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, and metamaterials. Through productivity and efficiency gains, these manufacturing technologies will accelerate delivery of technical capabilities to impact current warfighting operations, while reducing the cost, acquisition time and risk of our major defense acquisition programs. Advanced materials manufacturing technologies undergoing development include materials for ballistic survivability and ballistic protection, survivability and rapid fabrication of structural components. Advanced Propulsion Initiative: Advance propulsion has a crucial need to develop fuel efficient sustainable propulsion capabilities. Several technologies will be developed including Risk-based Life Cycle Management for System Sustainment and As-Manufactured and As-Maintained State Awareness. In addition, technologies will be pursued addressing capability gaps associated with adaptive engine design and high performance lightweight materials, organic matrix composites, oxide/oxide composites, thermal barrier coatings for high temperature structure and light weight alloys. Additional capabilities will focus on unique manufacturing challenges associated with affordable Medium-Small Engine fabrication methods including Expendables. Projects: 40MM M433 Warhead Producibility (FY 2015): Achieve improved anti-personnel lethality at the squad level, increasing first shot effectiveness against personnel targets through optimization of production process prior to transition to Full Rate Production, avoiding high cartridge unit costs with a projected $17/round cost reduction. Primary applications include Mk 19 GMG, M203 GL, M320GL, and M32 MSGL. Secondary applications include Cannon and Tank Calibers, and Hand Grenades. Automated and Rapid Boot Installation (FY 2015-2016): Achieve an F-35 Program-wide 30% reduction in touch labor for boot installation and boot hole cutting. Improve fit and finish, reducing production span times (20s/fastener to 3s/fastener for boot hole cutting), reducing kitting, eliminating time for adhesive mixing, application, and vacuum bagging. Applicable to all aircraft acquisition and sustainment communities. Cold Spray Repair and Rebuild Phase II - Large Structures (FY 2015-2017): Expand the Cold Spray product envelope from 5 feet to a target of 40 feet to enable large tubular component repair. Applications include Seawolf Class Submarine Periscopes and TD-63 Actuators. Dimensions on Day One (FY 2015, FY 2017): Demonstrate a methodology that accurately predicts and accounts for the numerous geometric, tooling and material factors impacting finished composite parts enabling the correct upfront process and tooling design to yield first article parts meeting the “dimensional requirements on day 1”. Applications include F-35/UCLASS/F/A-XX/Long Range Strike for maintaining part and aircraft tolerances, which enables survivable, supportable and affordable air vehicles. Large Scale Encapsulate Ceramics - Phase II (FY 2016): Enable combat vehicles to defeat the large caliber Kinetic and Chemical Energy objective threats within the allocated weight parameters. Help address affordability of the armor, with an estimated cost reduction of $10K /sq. foot. Armor panels will be producible in the shapes required by individual vehicles. Applications include Abrams, which has a known protection limitation. GCV and other vehicles will use this technology to design those areas of vehicles subject to large caliber KE and CE threats. Out of Autoclave Processing of Organic Matrix Composites (OMCs) for Advanced Propulsion (FY 2017): Current state of the art out of autoclave processable OMCs are currently limited to a service life of between 325F and 375F limiting advanced propulsion applications. Expanding performance of OMCs to temperatures between 400F and 625F will dramatically increase the design trade space for developing the next generation advanced propulsion systems. Advanced propulsion structure includes front frames, vanes, stators and outer by-pass ducts. Insertion of this technology onto the Adaptive Engine Transition Programme (AETP) will lower cost, increase range and maintain performance for the next generation tactical aircraft. Fabrication of Non-Eroding Metallic Throat (FY 2016-2017): Scale the manufacturing of Thin walled, Non-Eroding Tungsten (W) Throats from 4” up to 12” inner throat diameters. Applications include Stage 2 & Stage 3 ICBMs as well as Stage 2 Standard Missile III.
Document Details
- Document Type
- Accomplishment
- Publication Date
- Oct 01, 2017
- Source ID
- 67fd06de59a914fe585af032b801f2e0