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Path to Inclusion of Static Design Properties in the Metallic Materials Properties Development

and Standardization (MMPDS) Handbook

forTechnology Exchange

at Penn StateNovember 5, 2013

Jana RubadueBattelle

MMPDS Project Manager

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MMPDS Bottom Line Up Front:

The MMPDS Handbook is the primary source in the United States and many other countries of statistically-based, design allowable properties for metallic materials and fastened joints used by the commercial and military aerospace industries

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Battelle’s Founding Mission

• Established by steel industrialist, Gordon Battelle

• Non-profit, charitable trust formed in 1925 in Columbus, Ohio

• Profits reinvested in science & technology, and in charitable causes

“Bring business and scientific interests together as forces for positive change”

Gordon Battelle’s last will and testament

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Battelle: A History of InnovationInspiring new industries; revolutionizing products

Battelle opens for business

Battelle founded per the Will of Gordon Battelle

Xerox office copier enters the market

Develops fuel for Nautilus –first nuclear powered submarine

Makes significant discoveries in Industrial Metals and Material Sciences

Develops Universal Product Code, cut-resistant golf ball, sandwich coins

Develops compact disk and cruise control technology

Forms a Fiber optics venture called Photonic Integration Research Inc (PIRI) with Mitsubishi

and Japan’s NTT Communications Group

Launches new ventures in medical, pharmaceutical, electronics, and software

Wins contract to manage PNNL

Verity – stress analysis wins international engineering award

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Agenda• MMPDS Overview

– Background– Organizational Construct – Handbook Contents

• Static Design Properties– Process– Data requirements– Analyses

• Additive Manufacturing– MMPDS activities– Path forward

• Summary

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Background

Date Key MMPDS Program Events

1937First publication of Army-Navy-Commerce Handbook 5 (ANC-5), which was “free issue”

1954Proponency shifted to the Air Force; Battelle began functioning as the MMPDS Secretariat

1997Industrial Steering Group (ISG) established to provide a source for increased partnership and additional sources of revenue via Handbook sales

2003Federal Aviation Administration (FAA) assumed responsibility for performing government oversight and continues to exercise that function today

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MMPDS Overview (Cont’d)

• Battelle serves as impartial data reviewer–All data is held company proprietary–Established statistical guidelines

• Recognized by the FAA, all Department of Defense (DoD) organizations and agencies, and the National Aeronautics and Space Administration (NASA) within the limitations of the certification requirements of the specific government agency.

AA&S 2012

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MMPDS Organizational Construct

Guidelines

Materials

Fasteners Airframes

Material & Tech Services

Industry Steering Group

(ISG)

Government Steering Group

(GSG)

Secretariat (Battelle)

Propulsion

Great Example of Effective Industry and Government Partnership!

Steering Groups

Task Groups

General Coordinating Committee

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2013 ISG Members*Metallic Material Producers or Technical

Service ProvidersAircraft Producers

(Metallic Material Users)Alcoa Airbus

Aleris Aluminum Boeing Allfast Bombardier

Alro S.A. Cessna ATI Allvac Embraer

Aubert & Duval Goodrich Corp. - Aerostructures Cherry Aerospace Hamilton Sundstrand

Constellium Honeywell Granta Design ITP Industries

Haynes International Korea AerospaceKaiser Aluminum Lockheed Martin Corp.

Magnesium Elektron Lord Corp.Materion Mitsubishi Heavy Ind.

QuesTek Innovations Northrop Grumman Sumitomo Light Metal Industrial Rolls Royce

Universal Alloy Spirit Aerosystems Westmoreland Mechanical

* Member organizations headquartered in 8 different countries worldwide

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MMPDS Contents

Modulus (Typical)

Physical Properties (Typical)

Tensile

Compression

Shear

Bearing

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Additional Tables

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Graphical Data Examples

Next – Static Design Properties

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Design Value Development Process

Material Producer

Meeting Minutes

Handbook and Change Notices

Yes

No

Material Producer

OEM, Data UserFAABattelleMMPDS GCC

ProductionMaterial

Data Meets Handbook

Requirements ?

Approve DesignValues?

Acceptable PublicSpecification

Available?

Coordinate Creation ofAcceptable

Specification

Mechanical PropertyDatabase Generation

Review And Acceptance

Of Design

StatisticallyBased DesignValues

AdditionalData

Needed?

Statistical Analysis of

Data

Archive DataPackage and

Record Decision in Minutes

Develop Proposed

Design

Revise Handbook and Change Notices

Prepare Data Package for GCC Review

AMS, ASTM, etc.

Yes No

Yes

No

Yes

No

Yes

No

Yes

Part Manufacture

Part in Service

MMPDS Process

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Comparison of Minimum Data Requirements

• AMS Specification (S-basis)– For tensile, compression,

elongation, RA, fracture toughness

– 3 Heats, Chemistries– 30 Tests

• MMPDS– Primary tensile properties

for A- and B-basis- 10 Heats/ 10 Lots- 100 tests - (or 299 for non-parametric)

– Primary tensile properties for S-basis- Same as AMS Specification

minimums

– Secondary properties- 3 Heats/ 10 Lots- 20 tests (paired, prefer 2/lot)

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Property Basis Definitions

• A-basis: The lower of either a statistically calculated T99 or specification minimum. T99 is the value at which at least 99% of population is expected to equal or exceed with 95% confidence.

• B-basis: Same as T90; at least 90% of population is expected to equal or exceed with 95% confidence.

NOTE: A- and B-basis for static design properties are based on minimum population of 100

• S-basis: Specification minimum, or value based on specification minimum. (recent are based on minimum population of 30 for AMS specs.)

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What is a Statistical Design Allowable?

T99

T90

T90T99

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Considerations for Design Allowables

• Public specification (indicates material reflects a standard practice)

• Production Method• Distribution of material

– Supplier to Supplier– Within single supplier (heats and lots)– Materials are not normally distributed

- Minimum population of 100 is needed to adequately determine skewness for A-basis, if it will fit Pearson or Weibull distribution.

- Minimum population of 299 is needed for non-parametric A-basis

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Reality – Producer-to-Producer Variability Often Significant

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Analysis Methods used by MMPDS

• Direct (minimum of 100 required for A- and B-basis)– 3 parameter Weibull

- Upper tail censoring- Upper tail censoring with backoff

– Pearson type III- backoff

– Non-parametric (minimum of 299)– Normal (for small sample sizes <100)

• Indirect using reduced ratios• Regression; linear or quadratic (used for Direct or

Indirect Methods) Next: Additive Manufacturing

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Define “Emerging Materials”

Determine variables/

parameters

Document thru Specs and Stds.

Define properties to be published

Define submission guidelines

Determine statistical guidelines

Develop properties

MMPDS Discussions Related to Additive Manufacturing

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Process Sensitive Material(Preliminary Definition)•A material system where additional variables, outside the material specification, orientation, and product thickness, drive significant variability in the mechanical property results.

•Additionally, for a given material property, the variability in a material property at a given location within a given process map is much lower than the variability in the material property when a data set is comprised of material from different locations within the given process map.

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Example; Process Sensitive Materials

•Friction Stir Welding (2024-T3, 2024-T351, 2098-T8)• MMPDS has some data• Previous Analysis Completed• Standards Started

•Laser Additive Manufacturing• MMPDS has some data• Previous Analysis Completed

•Electron Beam Additive Manufacturing•Orbital Arc Welding: Ti-3-2.5•More…

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Path Forward

• Leverage efforts with other groups to– Determine variables– Develop public specifications and standards– Obtain data for analysis

• Initial efforts using current data (primarily additive manufacturing)

• Determine statistical guidelines– Define properties to be published– Consider CMH-17 methods

• Approval of FAA, DoD, and aerospace community

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Summary• MMPDS is a unique, cost-effective collaboration

between government agencies and industry which establishes allowable properties for aerospace metallic materials and fasteners.

• Battelle proudly serves as impartial, vendor-neutral data reviewer

• This MMPDS construct can be easily tailored to develop consensus guidelines for Additive Manufacturing.

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Questions ?

CONTACT INFORMATION

RubadueJ@Battelle.org

Jana RubadueBattelle

(614) 424-5948

www.mmpds.org