook Rebecca Helminen Middlebrook is a May 2003 graduate of the Instructional Systems Technology MS program at Indiana University. She is currently pursuing doctoral study in the field of Texts and Technology at the University of Central Florida in Orlando. Rebecca's current research interests include ethical and usability issues surrounding the use of persuasive technology in college writing/learning centers. She may be reached at rmiddleb@mail.ucf.edu.Search for more papers by this authorAngela Palchesko, Angela Palchesko Angela Palchesko is an Associate Instructional Designer for Concurrent Technologies Corporation (CTC), where she assists government and industry in the development of training solutions to improve productivity and effectiveness. She has a master's in Instructional Systems Technology from Indiana University, and her current interests include knowledge management and SCORM conformant content development. Angela may be reached at apalch esko@yahoo.com.Search for more papers by this author First published: 08 February 2007 https://doi.org/10.1002/pfi.4140430110 AboutPDF ToolsRequest permissionExport citationAdd to favoritesTrack citation ShareShare Give accessShare full text accessShare full-text accessPlease review our Terms and Conditions of Use and check box below to share full-text version of article.I have read and accept the Wiley Online Library Terms and Conditions of UseShareable LinkUse the link below to share a full-text version of this article with your friends and colleagues. Learn more.Copy URL Share a linkShare onFacebookTwitterLinkedInRedditWechat No abstract is available for this article. Volume43, Issue1January 2004Pages 44-46 RelatedInformation

The Energy Savings Analysis Protocol: A New Standard for Energy Auditing

ABSTRACT To present opportunities for whole-building upgrades, Concurrent Technologies Corporation (CTC)1 is developing a standard for energy auditing: the Energy Savings Analysis Protocol, or ESAP. By following the performance specification, or auditing guidelines, reports resulting from such enhanced audits will be approved as “ESAP Solutions.” The Energy Savings Analysis Protocol follows an approach of “approving, adapting, or enhancing” existing auditing tools and formats, and then combining them to form a coordinated and complete package. It then adds features not found in conventional energy audits. In creating this set of standards, market research was conducted on the concept, on current auditing procedures, and on integration with related federal programs. To ensure a market-based perspective, a peer review panel of industry experts was also convened. In phase one preliminary design, protocols were developed for approving existing auditing tools. Phase two called for the ESAP guidelines to be developed in draft form and presented to a wide array of stakeholders in the energy marketplace for two purposes: 1. to solicit input and secure commitments of support and2. to establish an organizational framework for the subsequent stages of project development.

Industrial Health Risk Assessment for Routine Workers in a Military Paint Shop

ABSTRACT An industrial health risk assessment was conducted for employees engaged in routine tasks in a military paint shop. These workers handle a variety of compounds, including chromates, volatile organic compounds, and isocyanates. A risk assessment conforming to well-accepted, widely used guidance was conducted. The site-specific assessment incorporated data on task durations and personal protective equipment (PPE) use. The estimated chronic daily intake (CDI) for routine on-site workers was compared to U.S. Environmental Protection Agency (U.S. EPA) Reference Doses (RfDs) to estimate the likelihood of non-cancer effects. When the U.S. EPA's Integrated Risk Information System (IRIS) lacked RfDs for compounds, efforts were made to utilize surrogates or guidance from other agencies. For carcinogenic effects the CDI was multiplied by the U.S. EPA slope factor and the resultant risk estimate compared to target incremental risk ranges. Using PPE recommended by the site's industrial hygiene department, it is anticipated that the U.S. EPA non-cancer threshold hazard index (HI) of 1.0 and target incremental cancer risk (R) of 10−4 to 10−6 will not be exceeded. However, under baseline modeling assumptions (i.e., no use of PPE), the concentrations of chemicals of potential concern (COPC) present in the air during routine operations suggest a potential health hazard. The baseline estimates emphasize the importance of proper PPE in the paint shop workplace and use of site-specific information in modeling. ** This work was supported by the Department of Defense under Prime Contract No. DAAA-21-93-C0046 to the National Defense Center for Environmental Excellence, operated by Concurrent Technologies Corporation (CTC).

The cost‐benefit analysis of pollution prevention projects—environmental cost analysis methodology (ECAM)

AbstractThis article discusses the implementation of the Environmental Security Technology Certification Program's (ESTCP) Environmental Cost Analysis Methodology at six Department of Defense (DOD) facilities. The article documents the successful application of this methodology on innovative technologies that target urgent environmental needs as identified by the DOD. This methodology successfully identified previously undocumented savings in excess of $1.0 million where it was applied. Highlighted are increased return on investment (ROI), payback, and net present value results quantified in the application of this methodology.Through the efforts of the ESTCP and the National Defense Center for Environmental Excellence (NDCEE), operated by Concurrent Technologies Corporation (CTC), and Coopers & Lybrand, L.L.P. (C&L), the Environmental Cost Analysis Methodology (ECAMSM) was developed to provide users with a consistent and accurate tool for conducting financial analyses, especially where new technologies are being considered. Discussed in ECAM are activity‐based costing (ABC) methods and techniques used in the analysis and evaluation of new or modified technologies. The ECAM significantly improves the identification and assignment of conventional and environmental costs.

Mechanical properties of acrylic based injection moulding feedstocks: J. Valencia et al. (Concurrent Technologies Corporation, USA)

Mechanical properties of acrylic based injection moulding feedstocks: J. Valencia et al. (Concurrent Technologies Corporation, USA)

On microsuperplasticity in aa7475 domes

M.G. ZELIN, formerly Post Doctoral Researcher with the Department of Chemical Engineering and Materials Science, University of California, Davis, CA 95616-5294, is Senior Engineer, Concurrent Technologies Corporation, Johnstown, PA 15904. Manuscript submitted October 24, 1995. deformed surface of unfailed materials, t6,71 Since the appearance of these fibers suggests extremely high ductility of the material, the process of fiber formation has been referred to as microsuperplasticity phenomenon.tJ,z.31 Predominately, the observations of microsuperplasticity phenomenon were reported in materials subjected to the uniaxial tension. Recent s t u d y [8'91 of the deformed surface of superplastically bulged AA7475 domes demonstrated fiber formation after biaxial stretching. This article summarizes the results of the observation of fiber formation in AA7475 domes of various shapes. AA7475 blanks, 50 X 50 x 1.5 mm 3 were bulged with the punches of hemispherical, cylindrical, and conical shape. The experimental details can be found elsewhere.[8,9~ Superplastic AA7475 sheet material with a grain size of approximately 10/~m was obtained from Kaiser Aluminum and Chemical Co. (Pleasanton, CA). The rate of punch displacement and temperature corresponded to the optimum strain rate-temperature conditions for this alloy: f6,7,1~ l] ~: = 2 x 10 4 S-I and T = 516 ~ The blanks were mechanically polished before deformation with the final polishing on alumina with 0.5 /xm particle size. Marker lines were inscribed at the polished surface by using 9/~m diamond paste parallel and perpendicular to the rolling direction. The deformed surface was examined in a scanning electron microscope (SEM). Chemical analysis was performed by us-

Design of injection moulding processes and parts: T.J. McCabe et al. (Concurrent Technologies Corporation, USA)

Design of injection moulding processes and parts: T.J. McCabe et al. (Concurrent Technologies Corporation, USA)