Gearbox Corrosion PHM via Oil Condition Sensing and Model Fusion

Continued development of compact, high-reduction ratio gearboxes, including the F-35 Joint Strike Fighter Lift Fan Gearbox, relies on the use of advanced steel alloys and high-temperature fracture-tough coatings to create gear configurations with low noise and vibration characteristics. All gearbox materials, including the housing, must be sufficiently lightweight, affordable, and have the durability to operate in both high-and low-temperature lubrication environments. Due to the critical nature of these systems, it is imperative, wherever possible, to detect and correctly classify sources of contamination that could lead to premature equipment failure or retirement. To address corrosion effects with an innovative prognostics and health management (PHM) capability, Impact proposes implementing it’s Smart Oil Sensor (SOS) and fusing in vibro-acoustic information gained from existing on-board PHM sensors (primarily accelerometers). The SOS is a broadband electrochemical spectroscopy sensor with embedded processing capable of detecting contaminants and corrosion precursors, including salt and fresh water, well below existing Navy condemning limits. This information will be coupled with appropriate corrosion failure mode prediction models and prognostic algorithms to provide actionable maintenance information prior to significant corrosion progression.