ENGINEERING | RESEARCH | DEVELOPMENT | TESTING | EVALUATION 
SAFE Inc.
Loading

2019

Continue to support Maintenance, Repair, and Overhaul (MRO) facilities and Space companies with failure analysis to determine the root cause of failure in aerospace structures

Partnering with Southwest Research Institute on the Corrosion Policy and Oversight Technical Corrosion Collaboration program, "Mechanisms of Accelerated Cracking under Cyclic Relative Humidity Conditions"

Executing fatigue, crack growth and fracture toughness tests for a major business jet OEM

Continue to provide FAA Designated Engineering Representative (DER) support for Structures, Fatigue and Damage Tolerance for Major Repairs and Alterations on Part 23 and 25 aircraft

     Antenna installations

     Mechanical damage repair

     Maintenance induced damage repair

     Evaluation of widespread fatigue damage (WFD)

Developing a Durability and Damage Tolerance Analysis course for FAA Certification to be offered as requested and at the Jan 2020 AFGROW training class in Orlando, FL

Part of the Office of Naval Research team on Solid State Structural Repair (S3R) using Cold Spray

Executing a large fatigue test campaign for VRC Metal Systems as part of a NAVAIR SBIR

Sarah Galyon Dorman gave an invited talk, “The Effect of Corrosion Inhibitors on Fatigue under Complex Environmental Conditions,” at the Society of Automotive Engineers (SAE) AMS G8 Aerospace Organic Coatings Committee Meeting October 1, 2019 in Colorado Springs, CO.

Awarded program through the Corrosion Policy and Oversight Office FA7000-19-2-0026, “Mechanisms of Accelerated Cracking under Cyclic Relative Humidity Conditions” more details to come.

Presentations and Posters given at the 2019 DoD and Allied Nations Corrosion Conference August 11-15, 2019 Oklahoma City, OK

Kelly J., Goff, A., Galyon Dorman, S., (2019) “Effect of Inhibitor Leaching from Chromate and Chromate-Free Primers on the Corrosion Protection of AA7075-T651,” Proceedings of the 2019 DoD and Allied Nations Corrosion Conference, Oklahoma, OK, August 2019.

Galyon Dorman, S.E., Rausch, J.W., Niebuhr, J.H, Fawaz, S.A. (2019),”The Effect of Corrosion Inhibitors on Fatigue Damage Under Complex Environmental Conditions” Proceedings of the 2019 DoD and Allied Nations Corrosion Conference, Oklahoma, OK, August 2019.

Galyon Dorman, S.E., Niebuhr, J.H., Locke, J.S., Free, B. (2019),” The Development of a Method for Complex Environment Corrosion Fatigue Testing” Proceedings of the 2019 DoD and Allied Nations Corrosion Conference, Oklahoma, OK, August 2019.

Two student posters mentored by SAFE were also presented.

Presentation given at the Cold Spray Action Team Meeting, June 25-26, 2019 Worchester, MA.

Sarah Galyon Dorman and Scott Fawaz, “FAA Certification of Cold Spray Dimensional Repair” CSAT 2019, June 26, 2019 Worchester, MA

Presentation given at the Society for the Advancement of Material and Process Engineering conference, May 20-24, 2019 Charlotte, NC

Sarah Galyon Dorman, Saravanan Arunachalam and Scott Fawaz “Cold Spray Technology for Structural Restoration of Sea-Based Aviation Structural Materials” SAMPE 2019, Charlotte, NC, May 22, 2019.

Cadet Engineering Design Team mentored by Jason Niebuhr competed in and was successful in the University Design Challenge April 9-12, 2019 at the Northwest Florida State College, Niceville, FL

Cadet Engineering Design Team mentored by Sarah Galyon Dorman took 3rd place in the University Student Design and Applied Solutions Competition April 16-17, 2019 in Houston, TX


...check back for periodic updates


2018

Atlantic Track, Static & Dynamic Testing of Crane Rail Clips; Mechanical Testing

DAC, Consulting Services; Engineering Services

DFEM Design Support, Design Methodologoes in the Classroom, Industry and DOD; Engineering Services

DOT-FRA, Testing of Manway Covers; Mechanical Testing

Excet (NRL), Stress Intensity factor soultions for thumbnail cracks in the thread root of 0.5-13 UNC and 1-8 UN bolts; Static Strength Analysis

Kinetic Research (SPEE3D), Machine testing and Failure Analysis; Engineering Services

LMI, Consulting Services; Engineering Services

Moog Aviation, - Substantiation for S-92 Oil Sump Housing Corrosion Repair using Cold Spray, - S-76 Bifilar Cold Spray Repair; Structural Analysis

MRO Technologies, Consulting Services; Engineering Services

National Institute of Aviation Research (NIAR) NIAR - F-35 Failure Analysis, "Level 1" Failure Analysis and "Level 2" Failure Analysis; Failure Anlaysis

NAVAIR, Fatigue Testing; Mechanical testing of Cold Worked Holes

NAVAIR, Fatigue testing of aircraft hooks

Office of Naval Research, Advanced Methods for Evaluation of Corrosion on Sea-Based Assets; R&D

Office of Naval Research, Effect of Galvanic Coupling and Corrosion Inhibiting Coatings on Environmentally Assisted Cracking; R&D

Ohio State University, Qualifacation and Prediction of Corrosion and Enviroment Assisted Cracking Failure in Atmospheric Corrsion Envirements; R&D

Sabreliner Aviation, KC-135 Analysis of Teardown Findings

Space X, Fatigue and fracture analysis for twenty block 5 subassemblies

United Launch Alliance, Failure Analysis of Spot Welds; R&D

United States Air Force Academy, Predicting and Managing Atmospheric Corrosion in DoD High Strenght Aluminum Alloys; R&D

VRC Metal Systems, Cold Spray Repair of Grade 5 Titanium IBRs; R&D


Completed program FA7000-15-2-0012 “Effect of Galvanic Coupling and Corrosion Inhibiting Coatings on Environmentally Assisted Cracking”


Completed program FA7000-14-2-0013 “Predicting and Managing Atmospheric Corrosion in DOD High Strength Aluminum Alloys”


Presentation given at the AFGROW User’s Workshop September 11-12, 2018, Ogden, UT.

Fawaz, S.A., (2018) “Environmental Effects on Fatigue Crack Growth.” AFGROW Users Workshop, Ogden, UT.


Presentation given at the Stress-Assisted Corrosion Damage V Conference July 15-20, 2018 in Hernstein, Austria

Galyon Dorman, Sarah, Justin Rausch, Jason Niebuhr, Saravanan R. Arunachalam, and Scott A. Fawaz (2018). The Effect of Corrosion Inhibitors on Fatigue under Complex Environmental Conditions. Stress-Assisted Corrosion Damage V Conference. Hernstein, Austria.

 

Presentation given at CORROSION 2018, April 15-19, 2018 in Phoenix, AZ

Galyon Dorman, S.E., Rausch, J.W., Niebuhr, J.H., Arunachalam, S.R., Fawaz, S.A., (2018) “The Effect of Corrosion Inhibitors on Corrosion Fatigue under Complex Environmental Conditions,” Proceedings of the 2018 NACE Corrosion Conference, Phoenix, AZ, April 


Completeprogram FA7000-15-2-0012 “Effect of Galvanic Coupling and Corrosion Inhibiting Coatings on Environmentally Assisted Cracking”
Completed program FA7000-14-2-0013 “Predicting and Managing Atmospheric Corrosion in DOD High Strength Aluminum Alloys”
Presentation given at the AFGROW User’s Workshop September 11-12, 2018, Ogden, UT.
Fawaz, S.A., (2018) “Environmental Effects on Fatigue Crack Growth.” AFGROW Users Workshop, Ogden, UT.
Presentation given at the Stress-Assisted Corrosion Damage V Conference July 15-20, 2018 in Hernstein, Austria
Galyon Dorman, Sarah, Justin Rausch, Jason Niebuhr, Saravanan R. Arunachalam, and Scott A. Fawaz (2018). The Effect of Corrosion Inhibitors on Fatigue under Complex Environmental Conditions. Stress-Assisted Corrosion Damage V Conference. Hernstein, Austria.
Presentation given at CORROSION 2018, April 15-19, 2018 in Phoenix, AZ
Galyon Dorman, S.E., Rausch, J.W., Niebuhr, J.H., Arunachalam, S.R., Fawaz, S.A., (2018) “The Effect of Corrosion Inhibitors on Corrosion Fatigue under Complex Environmental Conditions,” Proceedings of the 2018 NACE Corrosion Conference, Phoenix, AZ, April 

2017

Executed University of Akron program to transition Supersonic Particle Deposition (SPD) to AMES


Continued execution of FA7000-14-2-0013, “Predicting and Managing Atmospheric corrosion in DoD High Strength Aluminum Alloys”


Technical work is complete. Awaiting final close-out.


Continued execution of FA7000-15-2-0012, “Effect of Galvanic Coupling and Corrosion Inhibiting Coatings on Environmentally Assisted Cracking”


Continued Execution of VRC Independent Contractor Agreement for Cold Spray Engineering Support


Continued Execution of tasks under consulting agreement with Moog


Presentations given at the 2017 DoD and Allied Nations Corrosion Conference August 6-10, 2017 Birmingham, AL

Rausch, J.W., Fawaz, S.A., “Effect of Environment on the Pit-to-Crack Transition in 7075 Aluminum Alloy” Proceedings of the 2017 DoD and Allied Nations Corrosion Conference, Birmingham, AL, August 2017.

Jason Niebuhr, Saravanan Arunachalam and Scott A. Fawaz (2017). Effects of Atmospheric Environmental Conditions on Fatigue Crack Growth Rates. 2017 Department of Defense - Allied Nations Technical Corrosion Conference. Birmingham, AL.

Galyon Dorman, S.E., (2017) “The effect of Corrosion Inhibitors on the Corrosion Fatigue of a Legacy Aircraft Aluminum Alloy,” Proceedings of the 2017 Department of Defense - Allied Nations Technical Corrosion Conference. Birmingham, AL.

Galyon Dorman, S.E., Arunachalam, S.R. and Fawaz, S.A., (2017). “The Effect of Corrosion Inhibitors on Corrosion Fatigue Damage Under Complex Environmental Conditions. “Proceedings of the 2017 Department of Defense - Allied Nations Technical Corrosion Conference. Birmingham, AL.

Arunachalam, S.R., Buckley, R.T.  and Fawaz, S.A., (2017). “Effect of Electo Discharge Machining on the Corrosion Behavior of Aluminum Alloys,“ Proceedings of the 2017 Department of Defense - Allied Nations Technical Corrosion Conference. Birmingham, AL.

Arunachalam, S.R., Kaster, S.L., Buckley, R.T., Kelly R.G. and Fawaz, S.A., (2017). “Mechanical Impact of Corrosion Damage,“ Proceedings of the 2017 Department of Defense - Allied Nations Technical Corrosion Conference. Birmingham, AL.

 

Presentation and Posters given at The 29th Symposium of the International Committee on Aeronautical Fatigue (ICAF) in June 5-9, 2017 Nagoya, Japan

Galyon Dorman, S.E,  Arunachalam, S.R.  and Fawaz S.A (2017), “Effect of Chromate on Corrosion Fatigue in Service Relevant Concentrations,” The 29th Symposium of the International Committee on Aeronautical Fatigue, Nagoya, Japan.


Justin Rausch, Sarah E. Galyon Dorman, and Dr. Scott Fawaz, “Corrosion Fatigue Pit-to-Crack Test Methodology” Poster Session The 29th Symposium of the International Committee on Aeronautical Fatigue, Nagoya, Japan.

Saravanan Arunachalam and Scott Fawaz, “Structural Restoration Viability Using Cold Spray Technology,” Poster Session The 29th Symposium of the International Committee on Aeronautical Fatigue, Nagoya, Japan.

Cadet Engineering Design Team mentored by Sarah Galyon Dorman took 1st place in the University Student Design and Applied Solutions Competition April 14-15, 2017 in Houston, TX


2016

Completed work on Office of Naval Research contract N0001413C0113 “Corrosion Fatigue Test Protocol”.


Completed contract from Saberliner Aviation LLC to support FA7000-D-10-0014, task order 27, failure analysis of KC-135 NDI indications.


Completed Contract FA7000-11-2-0012, “Managing Environmental Impacts on Time-Cycle Dependent Structural Integrity of High Performance DoD Alloys”


Completed MSU-MILTECH for analysis of AFRL and DARCEO engineering and test reports on SPD military applications.
Completed contract for Twin Commander for Failure Analysis Report.


Performed one task, failure analysis and testing of railway tank car hulls under IDIQ Task order contract DTFR5315D00001 through the Department of Transportation Federal Railway Administration (DOT FRA).


Executed contract with Gulfstream Aerospace Corporation to provide fatigue and damage tolerance testing.


Executed University of Akron program to transition Supersonic Particle Deposition (SPD) to AMES


Continued execution of FA7000-14-2-0013, “Predicting and Managing Atmospheric corrosion in DoD High Strength Aluminum Alloys”


Continued execution of FA7000-15-2-0012, “Effect of Galvanic Coupling and Corrosion Inhibiting Coatings on Environmentally Assisted Cracking”




Completed work on Office of Naval Research contract N0001413C0113 “Corrosion Fatigue Test Protocol”.
Completed contract from Saberliner Aviation LLC to support FA7000-D-10-0014, task order 27, failure analysis of KC-135 NDI indications.
Completed Contract FA7000-11-2-0012, “Managing Environmental Impacts on Time-Cycle Dependent Structural Integrity of High Performance DoD Alloys”
Completed MSU-MILTECH for analysis of AFRL and DARCEO engineering and test reports on SPD military applications.
Completed contract for Twin Commander for Failure Analysis Report.
Performed one task, failure analysis and testing of railway tank car hulls under IDIQ Task order contract DTFR5315D00001 through the Department of Transportation Federal Railway Administration (DOT FRA).
Executed contract with Gulfstream Aerospace Corporation to provide fatigue and damage tolerance testing.
Executed University of Akron program to transition Supersonic Particle Deposition (SPD) to AMES
Continued execution of FA7000-14-2-0013, “Predicting and Managing Atmospheric corrosion in DoD High Strength Aluminum Alloys”
Continued execution of FA7000-15-2-0012, “Effect of Galvanic Coupling and Corrosion Inhibiting Coatings on Environmentally Assisted Cracking”
Completed work on Office of Naval Research contract N0001413C0113 “Corrosion Fatigue Test Protocol”.
Completed contract from Saberliner Aviation LLC to support FA7000-D-10-0014, task order 27, failure analysis of KC-135 NDI indications.
Completed Contract FA7000-11-2-0012, “Managing Environmental Impacts on Time-Cycle Dependent Structural Integrity of High Performance DoD Alloys”
Completed MSU-MILTECH for analysis of AFRL and DARCEO engineering and test reports on SPD military applications.
Completed contract for Twin Commander for Failure Analysis Report.
Performed one task, failure analysis and testing of railway tank car hulls under IDIQ Task order contract DTFR5315D00001 through the Department of Transportation Federal Railway Administration (DOT FRA).
Executed contract with Gulfstream Aerospace Corporation to provide fatigue and damage tolerance testing.
Executed University of Akron program to transition Supersonic Particle Deposition (SPD) to AMES
Continued execution of FA7000-14-2-0013, “Predicting and Managing Atmospheric corrosion in DoD High Strength Aluminum Alloys”
Continued execution of FA7000-15-2-0012, “Effect of Galvanic Coupling and Corrosion Inhibiting Coatings on Environmentally Assisted Cracking”
Completed work on Office of Naval Research contract N0001413C0113 “Corrosion Fatigue Test Protocol”.
Completed contract from Saberliner Aviation LLC to support FA7000-D-10-0014, task order 27, failure analysis of KC-135 NDI indications.
Completed Contract FA7000-11-2-0012, “Managing Environmental Impacts on Time-Cycle Dependent Structural Integrity of High Performance DoD Alloys”
Completed MSU-MILTECH for analysis of AFRL and DARCEO engineering and test reports on SPD military applications.
Completed contract for Twin Commander for Failure Analysis Report.
Performed one task, failure analysis and testing of railway tank car hulls under IDIQ Task order contract DTFR5315D00001 through the Department of Transportation Federal Railway Administration (DOT FRA).
Executed contract with Gulfstream Aerospace Corporation to provide fatigue and damage tolerance testing.
Executed University of Akron program to transition Supersonic Particle Deposition (SPD) to AMES
Continued execution of FA7000-14-2-0013, “Predicting and Managing Atmospheric corrosion in DoD High Strength Aluminum Alloys”
Continued execution of FA7000-15-2-0012, “Effect of Galvanic Coupling and Corrosion Inhibiting Coatings on Environmentally Assisted Cracking”

2015

September 15-16, 2015 – Presented “Environment Spectra Effects on Fatigue of Airframe Aluminum Alloys: Airframe Environment and Load-Time Spectra” and “Finite Width Correction for Very Narrow Plates – An Update” at the AFGROW User Workshop, Layton, UT

August 12-13, 2015 – Presented technical paper at the annual Office of Naval Research Sea Based Aviation Structures program review, Naval Sea Warfare Center – Carderock, MD.

July 7-8, 2015 – Participated in the DoD Corrosion Forum XXXIX, McLean, VA.

June 23-24, 2015 – Attended the 2015 Cold Spray Action Team workshop, Worcester Polytechnic Institution, MA

June 1 – 5, 2015 – Attended and presented technical paper at The 28th Symposium of the International Committee on Aeronautical Fatigue, Helsinki, Finland.

April 29, 2015 – Out-brief of the USAF Academy cadet corrosion projects to the OSD AT&L Director of Corrosion Policy and Oversight and staff.

March 30 – 2 April, 2015 – Attended the 2015 Aircraft Airworthiness and Sustainment Conference, Baltimore, MD

March 24 – 25, 2015, Participated in the DoD Corrosion Forum XXXVIII, McLean, VA.

January 11 – 12, 2015 – Participated in the 6th Annual Persh Workshop on Corrosion Protection and Control Policy, Alexandria, VA


2014

December 2 – 3, 2014 – Participated in the DoD Corrosion Forum XXXVII, McLean, VA.

September 16 – 17, 2014 – Attended the North American Cold Spray Conference, Bromont, Quebec, CA

September 9 – 10, 2014 – AFGROW Users Conference, Layton, UT.

August 12 – 14, 2014 – USAFA-CAStLE / SAFE / UVa Technical Corrosion Collaboration Team Meeting, Akron University, Akron, OH, VA.

July 22 – 25, 2014 – Sea-based Aviation National Naval Responsibility Structures and Materials Annual Review, Patuxent River, MD.

July 15 – 17, 2014 – Participated in the DoD Corrosion Forum XXXVI, McLean, VA.

July 1, 2014 – AFRL SBIR Phase I on Programmable Accelerated Environmental Test System for Aerospace Materials, AFRL/RX, Wright-Patterson AFB, OH.

April 30, 2014 – Out-brief of the USAF Academy cadet corrosion projects to the OSD AT&L Director of Corrosion Policy and Oversight and staff.

April 8 – 9, 2014 – Attended MRO Conference, Phoenix, AZ

March 25 – 27, 2014 – Participated in the DoD Corrosion Forum XXXVI, McLean, VA.


2013

December 3 – 5, 2013 – Participated in the DoD Corrosion Forum XXXV, McLean, VA.

November 11 – 15, 2013 – Supersonic Particle Deposition Technical Interchange Meeting with Australia’s DSTO, CSIRO, and Rosebank Engineering.

October 25, 2013 – Sponsor AIAA Annual Technical Symposium, University of Colorado-Colorado Springs.

August 13 – 15, 2013 – USAFA-CAStLE / SAFE / UVa Technical Corrosion Collaboration Team Meeting, The Ohio State University, Columbus, OH.

July 23 – 25, 2013 – Participated in the DoD Corrosion Forum XXXII, McLean, VA.

July 22 – 23, 2013 – Sea-based Aviation (SBA) National Naval Responsibility (NNR) Structures and Materials Annual Peer Review, Office of Naval Research, Washington, DC.

May 1, 2013 – Out-brief of the USAF Academy cadet corrosion projects to the OSD AT&L Director of Corrosion Policy and Oversight and staff.

April 23 – 26, 2013 –  The NATO School, Oberammergau, Germany.

March 17 – 21, 2013 – NACE Corrosion 2013, Orlando, FL

March 16, 2013 – Opening of the Orlando Science Center Corrosion Exhibit

February 26 – March 1, 2013 – Technical Interchange Meeting with USAF Academy / CAStLE.  Meeting with theDepartment of Engineering Mechanics and CAStLE leadership.  Critical Design Review (CDR) for cadet project, “Atmospheric Fatigue Capstone.”

February 21 – 22, 2013 – USAFA-CAStLE / SAFE / UVa Technical Corrosion Collaboration Team Meeting, University of Virginia, Charlottesville, VA.

February 11 – 15, 2013 – FAA DER engineering for Lufthansa’s Lockheed L1649A Super Star Restoration Project, Auburn, ME.

January 7 – 9, 2013 – Technical Corrosion Collaboration Interim Program Review at the University of Southern Mississippi, Hattiesburg, MS.


2012

Dececember 4 – 6, 2012, – Participated in the DoD Corrosion Forum XXXI, McLean, VA.

Novevember 27 – 29, 2012 – Attended the USAF Aircraft Structural Integrity Program Conference

November 20, 2012 – Briefing to Director, Corrosion Policy and Oversight regarding development of the Engineering Resource Data Management System, Arlington, VA.

November 15 – 16, 2012 – Technical Interchange Meeting with Monash University and the Defence Science and Technology Organization (DSTO) of Australia to discuss collaboration opportunities in the broad area of materials degradation.

November 11 – 14, 2012 – Attended the Australian Corrosion Association Inc. sponsored coference, Corrosion and Prevention 2012

September 11-12, 2012 – Presented technical paper at the AFGROW Users Workshop entiltled, Stress Intensity Values for Narrow Plates with a Centrally Located Hole Subject to Remote Tension

August 8 – 9, 2012 – USAF Corrosion Prevention and Control Executive Working Group Meeting, Dayton, OH.

July 24 – 26, 2012 – Program Review Technical Corrosion Collaboration, University of Virginia, Charlottesville, VA.

July 10 – 12, 2012 – Participated in the DoD Corrosion Forum XXX, McLean, VA.  Provided input to OSD AT&L Science and Technology Roadmap.

June 26 – 28, 2012 – Workshop to learn about recent developments of the Accelerated Corrosion Expert Simulator (ACES) and discuss the applicability to US Navy weapon systems.

June 4, 2012 – Technical Interchange Meeting with Dr. Dave Roberston the USAF Corrosion Control and Prevention  Executive (CCPE) to discuss the USAF corrosion program.

May 16 – 17, 2012 – Interim Program Review at The Ohio State University.  Evaluated the progress of the Technical Corrosion Collaboration research projects.

April 16 – 20, 2012 – Technical Interchange Meeting, CAStLE, USAF Academy.  Meeting with the OSD AT&L Director of Corrosion Policy and Oversight, CAStLE leadership, and cadets to review cadet final projects.

April 2 – 5, 2012 – Aircraft Airworthiness & Sustainment Conference, Baltimore, MD.

Session chair for “Structures – Tools for Integrity Assessment and Management”

Technical Presentation Co-author, “Stress Intensity Values for Finite Width Plates”

March 12-15, 2012 – Attended National Association of Corrosion Engineers (NACE) Conference and DoD Corrosion Forum (XXIX) in Salt Lake City, UT.  Reviewed state-of-the-art research in the areas of atmospheric corrosion and corrosion modeling.

February 3, 2012 – Awarded contract with SAIC to providing engineering consulting services to support the OSD AT&L Director of Corrosion Policy and Oversight