Advanced Materials Manufacturing
Abstract
Advanced Materials Manufacturing is a series of efforts addressing advanced manufacturing technologies for a wide range of materials such as composites, metals, ceramics, nanomaterials, metamaterials, and low observables. These efforts will provide significant productivity and efficiency gains in the defense manufacturing base. These manufacturing technologies will accelerate delivery of technical capabilities to impact current warfighting operations, and manufacturing technologies to reduce the cost, acquisition time and risk of our major defense acquisition programs. Advanced materials manufacturing technologies undergoing development include materials for ballistic survivability and materials for rapid fabrication of structural components. Cold Spray Deposition: The objective for Cold Spray Deposition is to create a proven repair process and original equipment manufacturer applied corrosion/wear prevention treatment for magnesium gearbox housings and parts on numerous platforms. Inability to repair is causing significant readiness, sustainment, and safety issues (20% of the fleet is affected at any given time). Working with the original equipment manufacturer to transition the process to industry to treat new parts and to maintain, repair, and overhaul condemned gearboxes in storage. Net-Shaped Field Assisted Sintering Technology (FAST): FAST will set the processing limits and qualify the process for the production of two ultra high temperature materials components that require full density materials with nano tailored microstructures that are not achievable via other processes. This technology addresses near net shaped, thin walled axial rocket nozzle inserts (flute shaped) made from W (Tungsten) and TaC alloys and sharp leading edges with attachment features made from Hf-based ceramics. This effort will mature the manufacturing readiness of conventional FAST while reducing costs and providing faster delivery times. Fastener Fill: The F-35 Fastener Fill project will address the challenges incurred in the manual fastener fill installation process, which can take as long as 2 minutes per fastener and provides no indication of installation quality other than feel. With over 40,000 fasteners per aircraft for F-35, this is a significant manufacturing issue. In addition, excess materials must be manually skived to meet flushness requirements. The project objective is to refine the contractor’s prototype Rapid Intelligent Fastener Fill System which is an automated combination melt, compress, and skive tool capable of installing fastener fill material in less than 15 seconds per fastener. Automated and Rapid Boot Installation Process: This process will reduce the labor-intensive nature of boot installation procedures, which are not suitable for full-rate production and represent 40% of the cost in component finishing. A risk assessment analysis has identified the following areas to be targeted: (1) automation of the hand-cut/trimmed, multi-piece boot installations; (2) automation of additional trimming, bonding, and pasting activities currently performed manually; (3) improved quality of technician skill/training; and (4) reduction of the waste incurred in cutting/darting boots. High Precision Air Vehicle Manufacturing: The most advanced air vehicles for military applications require unprecedented levels of precision structural fabrication to meet production goals and mission requirements. Precision fabrication simplifies assembly, reduces rework and enables improved weapon system cost and performance. Furthermore, they simplify aircraft sustainment and maintenance by increasing the interchangeability of components. Dimensions from Day One: Demonstrate a methodology that accurately predicts and accounts for the numerous geometric, tooling and material factors impacting finished composite parts; this will enable the correct upfront process and tooling decisions to yield first article parts meeting the dimensional requirements on “day one”. Large Scale Encapsulate Ceramics for Medium and Large Caliber Threat Defeat: This project will mature a novel lighter weight solution for passive armor protection from medium and large caliber threats. Automate the hot press process to manufacture thick ceramic tiles. Improve the dimensional controls for the finished ceramics. Improve the current assembly/multi-component operations for existing target panels with more efficient processes or a single cast approach using steel instead of titanium. Develop a rapid low cost coating operation for the ceramic tiles to prevent reaction with the steel during the casting process. Cast Eglin Steel: This effort will establish Cast Eglin steel chemistry specs to maximize strength and ductility for maximum protection and effectiveness for Hard and Deeply Buried Target (HDBT) targets. Will create a primary casting process for a single piece cast underbody protection system and bomb bodies. Developing cast-in pockets, slopes, and curves in order to meet geometric and blast requirements.
Document Details
- Document Type
- Accomplishment
- Publication Date
- Oct 01, 2015
- Source ID
- 437af07c69a79f4d2ff89a62b5a2b2be