1. May 16, 2003 Team #27 EA-6B Flaperon Actuator Team Members: Eric Sullivan (Project Manager) (Project Manager) Joseph Clark Casey Poeth Josselin Legeay Janice Wisely Advisor: Dr. DeBartolo Dr. DeBartolo

2. May 16, 2003 Team #27 Agenda The Model - Josselin Legeay The Model - Josselin Legeay Timeline - Janice Wisely Timeline - Janice Wisely Testing - Eric Sullivan Testing - Eric Sullivan Testing Setbacks - Eric Sullivan Testing Setbacks - Eric Sullivan Results - Casey Poeth Results - Casey Poeth Recommendations Recommendations –Clevis Design - Joseph Clark –Material Change - Joseph Clark Corrosion Issues - Josselin Legeay Corrosion Issues - Josselin Legeay

3. May 16, 2003 Team #27 The Model Scaled down Scaled down Stiffening Ridge Stiffening Ridge 1 2 3

4. May 16, 2003 Team #27 Timeline - GANTT

5. May 16, 2003 Team #27 Testing

6. May 16, 2003 Team #27 Testing 6 Tests 6 Tests –3 w/ ridge –3 w/o ridge Procedure Procedure –Set-up –Pre-load –Test

7. May 16, 2003 Team #27 Testing Setbacks Clevis Design Clevis Design Apparatus Inconsistency Apparatus Inconsistency Data Acquisition Techniques Data Acquisition Techniques

8. May 16, 2003 Team #27 Results

9. May 16, 2003 Team #27 Results Test 1: 745,155 Test 2: 766,682 Test 3: 957,059 Test 4: 1,573,111 Test 5: 2,000,000 Test 6: 1,029,879

10. May 16, 2003 Team #27 Recommendations

11. May 16, 2003 Team #27 Clevis Design One Piece Design One Piece Design Three Piece Design Three Piece Design

12. May 16, 2003 Team #27 Material Comparison

13. May 16, 2003 Team #27 Cu H2H2 Fe Zn Al Cu 2+ H+H+ Fe 2+ Zn 2+ Al 3+ +0.34V 0.00V -0.44V -0.76V -1.66V MnMn 2+ -1.18V Corrosion issues Copper could attack the aluminum Copper could attack the aluminum Could result in failure modes Could result in failure modes Aluminum oxide (Al 2 O 3 ) is impervious and coherent Aluminum oxide (Al 2 O 3 ) is impervious and coherent Corrosion stops when the layer is 1nm thick Corrosion stops when the layer is 1nm thick

14. May 16, 2003 Team #27 Conclusions Clevis design Clevis design Material Change Material Change Increase Number of Tests Increase Number of Tests –S-N curve –Statistical verification

15. May 16, 2003 Team #27 ¿ Questions ?

16. May 16, 2003 Team #27 Expenditures

17. May 16, 2003 Team #27 Maximum Working Force

18. May 16, 2003 Team #27 Pre-loading Force Pre-loading force greater than maximum working force.- Pre-loading force greater than maximum working force.-