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Advanced Ceramic Matrix Composites (CMC) Manufacturing and Machining Process Development Improve the fuel efficiency and reduce the weight of the UH-60 Black Hawk and AH-64 Apache helicopters through the use of lighter weight, higher temperature capable and more durable ceramic matrix composite (CMC) turbine engine components. UH-60 Black Hawk Helicopter 1 OBJECTIVE / SOLUTION Helicopters are weight and price sensitive. Propulsion engine weight and fuel efficiency impact mission duration and range. Application of advanced technologies will reduce weight and O&S costs. This project replaces conventional metallic engine component manufacturing processes with state of the art Ce- ramic Matrix Composite (CMC) processes. The application of new CMC technologies will significantly improve thrust-to-weight, specific fuel consumption (SFC), and reliability when compared to the current T-700 engine family. Fabrication, inspection and evaluation (destructive/nondestructive) of coupons and full-scale prototype hardware will validate the project’s success. ACHIEVEMENTS Project results will contribute to meeting Force Operating Capabilities Meets TRADOC Air Maneuver FOC-04-01 Responsive and Sustain- able Aviation Support, 04-02 Effective Aviation Operations in the Contemporary Environment, Mounted/Dismounted Maneuver, 04-05 Mounted Vertical Maneuver, 09-03 Alternative Power for Platforms, Maneuver Sustainment Increased Fuel Efficiency, FF7 Strategic Force Protection, FF5 Sustainment of Modular Forces, CF3 Logistics and Medical in Counterinsurgency (COIN) and non- contiguous battle space, CF4 Soldier Protection in Counterinsur- gency Environment Form/fit/function replacement design for new/retrofit applications Productionized CMC manufacturing processes, reduced O&S and recurring costs, and improved range (1% SFC) BENEFITS CMC 1st and 2nd stage High Pressure Turbine Shrouds (HPT) will be lighter and more durable than metallic HPT shrouds Improved power-to-weight margin and SFC equates to increased mission duration and lower operational costs Provides form/fit/func- tion replacement design for new and retrofit applications Improves damage tolerance and reduces recurring costs Improved specific fuel consumption (SCF) equates to safety due to reduced fuel convoys Reduces CO² emissions POC: Army ManTech Manager, U.S. Army Research, Development, and Engineering Command (RDECOM), Aviation Missile Research, Development and Engineering Center (AMRDEC), Manufacturing Science & Technology Division, ATTN: RDMR-SEM, 5400 Fowler Road, Redstone Arsenal, AL 35898-5000 STATUS Contract award (3Q FY10) first year tasks included: Requirements development and detailed program plan complete (FY10) Conceptual design and risk reduction plan complete (FY10) Evaluate advanced slurry composi- tions, system down selection, and run process trials (FY10-11) Evaluate process capability for multiple shroud geometries (FY10-11) Preliminary design complete (FY10) Environmental Barrier Coating (EBC) process application, strip and repair evaluation (FY10-11) Investigate improved tow coating process (FY10). WEAPON SYSTEMS / SECONDARY ITEMS IMPACTED UH-60 Black Hawk and AH-64 Apache Helicopter family Future rotorcraft engine programs for systems such as the Joint Heavy Lift (JHL) Helicopter POTENTIAL COST AVOIDANCE Return on Investment of 10.3 to 1 with a cost benefit of $82M T-700 Engine Engine Shroud AH-64 Apache Helicopter AIR SYSTEMS

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Page 1: Advanced Ceramic Matrix Composites (CMC) Manufacturing and ... · Missile Research, Development and Engineering Center (AMRDEC), Manufacturing Science & Technology Division, ATTN:

Advanced Ceramic Matrix Composites (CMC) Manufacturing and Machining Process DevelopmentImprove the fuel efficiency and reduce the weight of the UH-60 Black Hawk and AH-64 Apache helicopters through the use of lighter weight, higher temperature capable and more durable ceramic matrix composite (CMC) turbine engine components.

UH-60 Black Hawk Helicopter

1

OBJECTIVE / SOLUTIONHelicopters are weight and price sensitive. Propulsion engine

weight and fuel efficiency impact mission duration and range. Application of advanced technologies will reduce weight and O&S costs. This project replaces conventional metallic engine component manufacturing processes with state of the art Ce-ramic Matrix Composite (CMC) processes. The application of new CMC technologies will significantly improve thrust-to-weight, specific fuel consumption (SFC), and reliability when compared to the current T-700 engine family. Fabrication, inspection and evaluation (destructive/nondestructive) of coupons and full-scale prototype hardware will validate the project’s success.

ACHIEVEMENTS•• Project results will contribute to meeting Force Operating Capabilities•• Meets TRADOC Air Maneuver FOC-04-01 Responsive and Sustain-able Aviation Support, 04-02 Effective Aviation Operations in the Contemporary Environment, Mounted/Dismounted Maneuver, 04-05 Mounted Vertical Maneuver, 09-03 Alternative Power for Platforms, Maneuver Sustainment Increased Fuel Efficiency, FF7 Strategic Force Protection, FF5 Sustainment of Modular Forces, CF3 Logistics and Medical in Counterinsurgency (COIN) and non-contiguous battle space, CF4 Soldier Protection in Counterinsur-gency Environment •• Form/fit/function replacement design for new/retrofit applications•• Productionized CMC manufacturing processes, reduced O&S and recurring costs, and improved range (1% SFC)

BENEFITS•• CMC 1st and 2nd stage High Pressure Turbine Shrouds (HPT) will be lighter and more durable than metallic HPT shrouds •• Improved power-to-weight margin and SFC equates to increased mission duration and lower operational costs •• Provides form/fit/func-tion replacement design for new and retrofit applications•• Improves damage tolerance and reduces recurring costs•• Improved specific fuel consumption (SCF) equates to safety due to reduced fuel convoys•• Reduces CO² emissions

POC: Army ManTech Manager, U.S. Army Research, Development, and Engineering Command (RDECOM), Aviation Missile Research, Development and Engineering Center (AMRDEC), Manufacturing Science & Technology Division, ATTN: RDMR-SEM, 5400 Fowler Road, Redstone Arsenal, AL 35898-5000

STATUSContract award (3Q FY10) first year tasks

included: ― Requirements development and

detailed program plan complete (FY10) ― Conceptual design and risk reduction

plan complete (FY10) ― Evaluate advanced slurry composi-

tions, system down selection, and run process trials (FY10-11)

― Evaluate process capability for multiple shroud geometries (FY10-11)

― Preliminary design complete (FY10) ― Environmental Barrier Coating (EBC)

process application, strip and repair evaluation (FY10-11)

― Investigate improved tow coating process (FY10).

WEAPON SYSTEMS / SECONDARY ITEMS IMPACTED•• UH-60 Black Hawk and AH-64 Apache Helicopter family •• Future rotorcraft engine programs for systems such as the Joint Heavy Lift (JHL) Helicopter

POTENTIAL COST AVOIDANCE•• Return on Investment of 10.3 to 1 with a cost benefit of $82M

T-700 Engine

Engine Shroud

AH-64 Apache Helicopter

AIRSYSTEMS

Page 2: Advanced Ceramic Matrix Composites (CMC) Manufacturing and ... · Missile Research, Development and Engineering Center (AMRDEC), Manufacturing Science & Technology Division, ATTN:

POC: Army ManTech Manager, U.S. Army Research, Development, and Engineering Command (RDECOM), Aviation Missile Research, Development and Engineering Center (AMRDEC), Manufacturing Science & Technology Division, ATTN: RDMR-SEM, 5400 Fowler Road, Redstone Arsenal, AL 35898-5000

Automation Of Rotorblade Erosion Coating Application Maximize rotor blade erosion coating uniformity and minimize material waste by automating the application process. Provide a flexible solution for multiple aircraft platforms and multiple coatings.

UH-60 Black Hawk Helicopter

2

OBJECTIVE / SOLUTIONHelicopter main rotor blades are experiencing unac-

ceptable removal rates due to erosion from sand and moisture. The current manual UH-60 Utility Helicopter erosion protection coating process has the potential to exhibit out of tolerance coating thickness and can waste coating due to inefficient material transfer.

The automated coating system will be designed to accommo-date multiple coating technologies and multiple aviation platforms. Erosion protection is dependent on uniformity of application of three separate materials (primer, basecoat, topcoat) within strict thickness tolerances. Transfer efficiency that minimizes material waste is difficult given required applicator distance from coating source and geometry of coating coverage area. A multi-purpose solution requires interfaces for a variety of spray gun types, flex-ible fixturing, and an innovative coating delivery system. Consis-tent coating thickness will be achieved by utilizing system control feedback for automated process adjustments. The material source will be located at the best location to maximize effective material delivery to rotor blades. ”State of the Market” automated spray gun technology will be utilized to achieve precision spray pattern.

ACHIEVEMENTS•• Project results will contribute to meeting Air Maneuver Force Operating Capabilities (FOC) including FOC-04-01, Responsive and Sustainable Aviation Support (Tier 1) and FOC-04-02, Effective Avia-tion Operations in the Contemporary Operating Environment (Tier 1)•• Improved system components that maximize coating transfer efficiency•• System controls to include process monitoring, defect detection, and self adjustment•• Flexible automation to accommodate various coating materials and blade configurations•• Rotor blade fixtures with precision mounting points for automated process and mobility for material handling•• Increased throughput, reduction in coating material usage, reduced cost due to a more efficient process

BENEFITS•• Fleet-wide increase in operational readiness for the Warfighter due to longer lasting protection from sand and rain•• Reduction in number of blades that are deemed unserviceable, currently resulting in Aviation Units being required to replace blades•• Increased capability for organic industrial base to provide erosion coating protection on Army aviation platforms

Rotorblade Damage by Erosion

STATUS•• Program is in its second year of funding (FY11)•• Robotic System Integrator source selec-tion completed (FY11)•• System Integrator developing and testing automated erosion coating process (FY11)•• Leverages ATO-D (D.RO.2008.01) Rotor Durability for application to future adoption of erosion coating material

WEAPON SYSTEMS / SECONDARY ITEMS IMPACTED•• UH-60/HH-60 Black Hawk Helicopter family •• Other rotorcraft programs such as Army AH-64 Apache, CH-47 Chinook, UH-72 Lakota and Navy CH-53 Sea Stallion and CH-46 Sea Knight Helicopters

POTENTIAL COST AVOIDANCE•• Return on Investment of 16.7 to 1 with a cost benefit of $81.3M

AIRSYSTEMS

Page 3: Advanced Ceramic Matrix Composites (CMC) Manufacturing and ... · Missile Research, Development and Engineering Center (AMRDEC), Manufacturing Science & Technology Division, ATTN:

STATUS•• Program is currently in final year of funding •• Integration, assembly, and sensor network testing started in FY09 and has been successfully completed•• Conductivity demonstration and live fire testing started in FY10 and continues on a successful path for transition to the Apache Program Manager for qualification and flight test

WEAPON SYSTEMS / SECONDARY ITEMS IMPACTED•• AH-64 Apache Helicopter•• Unmanned Aircraft Systems•• Manned Aircraft Structures

POTENTIAL COST AVOIDANCE•• Return on Investment up to 17.7 to 1 with

a cost benefit of $95.3M

AH-64 Apache Helicopter

Primary Structural and Sensing Components for Composite Vertical Stabilizer (CVS)

OBJECTIVE / SOLUTIONDevelop and demonstrate manufacturing techniques

for integrating strain, temperature, vibration, and damage- detection sensors in composite structures. Identify adhesive materials and bonding techniques for integrating sensors

with composite materials; evaluate current composite repair tech-niques for incorporation of sensor network repair processes; develop affordable processes for manufacturing of sensors on flexible sub-strates; and demonstrate sensor network conductivity.

Due to limited flexible sensor technology, some helicopter airframes have been historically passive and function without the ability to detect and assess structural damage. Continual upgrades to add more capable mission equipment to the aircraft have increased weight and stresses on the airframe with no way to monitor the life-time effects on the structural components. There is a strong need to incorporate structural monitoring and battle damage detection capabilities into these structures.

ACHIEVEMENTSSuccessful testing has been completed including: ground testing of

the sensor network in the Composite Vertical Stabilizer (up to 100% of max load for landing gear, 60% of max flight load testing, and 90% of maximum load) and ballistic testing of sensors on composite panels at Aberdeen Proving Grounds. All panels and sensors performed as predicted.

BENEFITS•• Advance the capability for aircraft damage detection•• Provide opportunity to integrate into the aircraft platform condition-based maintenance system to produce structural health indicators•• Leverage the composite structures to produce lighter aircraft structures to allow for more mission equipment that can expand the soldier and aircrew warfighting capabilities•• Increase aircraft survivability•• Potentially can save lives

Embedded Sensor Processes for Aviation Composite Structures

Develop and demonstrate new manufacturing techniques for integrating sensor networks on

composite aviation structural components.

3

POC: Army ManTech Manager, U.S. Army Research, Development, and Engineering Command (RDECOM), Aviation Missile Research, Development and Engineering Center (AMRDEC), Manufacturing Science & Technology Division, ATTN: RDMR-SEM, 5400 Fowler Road, Redstone Arsenal, AL 35898-5000

AIRSYSTEMS

Page 4: Advanced Ceramic Matrix Composites (CMC) Manufacturing and ... · Missile Research, Development and Engineering Center (AMRDEC), Manufacturing Science & Technology Division, ATTN:

Guided Missile Antenna ManufacturingDevelop and demonstrate cost effective, repeatable manu-facturing technology and processes that can be utilized for conformal missile antennas, including transmit, receive, and datalink.

4

OBJECTIVE / SOLUTIONThe objective of this project is to develop and demonstrate

new methods and processes to produce low cost missile borne antennas in high volume. Currently manufacturing issues exist in antenna manufacturing for radar guided missiles. While the antennas can be and have been manufactured in a labora-tory environment it is clear that significant gains can be made in the reliability, producibility and cost of production through technology improvements. The benefits from this project are developing new processes that use the latest flexible circuit manufacturing techniques which increase their mechanical strength while at the same time retaining flexibility. New chem-ical etching and lay-up processes, reduction in wrap phases, and automated riveting and venting manufacturing will also be addressed.

ACHIEVEMENTS•• Design and implement new processes using the latest flexible circuit manufacturing techniques which increase mechanical strength while at the same time retaining flexibility•• Develop new chemical etching and lay-up processes, reduction in wrap phases, and automated riveting and venting manufacturing for use in many antenna applications

BENEFITS•• Increases yield rates by 25%•• Eliminates autoclave processes•• Decrease in labor time, wasted material, and life cycle costs (Average Unit Production Costs)•• Transition to PM Cruise Missile Defense Systems (CMDS) with EMD late in 2014

STATUSProgram is in first year of funding (FY11) with tasks

including: ― Evaluate nosecone and antenna materials ― Identify design concepts and vendor/suppliers ― Fabricate tooling and prototype ― Test to verify results ― Transition manufacturing improvements to Cruise Missile

Defense Systems (CMDS).

Traditional Multi-lay-ered Riveted Confor-mal Antenna

Two Piece Molded Conformal Antenna

EQ-36 Counterfire Target Acquisition Radar

POC: Army ManTech Manager, U.S. Army Research, Development, and Engineering Command (RDECOM), Aviation Missile Research, Development and Engineering Center (AMRDEC), Manufacturing Science & Technology Division, ATTN: AMSRD-AMR-SE-MT, 5400 Fowler Road, Redstone Arsenal, AL 35898-5000

WEAPON SYSTEMS / SECONDARY ITEMS IMPACTED•• Indirect Fire Protection Capability (IFPC) Incr 2•• Radars•• Ground Vehicles

POTENTIAL COST AVOIDANCE•• Return on Investment of 9.0 to 1 with a

cost benefit of $44.7M

AIRSYSTEMS

Page 5: Advanced Ceramic Matrix Composites (CMC) Manufacturing and ... · Missile Research, Development and Engineering Center (AMRDEC), Manufacturing Science & Technology Division, ATTN:

Low Cost Rotorcraft Cabin Floor StructureReducing the weight of the UH-60/HH-60 helicopter through the use of lighter weight, and more durable composite materials.

5

OBJECTIVE / SOLUTIONDevelop and demonstrate less labor intensive manu-

facturing processes capable of economically producing a lighter and more durable composite floor structure through the use of advanced materials and construction

techniques. Helicopters are weight and price sensitive. Excess weight trans-

lates into reduced mission duration, range, payload, and/or per-formance. Cabin floor structures that are lighter, provide increased operational performance—less weight equals more range and/or operational capability. The current floor is manufactured in a five step process, an inner composite skin, an outer skin, a core blan-ket (spliced and stabilized) as individual cured details and then assembled into a final bonding operation. This manufacturing pro-cess is labor intense and expensive. The proposed cabin floor will be manufactured as a single step, co-cured structure, assembled from carbon face sheets and K-Cor™ sandwich core material. It will be a form/fit/function drop-in solution on both new and retrofit applications. Fabrication, inspection and evaluation (destructive/non-destructive) of coupons and full-scale prototype hardware will validate the project’s success.

ACHIEVEMENTS•• Project results will contribute to meeting Force Operating Capability (FOC) Air Responsive and Sustainable Aviation Support (FOC-04-01), Strategic Force Protection (FF7), Future Force (FF11), Soldier Protection in Counterinsurgency Environ-ment (CF4), and CF6 goals •• Single step manufacturing pro-cesses, reduced O&S costs, improved rate of climb/maneu-verability and increased payload and range

BENEFITS•• New composite cabin floor structures will be lighter than the current cabin floor. (Current projection shows a savings of ~34lbs per ship set) •• Improved power-to-weight margin which equates to better performance and lower opera- tional costs •• Form/fit/function replacement design for new/retrofit applications

POC: Army ManTech Manager, U.S. Army Research, Development, and Engineering Command (RDECOM), Aviation Missile Research, Development and Engineering Center (AMRDEC), Manufacturing Science & Technology Division, ATTN: RDMR-SEM, 5400 Fowler Road, Redstone Arsenal, AL 35898-5000

STATUS•• Program is in its fourth and final year of funding (FY10)•• Requirements development, conceptual design, and risk reduction plan complete (FY07-08)•• Developed conceptual manufacturing, tooling plan, and materials optimization (FY08-FY09)•• Supplier selection complete and Purchase Orders awarded to Albany Engineered Com-posites and GKN Aerospace (FY10)•• Preliminary and detailed design complete (FY10)•• Tool design complete and first floor article manufacture is underway (FY11)•• Complete manufacturing process validation, fabrication of production representative proto-type articles , and fit-check (FY11-FY12)•• Continue leveraging 2010 Improved X/K-CorTM Capabilities Industrial Base Innovation Fund (IBIF) Program

WEAPON SYSTEMS / SECONDARY ITEMS IMPACTED•• UH-60/HH-60 Black Hawk Helicopter Family •• Future Rotorcraft Programs such as the Joint Heavy Lift (JHL) Helicopter

POTENTIAL COST AVOIDANCE•• Return on Investment of 4.1 to 1 with a cost benefit of $22M

UH-60 Black Hawk Helicopter

K-CorTM Compos-ite Material

Improved Cabin Floor (Proposed)

Floor Panels

AIRSYSTEMS

Page 6: Advanced Ceramic Matrix Composites (CMC) Manufacturing and ... · Missile Research, Development and Engineering Center (AMRDEC), Manufacturing Science & Technology Division, ATTN:

Low Cost Zinc Sulfide Missile Dome ManufacturingDevelop and demonstrate advanced manufacturing methods and processes that will provide a capability to produce affordable multi-mode windows and domes for the new generation of sensors for missiles, munitions, and surveillance systems.

OBJECTIVE / SOLUTIONThe existing material choice for long wave-infrared (LWIR) and semi-

active laser domes is multispectral zinc sulfide (ZnS), but current man-ufacturing processes are expensive and time consuming, resulting in major cost and lead time issues for missile systems that employ LWIR seekers. Variability of the current chemical vapor deposition (CVD) process limits repeatability of grown material.

Current processes [CVD and hot isostatic pressing (HIP)] are time-consuming, and yields are low. The objective of this effort is to develop and demonstrate manufacturing processes that are opti-mized for the production of durable, multi-spectral ZnS domes at a substantially lower cost and shorter lead time than currently avail-able.

ACHIEVEMENTSForecasted achievements are:

― Improved control of ZnS process parameters ― Improved zinc (Zn) flows ― Increased uniformity (ZnS thickness profile) ― Increased deposition rate ― Minimized size and concentration of inclusions and fibers in

the ZnS domes due to improved dust exhaust management ― Improved yields by obtaining a more uniform deposition profile ― Minimized cracking by employing better tooling design ― Increased number of dome sites through better management

of the Zn source ― Reduced cycle times for all processes.

BENEFITS•• Reduces dome cost by 62%•• Increases yields by 36%•• Increases strength by 43%•• Promotes competition among ZnS producers

STATUS•• Initial trades complete and on schedule•• Project transitioned to Non-Line-of-Sight Launch System (NLOS-LS) in FY09 •• Project transitions to Joint Air-to-Ground Missile (JAGM) in FY11

POC: Army ManTech Manager, U.S. Army Research, Development, and Engineering Command (RDECOM), Aviation Missile Research, Development and Engineering Center (AMRDEC), Manufacturing Science & Technology Division, ATTN: RDMR-SEM, 5400 Fowler Road, Redstone Arsenal, AL 35898-5000

6

WEAPON SYSTEMS / SECONDARY ITEMS IMPACTED•• Joint Air-to-Ground Missile (JAGM)•• Small Diameter Bomb II—Air Force•• Military systems employing ZnS windows and sensors

POTENTIAL COST AVOIDANCE•• Return on Investment of 19.4 to 1 with a cost benefit of $156M

Dome Optics

Laser Dome

Joint Air-to-Ground Missile (JAGM)

AIRSYSTEMS

Page 7: Advanced Ceramic Matrix Composites (CMC) Manufacturing and ... · Missile Research, Development and Engineering Center (AMRDEC), Manufacturing Science & Technology Division, ATTN:

POC: Army ManTech Manager, U.S. Army Research, Development, and Engineering Command (RDECOM), Aviation Missile Research, Development and Engineering Center (AMRDEC), Manufacturing Science & Technology Division, ATTN: RDMR-SEM, 5400 Fowler Road, Redstone Arsenal, AL 35898-5000

Manufacturing Technology for Advanced Nanocomposite CoatingsImprove manufacturing processes to efficiently implement advanced nanocrystalline diamond/amorphous carbon coat-ings on performance critical Army components.

7

OBJECTIVE / SOLUTIONThis ManTech effort will develop and demonstrate manufac-

turing improvements that optimize the manufacturing process for nanocrystalline diamond and amorphous carbon coatings. These coatings are produced using a room temperature Plasma Assisted Chemical Vapor Deposition (PACVD) process that al-lows the application of carbon thin films on a range of substrates achieving properties such as: improved optical transmission and durability for infrared devices; increased surface hardness; improved corrosion resistance; reduced friction; and increased wear performance.

This project will mature the manufacturing processes required to affordably produce and implement advanced nanocrystal- line diamond/amorphous carbon coatings on a variety of Army components.

ACHIEVEMENTSInitial efforts have included preparation for rapid fixture pro-

totyping equipment, design of an alternate etching chamber and modifications to the existing coating systems to improve efficiency.

BENEFITS•• Increased capacity through design and installation of large-scale manufacturing flexible deposition cells •• Decreased manufacturing time in existing and future coating systems through the addition of capabilities for rapid fixture prototyping, cleaning, polishing and in situ monitoring •• Additional efficiencies realized through improved coating pumping methods, data management and a dedicated etch/rework chamber•• Competitive pricing as a result of increased capacity, throughput and quality control

STATUSThe project is a four-year effort which began in FY 2011. The initial phase of the project has focused on modifying the

current coating systems and processes to improve efficiency. These modifications include reducing system pumping times, adding in situ monitoring capability, improved data management, a larger power supply, rapid fixture prototyping capability, part preparation enhancements, and preliminary design concepts for the first production coating deposition chamber.

WEAPON SYSTEMS / SECONDARY ITEMS IMPACTED•• AH-64 Apache Helicopter Target Acquisi-tion Designation Sight/Pilot Night Vision Sensor (TADS/PNVS), UH-60 Black Hawk Helicopter Rotor Component Applications for Corrosion and Wear

•• Potential additional applications for Optics durability include Targeting Optics (Avia-tion, Missile, Tank). Additional applications for corrosion include any surfaces with dissimilar metals prone to corrosion (transmissions, actuators, landing gear, fasteners). Coating has potential to im-prove wear resistance and reduce friction and additional applications include gears, missile rails, gimbals, and engine compo-nents

POTENTIAL COST AVOIDANCE•• Return on Investment of 6.0 to 1 with a cost benefit of $53M

UH-60 Black Hawk Helicopter

AH-64 Apache Helicopter

AIRSYSTEMS

Page 8: Advanced Ceramic Matrix Composites (CMC) Manufacturing and ... · Missile Research, Development and Engineering Center (AMRDEC), Manufacturing Science & Technology Division, ATTN:

Manufacturing Technology for Affordable and Reliable Unmanned Aerial Vehicle (UAV) PropulsionAddresses manufacturing issues that are inherent to all types of Very Small Heavy Fuel Engines (VSHFE) as well as utilizing addi-tive manufacturing techniques to enhance overall performance while reducing weight.

OBJECTIVE / SOLUTIONThe goal of the program is to demonstrate an affordable Very Small

Heavy/Multi Fuel Engine prototype viable for use in an operational system such as the Shadow and its upgrades. Currently, operational UAVs in the 30-80hp range use AVGAS or MOGAS and are not compli-ant with the “One-Fuel Forward” battlefield policy regarding heavy fuel application. Additionally, current propulsion systems have shown poor reliability and availability. This reliance on high-octane fuel has also been linked to a low Mean Time Between Failure (MTBF) for gasoline engines that operate at high RPMs over a sustained period of time.

This program is addressing manufacturing issues that are inher-ent to all types of Very Small Heavy Fuel Engines (VSHFE) as well as utilizing additive manufacturing techniques to enhance overall perfor-mance while reducing weight.

ACHIEVEMENTS•• Demonstrate a heavy fuel engine for tactical UAVs capable of Op-erational Readiness Rates of ~95% while utilizing battlefield fuels •• Project results will contribute to meeting Readiness, Reliability, Maintainability and Commonality for Sustained Operational Tempo (FOC-09-04), Power and Energy compliant (FOC-09-03) and Sup-ports Logistics under the Top Ten Warfighter Outcomes (WFO)•• Partnered with Air Force ManTech to leverage complementary additive manufacturing efforts•• Partnered with National Center for Defense Manufacturing and Machining (NCDMM) to evaluate and address manufacturing barriers

BENEFITS•• Mature critical manufacturing processes required to improve relia- bility, efficiency, and affordability of VSHFE in the 30 to 80hp class•• Address common technology issues inherent in these airbreathing compression engines to increase reliability, reduce attrition and decrease life cycle costs•• Program goals include increasing Mean Time Between Repair (MTBR) from 250 to 500 hours and reducing cost/hp from $750/hp to $700/hp, while maintaining or improving a cruise Brake Specific Fuel Consumption (BSFC) of 0.6 lbs/hp-hr

STATUS•• Conducted Block on Ring high performance coating tests through the National Center for Defense Manufacturing and Machining (NCDMM) to evaluate internal component coatings•• Manufacturing process development for the fabrication of a Rotor Half Keystone Side Seal •• Identified superior materials and improved machining processes for eccentric shafts

POC: Army ManTech Manager, U.S. Army Research, Development, and Engineering Command (RDECOM), Aviation Missile Research, Development and Engineering Center (AMRDEC), Manufacturing Science & Technology Division, ATTN: RDMR-SEM, 5400 Fowler Road, Redstone Arsenal, AL 35898-5000

8

WEAPON SYSTEMS / SECONDARY ITEMS IMPACTED•• The project will impact UAVs requiring a heavy fuel engine in the 30-80hp class (such as Shadow) as well as Auxiliary Power Units (APU) for air and ground vehicles

POTENTIAL COST AVOIDANCE•• Return on Investment of 8.2 to 1 with a cost benefit of $101.9M

Metal Additive Manufacturing

Shadow Unmanned Aerial Vehicle (UAV)

Coating Failure Inside UAV Engine

AIRSYSTEMS

Page 9: Advanced Ceramic Matrix Composites (CMC) Manufacturing and ... · Missile Research, Development and Engineering Center (AMRDEC), Manufacturing Science & Technology Division, ATTN:

Affordable ManTech for Structure and ArmorProvides design/planning tools and agile manufacturing tech-nologies to expedite and enable high capacity production for critically needed armor structure, composite armor assembly, and armor materials including ceramics, metallics and hybrid-ized composites.

OBJECTIVE / SOLUTIONProvide agile, affordable armor system/materials manufacturing

technologies for advanced ground combat vehicle structure and armor solutions including:

― Agile manufacturing technologies for affordable production of armor materials and structures

― Model Based Environment (MBE) to enable seamless annotation in coupling computer-aided design and manufacturing planning/processes

― Affordable production of advanced armor materials (e.g. silicon carbide, bi-metallic laminates, metal matrix composites (MMC), high performance magnesium alloys, and tailored 3D woven composites)

― Friction-stir welding (FSW) and Gas Metal Arc Welded (GMAW) technologies for joining dissimilar materials and sub-assemblies

― Design and fabrication of a ballistic hull & turret (BH&T) demonstrator to validate MBE and FSW technologies.ACHIEVEMENTS•• Successfully completed and showcased the ManTech BH&T Demonstrator at AUSA and Defense Manufacturing Conferences; validating the MBE practices through collaborative efforts of BAE and GDLS in a joint design and manufacturing venture, friction stir welding of the hull, and build-to-print armor manufacturing•• Demonstrated significant weight reduction (>120 lbs) of a Stryker Troop Ramp by using high performance magnesium alloy•• Validated automated manufacturing processes for silicon carbide tile at a reduced cost ($135/lb to $58/lb)•• Demonstrated high ballistic performance of both titanium and aluminum MMC encapsulated structures and WE43 magnesium alloy•• Demonstrated cost effective manufacturing of a 3D woven through-thickness reinforced ceramic composite armor panel ($550/sq/ft excluding ceramic costs)

BENEFITS•• Provides enhanced, lighter weight, survivable platforms with the affordable high-performance armor planned for next generation ground combat vehicles •• Reduces combat vehicle design-to-production cycle time and cost of manufacturing by 25-40%

POC: Army ManTech Manager, U.S. Army Research, Development and Engineering Command (RDECOM), U.S. Army Research Laboratory (ARL), ATTN: RDRL-WMM-D, Aberdeen Proving Ground, MD 21005-5069

9

STATUS•• In construction of second generation continu-ous hot press furnace to reduce silicon car-bide tile cost from $58/lb to a goal of $40/lb •• Conducting process validation production runs for both titanium and aluminum MMC encapsulated ceramic tile modules, 3D woven composite panels (1 vendor already completed), and cryomilled aluminum matrix composites•• 3D woven composite panels are now con-sidered to be a qualified ManTech material option for use in primary armor design applications•• Ceramic armor tile encapsulated with Al, Ti, and steel has demonstrated high potential as an armor material

WEAPON SYSTEMS / SECONDARY ITEMS IMPACTED•• All present and future tactical and ground combat vehicles requiring armor and protection upgrades•• Advanced armor materials for Individual Warfighter Protection

POTENTIAL COST AVOIDANCE•• Return on Investment of 17.4 to 1 with a cost benefit of $1.082B

Model Based Environment (MBE) Ballistic Hull and Turret

GROU

NDSYSTEMSAN

DPR

ECISIONMUN

ITIONS

Page 10: Advanced Ceramic Matrix Composites (CMC) Manufacturing and ... · Missile Research, Development and Engineering Center (AMRDEC), Manufacturing Science & Technology Division, ATTN:

POC: Army ManTech Manager, U..S Army Research, Development and Engineering Command (RDECOM), U.S. Army Research Laboratory (ARL), ATTN: RDRL-WMM-D, Aberdeen Proving Ground, MD 21005-5069

Transparent SPINEL Armor Manufacturing Scale Up Scale up of manufacturing capabilities to produce large, transparent SPINEL armor windows and SPINEL plates for other applications.

10

OBJECTIVE / SOLUTIONThere is a compelling need to reduce the cost to produce

large, transparent ceramic armor windows to provide lighter weight improved ballistic protection for tactical vehicles. Recent ballistic experiments on ceramic based armor against advanced threats at Aberdeen Proving Ground have demonstrated multi-hit performance at weights and thicknesses 50-60% less than currently deployed glass-based armor. Direct spin-offs for rotor-craft and anti-tank airborne vehicles would become feasible.

ACHIEVEMENTSThe interchangeability of SPINEL and aluminum oxynitride

(ALON) in armor designs has been demonstrated.

BENEFITSImproved multi-hit protection against current and emerging

threats: ― Light weight transparent armor in sizes up to 16” x 40” ― Weight savings and thickness reductions of 50-60% over

current systems ― Reduce cost per square foot by 20-50% for SPINEL

ceramic plates for armor ― Superior resistance to scratching, sand erosion and frac-

ture due to rock strikes will provide major replacement cost avoidance payoffs

― Operations and Support (O&S) cost savings will be achieved as a result of reduced vehicle maintenance and increased window service life

― Reduce SPINEL manufacturing costs by up to 50%.STATUS•• Demonstration of volume manufacturing process of SPINEL and ALON plates for integration and government certification of low-weight transparent armor solutions to Level 3A threats IAW ATDP 2352 is ongoing•• The ballistic performance of SPINEL from 3 separate manufac-turers, as well as ALON is being evaluated•• The size of hot-pressed ceramic plates available for DoD applications has been increased from 170 to 400 in2

•• The ManTech spinel production line at Technology Assessment and Transfer (TA&T) has transitioned to a low-rate initial produc-tion (LRIP) capable transparent armor integration line at AMOR-LINE. ARMORLINE is funded by private investments•• ARMORLINE Facility: 257K sq ft., Target date for full scale production (230 Metric tons a year) - 4QFY12•• CoorsTek Armor Solutions and BAE Advanced Ceramics continue to develop manufacturing processes for SPINEL and Surmet continues to develop manufacturing of ALON

WEAPON SYSTEMS / SECONDARY ITEMS IMPACTED•• This ManTech program will enable ceramic based transparent armor to be fabricated in sizes large enough to meet vehicle dimen-sions including Heavy Expanded Mobility Tactical Truck (HEMTT) and Family of Medium Tactical Vehicles (FMTV)•• Coordinated with Army’s Long Term Armor Solution program•• Other potential platforms include Army, Air Force, Navy, and Marines systems – F18 - Advanced Targeting Forward-Looking Infrared (ATFLIR) and SNIPER XR Targeting Pod – Navy DDG-1000 Destroyer•• Potential to impact rotorcraft, airborne vehicle, and infrastructure protection throughout the US military

POTENTIAL COST AVOIDANCE•• Return on Investment of 8.7 to 1 with a cost benefit of $68M

Hot-pressed SPINEL Window for Forward Looking Infrared Targeting Pod (AT-FLIR)

ALON-based Transparent

Armor Window for Aircraft

Segmented 16” x 29” SPINEL Front Armored Window for FMTV

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POC: Army ManTech Manager, U.S. Army Research, Development and Engineering Command (RDECOM), Armament Research, Development and Engineering Center (ARDEC), Enterprise and Systems Integration Center (ESIC), ATTN: RDAR-MEE-P, B65, Picatinny Arsenal, NJ 07806-5000

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Cannon Life Extension ProgramDevelop a reliable and consistent process of cladding steel barrel forgings and a crown broach set for affordable machining of rifling in cannon barrels.

OBJECTIVE / SOLUTIONThe goal is to formulate a unique manufacturing method for

affordable chromium free manufacturing of cannon barrels. The Defense community faces significant challenges and de-

ficiencies as the next generation cannons are developed for our war fighting forces. There is also an environmental mandate from the Under Secretary of Defense to minimize the use of hexavalent chromium. The requirement for increased muzzle velocity and penetration capability necessitates the development of propel-lants with increased energy and flame temperatures. These ad-vanced propellants increase the wear and erosion of the barrel in all calibers of gun systems.

The Cannon Life Extension program is facing two technical chal-lenges, one achieving a consistent Inner Diameter (ID) on the Tantalum Tungsten alloy (Ta-10W) lined tube after the explosive bonding process. The other is machining rifling into the Ta-10W lined cannon barrels.

ACHIEVEMENTSTwo-point rifling cutters have been developed and successfully

demonstrated to work on Ta-10W lined cannon barrels.

BENEFITS•• Eliminate the hazards associated with hexavalent chromium•• Develop a minimum of a 3 times extension of the barrel life•• Provide the ability to utilize propellants that are more energetic, leading to increased muzzle velocity

STATUS•• A study was conducted to identify the best honing stones to hone Ta-10W on the current machines (report available August 2011)•• Characterization of the Ta-10W explosive bonded tubes (report due September 2011)

WEAPON SYSTEMS / SECONDARY ITEMS IMPACTED•• Medium caliber cannons (M242 25mm, M68 105mm)•• Technology will transfer to large and small caliber weapons systems (M256 120mm, M776 155mm)

POTENTIAL COST AVOIDANCE•• Return on Investment of 28 to 1 with a cost benefit of $285.5M

M2 Bradley Fighting Vehicle

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Advanced Munitions Warhead Manufacturing ImprovementsDevelopment of manufacturing techniques on key compo-nents and assembly/loading process to reduce advanced munition warhead manufacturing costs and enable munition optimization.

OBJECTIVE / SOLUTIONDevelop novel manufacturing techniques to enable mu-

nition optimization of weight, cost and performance. Focus areas include:

― Molding of insensitive munition (IM) and fragment generating sleeves for warheads

― Multi-explosive formed penetrators (M-EFP) ― Embedded tungsten fragmenting components ― Single increment, no-post machine explosive loading

process for warhead bodies.ACHIEVEMENTS•• Investigated the feasibility of a technically viable and cost effective solution for single increment, no post machine warhead pressing and designed a warhead loading tool system using a novel approach•• Identified and tested multiple candidate polymers for construc-tion of the IM sleeve and successfully molded using various processes inside a small scale cylinder. 2 of the 5 processes had a uniform sleeve thickness and will melt at desired temp-erature to meet the IM requirement

BENEFIT•• Lower cost through reduced number of manufacturing processes•• Improved safety by decreasing touch labor during munition manufacture•• More reliable munitions using fragmenting sleeves enabling warheads to fragment into reliable sized fragments and achieve IM requirements

STATUS•• IM Sleeve and warhead pressing work is in process. Expected manufacturing process transition into Military Operations on Urban Terrain (MOUT) starting at the end of FY12 •• M-EFP liner and embedded fragment component processes to be evaluated in FY12

Advanced Munitions Warhead Manufacturing Process Improvements

M1A2 Abrams Main Battle Tank

Shoulder Fired Weapon System

WEAPON SYSTEMS / SECONDARY ITEMS IMPACTED•• Military Operations on Urban Terrain (MOUT) ATO, Shoulder Fired Munitions•• Extended Area Protection & Survivability (EAPS) ATO•• 120mm Advanced Multi-Purpose (AMP)•• Cluster Munition Replacement (CMR)•• M1A2 Abrams Main Battle Tank•• Shoulder Launched Munitions

POTENTIAL COST AVOIDANCE•• Return on Investment (ROI) of 8.5 to 1 with a cost benefit of $60M

POC: Army ManTech Manager, U.S. Army Research, Development and Engineering Command (RDECOM), Armament Research, Development and Engineering Center (ARDEC), Munitions Engineering and Technology Center (METC), ATTN: RDAR-MEM-L, B65-S, Picatinny Arsenal, NJ 07806-5000

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POC: Army ManTech Manager, U.S. Army Research, Development and Engineering Command (RDECOM), Armament Research, Development and Engineering Center (ARDEC), Energetic, Warheads and Environmental Technology Directorate, Building 94, 2nd Floor, ATTN: RDAR-MEM-S, Picatinny Arsenal, NJ 07806-5000

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Grenade Initiation Module (GIM)Improve the current Grenade Initiation Module (GIM) production line, by reducing cost and increasing the production rate and reliability.

OBJECTIVE / SOLUTIONImprove the current Grenade Initiation Module (GIM)

production line, by reducing cost and increasing the pro- duction rate and reliability. The Spider, XM7 Network Command Munition, utilizes a Miniature Grenade Launch-er (MGL) for both lethal and non-lethal responses. The Grenade Initiation Module is the electronic initiator for the Miniature Grenade Launcher.

ACHIEVEMENTS•• Successfully completed the prove out of new production process•• Successfully transitioned the new production process to the current production line•• Reduced cost, improved yield, increased production rate and reliability

BENEFITS•• Increases the production rate utilizing automated process•• Improves first pass yield (reliability)•• Lowers cost, reduces manpower to run production line

STATUS•• Project has successfully completed the prove out on the new production process•• Process is being used on the current production line•• Successfully achieved the project goals, i.e., increased production rate, improved first pass yield and reduced labor cost

WEAPON SYSTEMS / SECONDARY ITEMS IMPACTED•• XM7 Network Command Munitions (Spider)

POTENTIAL COST AVOIDANCE•• Return on Investment of 3.0 to 1 with a cost benefit of $3.0M

Grenade Initiation Module (GIM)

Production line Potting tanks

XM7 Spider Munition

Production Automated Potting Machine (35 GIMS)

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Cost Reduction of Solventless PropellantsIncreasing the affordability of solventless propellants in an effort to increase usage. Solventless propellants are an excellent option for enhanced Warfighter survivability, safety, and decreased environmental impact.

OBJECTIVE / SOLUTIONDevelop a process for manufacturing solventless propellant, PAP-

8386, safely using a shear roll mill, and possibly a twin screw extrud-er, that would significantly reduce the cost of solventless propellants manufactured using the current conventional and labor intensive Preroll and Evenspeed operations. Density, burn rate and mechan-ical properties will be examined and compared for propellants manufactured using the new and existing process.

ACHIEVEMENTS•• Awarded Task Order to a European company June 2010•• Awarded a second contract to a Domestic company August 2010 and a second European company in March 2011•• Successfully extruded a 5/8 inch outside diameter chord of inert propellant utilizing a 40mm twin-screw mixer/extruder

BENEFITS•• Cost reduction in solventless propellant utilizing an automated process•• Minimizes the risk of potential Warfighter safety problems with residual solvent in propellant•• Improve Insensitive Munition (IM) and precision performance•• Eliminates solvent (ether) emissions during processing and propellants are environmentally friendly (green)

STATUS•• Processing of 100 pounds of inert material with a Shear Roll Mill (SRM) by the European company was completed in May 2011•• Twin Screw Extruder (TSE) to process and characterize inert material was completed in April 2011•• TSE live material to be processed by the European Company in Summer and Fall 2011

WEAPON SYSTEMS / SECONDARY ITEMS IMPACTED•• M865 and M1002 Tank Training Rounds•• AA2 Propellant for MK90 Rocket Grains•• N5 Propellant for Mine Clearing Line Charge (MICLIC) and Anti-Personnel Obstacle Breaching System (APOBS)•• JA2 Propellant for M830A1 Tank Cartridge•• RPD-380 Propellant for M829A3 Tank Cartridge•• Surface Coated Double Base Propellant for 120mm Tactical Rounds•• High-Explosive AntiTank Multi-Purpose Training (HEAT-MP-T) Rounds •• 25mm M793 Training Rounds•• M1A2 Abrams Main Battle Tank

POTENTIAL COST AVOIDANCE•• Return on Investment of 7.5 to 1 with a cost benefit of $10-$15/lb.

M1A2 Abrams Main Battle Tank

Automated Solventless Process

Twin Screw

Extruder

Shear Roll Mill (SRM) and Pelletizer

PAP-8386 Etherless Propellant for 120mm Tank Training Rounds

POC: Army ManTech Manager, U.S. Army Research, Development and Engineering Command (RDECOM), Armament Research, Development and Engineering Center (ARDEC), Development and Engineering Center, Propulsion and Direct Fire Branch, ATTN: RDAR-MEE-W, B382, Picatinny Arsenal, NJ 07806-5000

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POC: Army ManTech Manager, U.S. Army Research, Development and Engineering Command (RDECOM), Armament Research, Development and Engineering Center (ARDEC), Enterprise and Systems Integration Center (ESIC), ATTN: RDAR-EIP, Armament Systems Integration Center, Bldg1, 2nd Floor, Picatinny Arsenal, NJ 07806-5000

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IMX-104 Manufacturing Process OptimizationProvide inherent cost benefits for scale-up of IMX-104 manufacturing.

OBJECTIVE / SOLUTIONEstablish a capability to

manu- facture IMX-104, a Government-owned formula-tion, with optimum process parameters to reduce the unit price while maintaining its insensitive munitions (IM) properties.

ACHIEVEMENTS•• Examine/evaluate factors influencing product quality•• Identify operating parameters that affect IM properties on a large scale manufacturing process•• Optimize critical operating parameters •• Prove-out process•• Confirm product quality and IM properties•• Loading operations

BENEFITS•• Insensitive Munition (IM) compliant product for warfighters•• Improved manufacturing efficiency•• Better understanding of operating conditions on the quality of final product •• Reduces unit cost by 20%

STATUS•• A request for cost proposal has been forwarded by the contracting office•• Developed and finalized a test plan for program execution

WEAPON SYSTEMS / SECONDARY ITEMS IMPACTED•• IMX-104 will support the production of the 81mm High Explosive (HE) mortar•• IMX-104 is the leading candidate to replace Composi-tion B and its equivalence, PAX-21 and PAX-41 as the HE fill in various munitions items

POTENTIAL COST AVOIDANCE•• Return on Investment of 24.7 to 1 with a cost benefit of $55.3M

IMX-104 Explosive Flakes Hand Grenade

81mm Mortar

Improved Manufacturing Technology (ManTech) for Insensitive Munitions (IM)Provides inherent cost benefits for scale-up of Insensitive Munitions.

OBJECTIVE / SOLUTIONOptimize process parameters for the full scale produc-

tion of NTO (3-Nitro 1, 2,4-Triazol-5 One). NTO is a key con-stituent in the new insensitive munition (IM) formulations. Through leveraged funding, this program will install and integrate process equipment to the existing NTO process line and verify the process modifications increase yield and meets and exceeds NTO specifications.ACHIEVEMENTS•• Completed baseline assessment on NTO manufacturing•• Completed a design of experiments (DOE) study, the

variables included: ― Final re-crystallization temperature ― Cooling Rate ― Initial NTO Concentration ― Agitation ― Hold Temperature.

•• Procured Scanning Election Microscope (SEM) to verify crystal structure and morphology of NTO•• Demonstrated increased NTO yield of up to 10% in

a lab-scale environment. This can easily translate in increased yield in production material•• Verified NTO crystal structure and morphology; crystal

structure intact and would likely pass Mil Spec require-ments•• Conducted preliminary production scale design on

equipment sizing and ancillary equipmentBENEFITS•• Safer munitions - no inadvertent detonations from fire,

accident or enemy fire•• Provide the Warfighter with optimized energetic con-

stituents used in new IM formulations•• Provide the US Army a better energetic to cost ratio per

Insensitive Munition (IM) benefitSTATUS•• Second year ManTech Program•• Completing 30% Design

WEAPON SYSTEMS / SECONDARY ITEMS IMPACTED•• Insensitive Energetic Munitions, IMX-101 - used in

155mm M795 and 105mm M1 High Explosive (HE) Insensitive Munitions (IM)•• Insensitive Energetic Munitions, IMX-104 - Used in 120,

81, and 60mm High Explosive (HE) Mortar FamilyPOTENTIAL COST AVOIDANCE•• Return on Investment of 3.7 to 1 with a cost benefit of

$5.9M

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POC: Army ManTech Manager, U.S. Army Research, Development and Engineering Command (RDECOM), Armament Research, Development and Engineering Center (ARDEC), Energetic, Warheads and Environmental Technology Directorate, B321, ATTN: RDAR-MEE-P, Picatinny Arsenal, NJ 07806-5000

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Laser Ignition Manufacturing TechnologyDevelop a manufacturing process to provide an affordable, produc-tion capable process for a high shock tolerant laser ignition system (LIS) for use with US 155mm large caliber weapon systems.OBJECTIVE / SOLUTION

Improve affordability of a militarized solid state laser ignition system (SSLIS) by demonstrating a robust production capable manufac-turing process and reducing unit cost by 40%. The SSLIS supports the M-777A2 155mm Light Weight Howitzer (LW155) and carries poten-tial for application to M109A6 Paladin 155mm Howitzer and other US 155mm caliber weapons.

This effort will utilize unique fabrication processes, advanced materials, and component configurations not typically found in industry standard manufacturing practices. ACHIEVEMENTS

Program is in its third year of funding. Significant advancement has been made toward achieving the program

goals for the development of a manufacturing technology to provide an affordable, production-capable process for a high shock tolerant diode pumped laser ignition system (DPLIS) for use with the US 155mm large caliber weapon systems.

FY09-11 efforts developed manufacturing processes for fabricating diode laser bars that:

― Operate at temperatures up to 115°C, exceeding current industry temperature capabilities

― Developed unique robust manufacturing processes and techniques for a high shock-high temperature laser igniter

― Improved design and manufacturing processes for a robust high pressure chamber window that provides an optically clear path for transmitting the laser beam and seals the high pressure-high temperature combustion gases in the gun chamber

― Improved design and manufacturing processes for the laser pulse generator

― Successfully conducted DPLIS live fire testing with over 2,700 rounds fired during engineering testing without failure

― Obtained safety releases and successfully conducted a Limited User Assessment (LUA) with a 10 man US Army gun crew live firing a LW155 howitzer with laser ignition for the first time.

BENEFITSThe SSLIS has potential for replacing primer based ignition sys-

tems conventionally used with US 155mm large caliber artillery.Primer based ignition systems require the manufacture, storage, sur-veillance, resupply and demilitarization of explosive primers (black powder filled brass cartridges). Current LW155 primer based ignition systems have known operational issues which are attributed to me-chanical jamming of complex, high maintenance primer feed mecha-nisms (PFM) and premature firing due to primer sensitivity. The SSLIS has potential to eliminate the need for primers and the PFM by using laser energy to ignite the propelling charge rather than using explosive energy from primers. Laser ignition has potential to reduce weapon logistics and provides the warfighter with safe and reliable propellant ignition.

STATUSProcess work on key laser ignition

system components has commenced at several potential suppliers.

WEAPON SYSTEMS / SECONDARY ITEMS IMPACTED•• M-777A2 155mm Lightweight Howitzer (LW155)•• M109A6 Paladin 155mm Howitzer

POTENTIAL COST AVOIDANCE•• Return on Investment of 3.9 to 1 with a cost benefit of $18.6M

Diode Pumped Laser Head

M109A6 Paladin 155mm Howitzer

M-777A2 155mm Lightweight Howitzer (LW155)

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POC: Army ManTech Manager, U.S. Army Research, Development, and Engineering Command (RDECOM), Aviation Missile Research, Development and Engineering Center (AMRDEC), Manufacturing Science & Technology Division, ATTN: RDMR-SEM, 5400 Fowler Road, Redstone Arsenal, AL 35898-5000

Multi-Purpose Warhead Manufacturing ImprovementsDevelop and demonstrate precise manufacturing methods and processes to provide affordable multi-purpose warheads needed to enable current and future tactical missile systems with the capability of defeating Explosive Reactive Armor Protected Tanks, Soft Targets, Military Operations on Urban Terrain Targets and Personnel.

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OBJECTIVE / SOLUTIONThis project will establish new processes to improve multi-

purpose warhead manufacturing on current and future missile systems. Currently there are innovative manufacturing process-es which are increasing the capabilities and performance of warheads. However, insufficient investment is being made in the development and maturation of these technologies fo-cused on lowering the life cycle cost of warhead production.

The benefits from this project include reduction in variability, material loss, machining time, labor costs, and tool wear while increasing overall performance and reliability. These benefits will be achieved by utilizing near net shape preforms and heat treatment of assemblies.

Forging the liner into a near net shape preform will reduce material loss, machining time, labor cost, and tool wear. The cur-rent bar process has many manufacturing steps that are labor in-tensive and lead to material waste. Near net shape preforms will eliminate this problem by reducing material waste, forging steps, and machining time. A post assembly heat treatment will also be utilized to improve multi-purpose warhead manufacturing. Current warhead assembly techniques induce stress in the ex-plosive billet. A heat treatment process after warhead assembly will allow relief of internal stresses and ensure a bond between the liner and explosive. This process will reduce any variability introduced by the press and increase warhead reliability.

ACHIEVEMENTS•• Forged near net shape billets with 40% less material by weight than the current method•• Reduced forging steps•• Reduced porosity

BENEFITS•• Reduces cycle times and increases throughput for multi-purpose warhead shape charge manufacturing•• Provides significant reductions in manufacturing variability to decrease variability in performance •• Decreases in labor time, wasted material, and life cycle cost (Average Unit Production Cost) •• Permits current and future tactical missile system upgrades such as Javelin, TOW, other Army systems•• Reduces warhead cost by 15%

STATUSProgram is in second year of funding (FY11)

with tasks including: ― Develop post assembly heat treatment

process ― Demonstrate and analyze post assembly

heat treatment process ― Test to verify results ― Transition manufacturing improvements

to Close Combat Weapon Systems (CCWS) PM.WEAPON SYSTEMS / SECONDARY ITEMS IMPACTED•• Javelin Missile•• Tube-Launched, Optically-Tracked, Wire- Guided Missile (TOW)•• Future multi-purpose warhead systems

POTENTIAL COST AVOIDANCE•• Return on Investment of 3.8 to 1 with a cost benefit of $16.3M

Multi-Purpose Warhead

Javelin Missile

Near Net Shape Preform vs. Normal Preform

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Chip Scale Atomic Clock (CSAC)Providing affordable precision timing for military communications systems.

OBJECTIVE / SOLUTIONGlobal Positioning Systems (GPS) are vulnerable to interference

and unreliable in urban areas and dense forests. A Chip Scale Atom-ic Clock (CSAC) enabled common timing module will provide more stable, reliable communications to the Warfighter. The goal of this program is a low cost CSAC which will be attained by improving the manufacturing capability to enable mass-production. By leveraging Defense-wide MS&T investments, fabrication costs will be reduced with a corresponding expansion of application volumes.

Specific program objectives include design for manufacturability, yield enhancement, supply chain management, and transition to a disciplined volume manufacturing environment.ACHIEVEMENTS•• Contracts awarded to Honeywell International, Symmetricom and Teledyne Reynolds•• Contractor completed Physics Package Iteration 1•• Command and Control Directorate personnel tested the Defense Advanced Research Projects Agency (DARPA) Phase 4 CSAC (sponsored by DARPA)

BENEFITS•• Significantly reduces acquisition cost for Joint service applications requiring precision timing subsystems in warfighter communication systems•• Lowers unit cost and reduced program risk through the establishment of multiple sources•• Moves from manual fabrication to automated assembly•• Increases unit volume manufacturing capability from 10 units/year (MRL-4) to >20,000 units/year (MRL-8)

STATUSProgram is in its second year of funding.Contractors are: adapting MEMS manufacturing processes and

automating the assembly and test processes for miniaturized atomic time and frequency reference units; if necessary, redesign-ing the miniaturized atomic time and frequency reference units including physics package, electronics, and housing for manufactur-ability, environmental immunity and reliability; and developing batch processes, assembly fixtures, and equipment for manufacturing miniaturized atomic time and frequency reference unit physics package to improve yield, lower labor costs, and reduce risks in reliability. WEAPON SYSTEMS / SECONDARY ITEMS IMPACTED•• Joint Improvised Explosive Device Defeat Organization (JIEDDO) Counter Remote Control Improvised Explosive Device (RCIED) Electronic Warfare (CREW) Timing Module, and all Ground Combat Systems•• Global Positioning System (GPS) User Equipment•• Soldier Communications Equipment

POC: Army ManTech Manager, U.S. Army Research, Development and Engineering Command (RDECOM), Communications-Electronics Research, Development and Engineering Center (CERDEC), Command and Control Directorate, ATTN: RDER-CCB-PT, Building 6007, Aberdeen Proving Ground, MD 21005

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Phase III Physics Package, Photodiode Up Mounted

in Lower Half of the Vacuum Package,

Ceramic Leadless Chip Carrier (LLC)

Leadless Ceramic Package

Atomic Clock

M2 Bradley Fighting Vehicle

POTENTIAL COST AVOIDANCE•• Return on Investment of 42 to 1 with a cost benefit of $978M

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POC: Army ManTech Manager, U.S. Army Research, Development and Engineering Command (RDECOM), U.S. Army Research Laboratory (ARL), ATTN: RDRL- SEE-E, 2800 Powder Mill Road, Adelphi, MD 20783

Flexible Electronics and DisplaysEstablish an integrated pilot line and processes to manu-facture affordable flexible full-color active matrix displays to improve yield and reduce manufacturing costs.

OBJECTIVE / SOLUTIONEnable a pilot-line compatible process to deliver 1000 flexible

displays/year the requirements of the Army transformation, and to improve the yield and reduce manufacturing costs. Reflective and emissive technologies implemented will be more rugged and efficient than current displays in use. Flexible display is the first implementation of large area high performance electronics and will be extended to additional electronics platforms includ-ing imaging devices, sensors, and energy harvesting. Ultimately the display and electronics can be combined into highly confor-mal systems and integrated onto soldier or vehicle platforms.

ACHIEVEMENTSProcess and tool development work has enabled fabrication

of 4” diagonal full color reflective ultra low power displays at high transistor yield (approaching 100%) and display pan-el yield (75-80%) on plastic substrates. Began the de-velopment of high performance transistor technology on the 6” process development line and demonstrated fully functional higher resolution organic light emitting diode (OLED) displays with industry partner Universal Dis-play Corporation (UDC). Installed and qualified organic deposition tool to enable GENII size OLED manufactur-ing. Demonstrated functional reflective flexible displays on the GEN II pilot line. In FY11, the Flexible Display Cen-ter (FDC) continued transitioning flexible displays to military integrators for Army system demonstrators. A fully auto-mated bond-debond process has been developed at the 6” wafer-scale and demonstrated at GEN II.

The GEN II pilot manufacturing line is now fully installed, 100% qualified, and has demonstrated functional transistors at the Army’s Flexible Display Center in Tempe, AZ. The program has initial demonstrations of flexible electronics. The program has developed functional electrostatic actuated MEMs on plastic substrates for acoustic transmitters and potentially receivers.

BENEFITS•• Lightweight, rugged, low-power flexible displays will enable situational awareness in daylight, night,

and adverse weather conditions •• Flexible electronics will enable wide area sensing•• Flexible display technologies will enable situational

awareness from technology not commercially available with attributes that cannot be realized from glass-based displays •• $600/diagonal inch cost reduction per display unit,

from $800/diagonal inch to $200/diagonal inch•• Possible 5X savings in life cycle costs

STATUS•• Improved yield and lower defect displays from the GEN II tool set •• Center has 30 (an additional 3 partners from FY09) industrial partners and three academic partners•• Demonstrated the first full color OLED displays on PEN substrates using a bond-debond process •• Continue to support license agreements and supply chain industry partners•• Demonstrated improved color reflective dis-plays integrating a new transistor technology (metal-oxide thin film transistors. MO-TFTs have higher performance and improved sta-bility compared to amorphous silicon TFTs

WEAPON SYSTEMS / SECONDARY ITEMS IMPACTED•• Two (TTAs) to transition flexible displays to PEO Soldier and PM Common Controller•• Transitioned flexible displays to Military Integrator for Army system demonstrator

POTENTIAL COST AVOIDANCE•• Return on Investment of of 4.3 to 1 with a cost benefit of $72M

Flexible Display

GENII OLED Tool Installed at Flexible Display Center

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CMOS Circuit on Plastic

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High Operating Temperature and Multi-Band Focal Plane ArraysReduce the cost of infrared focal plane arrays (IR FPAs) using III-V epitaxial material in order to make large format, high operating temperature and multi-band/multi-color FPAs. This effort will provide affordable, 5000x5000 pixel format compound IR sensors for persistent surveillance and 1280x720 pixel format IR sensors for enhanced situational awareness and target search.

OBJECTIVE / SOLUTIONHigh performance IR FPAs are expensive and are dominated by

yield, growth and fabrication and not by die/wafer costs. The ad-vances in making these FPAs, point towards an opportunity for an investment that will result in significant cost avoidance. Examples of anticipated advances are:

― new detector structure whose manufacturing approach avoids defects associated with passivation of the detector material

― detector material that uses the III-V material system enabling leverage of the III-V material commercial industrial resulting in an increase in the yield and uniformity of these detectors

― FPAs that can operate at higher operating temperatures which significantly reduces the size, weight and power (SWAP) of cryogenic coolers, which enables use of com pound, very large format FPAs in persistent surveillance applications.

ACHIEVEMENTS•• On site review of potential focal plane array vendors completed•• One contract has been awarded to Lockheed Martin Santa Barbara Focal Plane Array •• Work initiated to improve flatness of Gallium Antimonide (GaSb) substrate •• CERDEC-NVESD has completed in house testing of prospective vendors

BENEFITS•• 1280 x 720 high operating temperature and multi-band focal plane arrays (HOT MB FPAs) provide search, identify and track mobile targets in all day/night visibility and battlefield conditions•• HOT MB FPAs combine to provide reduced quantity and SWAP (3-5x) of IR cameras thru reducing FPA size and FPA cooling requirements

POC: Army ManTech Manager, U.S. Army Research, Development and Engineering Command (RDECOM), Communi-cations-Electronics Research, Development and Engineering Center (CERDEC), Night Vision Electronics Sensors Directorate, ATTN: RDER-NVS-STD, Ft. Belvoir, VA 22060-5806

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M1A2 Abrams Main Battle Tank

AH-64 Apache Helicopter

STATUSFuture/planned efforts include:•• Transition from pilot line to commercial foundry manufacturing line with III-V epi •• Increase diameter / die per wafer (10x) and reduce material cost (10x) by transitioning to Gallium Arsenide (GaAs) substrates•• Improve pixel fabrication (etching, passiv-ation) and growth processes. Transition to buried diode structure eliminating passivation process step

WEAPON SYSTEMS / SECONDARY ITEMS IMPACTED•• Ground Combat Vehicle •• Abrams Main Battle Tank Modernization Program •• AH-64 Apache and Armed Reconnaissance Helicopter (PEO Aviation) •• Advanced Common Sensor Payload (ACSP) and Follow-on CSP Production •• Air Force Space Based Infrared System (SBIRS) Program/ High Stare Program•• Persistent Surveillance programs•• Long Endurance Multi Intelligence Vehicle

POTENTIAL COST AVOIDANCE•• Return on Investment of 22.5 to 1 with a cost benefit of $636M

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OBJECTIVE / SOLUTIONFuture Army imaging programs, such as the Enhanced Night

Vision Goggle-Digital (ENVG-D), will rely on image fused, high resolution (1280 x 1024) sensors and displays to replace the current capabilities (such as standard night vision goggles). These systems will require an affordable, high performance, artifact free, low power, full color micro-display to meet the desired Key Performance Parameters (KPPs) of system weight, power, situational awareness, and target acquisition.

Performance and manufacturing goals include increased contrast ratio and transmission rate; increased viewing angle; decreased display response time and reduced display unit cost.ACHIEVEMENTS•• Produced improved, thin backlights to reduce both power (by

0.25 watts) and size of the micro-displays •• Improved the full-function display companion Application

Specific Integrated Circuit (ASIC) •• Display process improvements, combined with the improved

backlight and ASIC, reduced the integrated micro-display power consumption to <400 mW

BENEFITS•• An affordable, high performance, micro-display enables pre-

sentation of digital image fusion to increase Warfighter mo-bility with multi-spectral imagery from two to three sensors. •• Reduction in cost allows for a larger procurement of imager

systems. The program also developed lower power displays than the current display—approximately 1W, projected display <0.5W and reduces the system power and the number of batteries required to complete the mission

STATUS•• Transitioned prototype displays to ENVG-D program for

insertion into systems for Limited User Evaluation•• Government furnished equipment (GFE) 1280 x 1024

displays to Joint Effects Targeting System (JETS) program •• Transitioned prototype displays to Soldier Sensor Compo-

nent and Image Processing Army Technology Objective (ATO)-R program •• 800 x 600 color display from 8” wafer line transitioned to

ENVG-O programWEAPON SYSTEMS / SECONDARY ITEMS IMPACTED•• Enhanced Night Vision Goggle–Digital •• Fused Weapon Sight (FWS) •• Night Sight-Semi Automatic Sniper System (NS-SASS) •• Handheld Target Locator - Talon+

POTENTIAL COST AVOIDANCE•• Return on Investment of 30.1 to 1 with a

cost benefit of $154M

OBJECTIVE / SOLUTIONDevelop large format, multi-band, multi-color Focal Plane

Arrays (FPAs) at comparable costs to single band Indium Antimonide (InSb) FPAs. This will enable affordable, high definition television (HDTV) infrared (IR) sensors for enhanced situational awareness/target search. ACHIEVEMENTS•• On site review of potential FPA vendors completed•• Night Vision and Electronics Sensors Directorate (NVESD)

has completed in house testing of prospective vendors•• Method established to improve operability through getter-

ing from Silicon (Si) substrates•• Improved buffer layer crystallinity (<30 arc sec)•• First set of baseline arrays on Gallium Arsenide (GaAs) sub-

strates (640x480 20 micron pixel) show operability at 99%BENEFITS•• Reduced quantity, cost, size, weight and power of IR

cameras •• Provides increased field-of-view of dual band 3rd

Generation FPAs •• Provides high definition, multi-band situational awareness •• Enables a new Warfighting capability in urban environ-

ments using wide area electro-optic (EO) persistent surveillance from high altitude and from multiple, tactical unmanned aerial vehicles (UAVs) operating below the clouds

STATUS•• Program is in its second year of funding•• First year funding was through a task order•• Broad Area Announcement (BAA) announced in November

2010. One contract awarded and a second is pending •• Complete detector lot data on baseline 640x480 pixel,

20µm (2 color)•• Begin detector lot data on 1280x720 pixel, 12µm

(2 color) on 6” wafersWEAPON SYSTEMS / SECONDARY ITEMS IMPACTED•• Ground Combat Vehicles •• Tactical Unmanned Aerial Vehicle (TUAV) Q2, Q3•• Lightweight Laser Designator Rangefinder (LLDR)•• AH-64 Apache Helicopter•• Common Sensor Payload•• Joint Strike Fighter

POTENTIAL COST AVOIDANCE•• Return on Investment of 15.5 to 1 with a

cost benefit of $664M

POC: Army ManTech Manager, U.S. Army Research, Development and Engineering Command (RDECOM), Communi-cations-Electronics Research, Development and Engineering Center (CERDEC), Night Vision Electronics Sensors Directorate, ATTN: RDER-NVS-STD, Ft. Belvoir, VA 22060-5806

Color 1280 x 1024 Micro-DisplayManufacturing TechnologyDevelop a manufacturing process to provide affordable, high resolution, full-color micro-displays (.097” format) for insertion into Soldier borne, head mounted image fusion and weapon sight systems.

High Definition Multi-Band Focal Plane Arrays (HDMB FPAs)Develop low cost substrates for third generation focal planes that will significantly reduce focal plane costs and allow larger size focal plane arrays. This effort also will develop a small pixel format that will provide high definition image quality and improve overall system performance.

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POC: Army ManTech Manager, U.S. Army Research, Development and Engineering Command (RDECOM), Communica-tions-Electronics Research, Development and Engineering Center (CERDEC), Night Vision Electronics Sensors Directorate, ATTN: RDER-NVS-STD, Ft. Belvoir, VA 22060-5806

Large Affordable SubstratesDemonstrate the feasibility of growing and polishing Cadmium Zinc Telluride (CdZnTe) substrates. This program will take it to the next level by increasing the diameter of the substrates and increasing the growth and processing yield. OBJECTIVE / SOLUTION

The pilot program(s) at each selected depot/arsenal will demon-strate current and future Army Infrared Focal Plane Arrays (IR FPAs) that use Mercury Cadmium Telluride (HgCdTe) detectors are expen-sive, in large part due to the small size of the underlying Cadmium Zinc Telluride (CdZnTe) substrate (currently 36cm2). Additionally, the CdZnTe substrates are available through a single foreign source, put-ting future production at risk of disruption. Small substrates inherently drive up the cost of detectors as labor costs are essentially the same independent of substrate size. Developing the manufacturing tech- nology (substrate polishing) to enable a domestic source of larger CdZnTe substrates (up to 100cm2) would decrease the cost and risk of Army IR FPAs.ACHIEVEMENTS

The selected domestic CdZnTe supplier is Raytheon Vision Systems (RVS). RVS, working in conjunction with Teledyne Imaging Systems (TIS), are improving the polishing roughness and uniformity of the CdZnTe substrates required for molecular beam epitaxy (MBE) deposition of HgCdTe infrared detectors. In FY08, the program demonstrated 6x6cm CdZnTe substrates mined from a 93mm boule. In FY09, demonstrat-ed an improved polishing process for IR FPA defect reduction. HgCdTe infrared detector material, deposited on domestically produced and polished wafers from this program, demonstrated a factor of 3 total defect reduction from those deposited on the sole source supplier from Japan. BENEFITS•• Significantly reduces acquisition and total ownership costs of IR FPAs•• Cost savings – 30% unit cost reduction•• Significantly reduces supplier risk of multiple Department of De-fense (DoD) IR FPA development and pre-production programs through establishment of domestic supplier of CdZnTe substrates •• Provides combat overmatch - Warfighter can identify threat before they can even detect presence, See First/Act First•• Increased survivability - Warfighter can rapidly search wide areas while on-the-move with improved standoff•• Reduced crew burden - Warfighter fatigue is decreased through aided search and detection for surveillance tasks and difficult/ obscured targets with shorter target reporting timelines

STATUSIn FY10, the program delivered two 3rd Generation forward look-

ing infrared (FLIR) system development and demonstration (SDD) FPAs on domestically grown 6x6cm CdZnTe substrates (Manufac-turing Readiness Level (MRL) 4). Operability for both mid-wave and long-wave bands was above 99%. This effort developed improved seeded growth process (on 93mm boule) to increase single-crystal

yield. In the future (FY11-13), this program will scale the boule growth processes to 150mm to increase yield of large substrates (including upgrading the furnace, tooling and sawing). This will enable both vendors to process uniform large area domestically grown 10×10cm CdZnTe substrates.WEAPON SYSTEMS / SECONDARY ITEMS IMPACTED•• 3rd Generation Forward Looking Infrared SDD Program (Program Manager-Forward Looking Infrared (PM-FLIR)/Program Manager-Night Vision/Reconnaissance Surveillance and Target Acquisition (PM-NV/RSTA)•• SM-3 Program (Missile Defense Agency)•• Common Sensor Payload (US Army)•• Long Range Advanced Scout Surveillance System (LRAS3) pre-planned product improvement (P3I)•• High Mobility Multi-Purpose Wheeled Vehicle (HMMWV) and Stryker vehicle•• Incremental Spirals [Ground Combat Vehicle (GCV), Unmanned Aerial Vehicle (UAV)] •• Program Executive Office (PEO) Aviation: Apache Helicopter

POTENTIAL COST AVOIDANCE•• Return on Investment of of 13.3 to 1 with a cost benefit of $147M

Long Range Advanced Scout Surveillance System (LRAS3)

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Ground Combat Vehicle (GCV)

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SYSTEMSLow Light Level Sensor

Digital low light level devices for emerging Soldier vision systems that provide the same or better performance than current image intensifier tubes.

OBJECTIVE / SOLUTIONCurrent digital low light level sensors have insufficient resolu-

tion, are too expensive, and fail to meet all performance require-ments. This project will increase the manufacturing yield and lower the cost of these sensors, while concurrently increasing their performance for various multi-service applications (ground, surveillance, vehicle and aviation platforms) and accelerating their availability to the Warfighter. The final product will be a fully mature production capability for a high resolution, digital, low light level sensor that can replace traditional image intensi-fier tubes in emerging systems. The effort also will result in a sufficient manufacturing capacity to meet initial Department of Defense (DoD) system level production requirements. Thirty cameras will be delivered throughout the effort in order to demonstrate that yield and performance improvements are being achieved.ACHIEVEMENTS

Project is in the first year of funding. Actual accomplishments include:

― Program was chosen to receive funding from the Army Man Tech Office – initial funding increment was received

― Initial funding was utilized to begin work in order to increase sensor photo response.

POC: Army ManTech Manager, U.S. Army Research, Development and Engineering Command (RDECOM), Communica-tions-Electronics Research, Development and Engineering Center (CERDEC), Night Vision Electronics Sensors Directorate, ATTN: RDER-NVS-STD, Ft. Belvoir, VA 22060-5806

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AN/PSQ-20 Enhanced Night Vision Goggles

Image Viewed through Night Vision Goggles

BENEFITS•• Greater than 75% reduction in the cost of the first fully capable digital low light level sensor and optimization of its per-formance characteristics

STATUSPlanned accomplishments for 2nd and

3rd Qtr 2011 include: ― Award of task order under closely

related NavAir Broad Agency Announcement (BAA)

― First increment toward the planned overall increase in average sensor photo response of more than 12%

― Begin initial process implementation on new automated equipment.

WEAPON SYSTEMS / SECONDARY ITEMS IMPACTED•• Army fused night sight programs•• Navy pilotage night vision goggle programs•• Army helicopter pilotage night vision goggle programs•• Other Department of Defense (DoD) fused night vision goggle efforts

POTENTIAL COST AVOIDANCE•• Return on Investment of 66.0 to 1 with a cost benefit of $903M

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Enabling Hybridized Manufacturing Processes for Lightweight Body Armor Provides the development, integration, and deployment of new, scalable manufacturing technologies to enable lighter body armor by exploiting advances in both multi-scale material and process technologies.

OBJECTIVE / SOLUTION The U.S. Army, and indeed the DoD-wide small arms body armor

user community, has requested that lighter versions of their highly successful ceramic-based armor be developed and fielded as soon as possible. The objective of this ManTech effort is to develop an inte-grated suite of manufacturing technologies based on recent material and process advances which can cumulatively deliver the same level of protection with at least a 10% reduction in total system weight.

ACHIEVEMENTS•• Designed, built, and deployed first generation Backing Assembly Machine (BAM) for the semi-automated, precisely controlled build-up of multioriented fiber architectures and functionally graded resin treated fabrics•• Incremental Pressure Application System (IPAS) brought on line and in the preliminary “shake down” phase for the fabrication of locally consolidated thermoplastic backing materials (including ultra high molecular weight polyethylene materials)•• Successfully demonstrated initial process for fabrication of highly conformal, fully dense B4C at full thickness

BENEFITS•• 20-30% touch labor reduction by the development and implementa-tion automated and semi-automated material handling and stacking technologies •• Cumulative 10% weight reduction in ceramic/composite body armor systems•• Ability to co-process ceramic and polymer composite hydrostatically at pressures in excess of 5000 psi•• Semi-automation and integrated batch operations allow for 15-30% reduction in assembly cycle time

STATUS•• Exercising Backing Assembly Machine in the cycle-efficient assem-bly of uni-directional (including cross plied) materials•• Fabricated array of partially consolidated thermoplastic backing ma-terial under locally controlled heat, pressure, and cool down phases•• Fabricated ceramic plates using novel ceramic composition and modified extrusion process

POC: Army ManTech Manager, U.S. Army Research, Development and Engineering Command (RDECOM), Army Research Laboratory (ARL), ATTN: RDRL-WMM-D, Aberdeen Proving Ground, MD 21005-5069

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WEAPON SYSTEMS / SECONDARY ITEMS IMPACTED•• Small Arms Protective Inserts (SAPI)•• Enhanced Small Arms Protective Inserts (ESAPI)•• X-Threat Small Arms Protective Inserts (XSAPI)•• Deltoid Auxiliary Protection System (DAPS)•• Side Plate Protection Systems•• Potentially commercial applications include law enforcement and private protection personnel armor systems

POTENTIAL COST AVOIDANCE•• Return on Investment of 12.0 to 1 with a cost benefit of $96M

Body Armor Protective Insert

Enhanced Small Arms Protective Inserts (ESAPI)

Concept and Design of Backing Assembly Machine (BAM)

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POC: Army ManTech Manager, U.S. Army Research, Development and Engineering Command (RDECOM), Natick Soldier Research, Development and Engineering Center (NSRDEC), Combat Feeding Directorate, ATTN: RDNS-CFE, Natick, MA 01760

Improved Chemical HeatingProviding affordable air-activated heating for combat rations.

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OBJECTIVE / SOLUTIONA new ration heating technology based on the oxidation of

zinc and oxygen (air) has been established and the appropriate technical metrics have been met. In order to effectively manu-facture this technology for potential use in military rations, as well as the commercial sector, a production line must be established that can satisfy a significant portion of the cur-rent Meal, Ready-to-Eat (MRE) production rate.

As part of the scale up, three specific operations within the manufacturing process must be established and optimized: raw material mixing, rolling/calendaring of heater sheets, and reduction of activated zinc within oxygen deficient settings. In order to consider this heater technology for military Services approval, several metrics must be met, most notably: weight, cost, safety, and ease of use. By establishing a lean manufac-turing process, these metrics can be attained.ACHIEVEMENTS

This project, in the second year of fundng, is leveraging efforts with the Army Small Business Innovation Program (SBIR) to eval-uate packaging materials, shelf life, and improved efficiency.

BENEFITS•• Based entirely on low cost, food-safe, environmentally friendly materials that meet consumer waste disposal standards•• Increases competition in ration heater industry through the establishment of multiple sources•• Moves from manual fabricated prototypes to automated assembly, validating cost estimates •• Improves Manufacturing Readiness Level (MRL) from MRL 6 (1000’s units/year) to MRL 8 (10M units/year) in processes representative of full-scale production

STATUS•• Batch production amounts have been increased to 5kg Zn/batch. By establishing this batch capacity, the mixing and rolling processes have been improved to produce heater sheet lengths of 50+ ft. A 16ft convection oven has been optimized to increase throughput in the drying process. •• Quality Assurance (QA) methods have been established to identify composition or performance issues early in the manufacturing process

WEAPON SYSTEMS / SECONDARY ITEMS IMPACTED•• Individual Rations: Meal, Ready-to-Eat (MRE)•• Group Rations: Hot Pack beverage heating system•• Potential for expansion into currently unsupported ration platforms

POTENTIAL COST AVOIDANCE•• Return on Investment of 3.5 to 1 with a cost benefit of $3M

Meal, Ready-to-Eat (MRE)

Heater Sheet Integrated with Packaging to Heat MRE Entree Pouch

Using MREs in the Field

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SOLDIERSYSTEMS

POC: Army ManTech Manager, Research, Development and Engineering Command (RDECOM), Natick Soldier Research, Development and Engineering Center (NSRDEC), Shelters Technology Engineering and Fabrication Diectorate (STEFD), ATTN: AMSRD-NSC-ST-F, Natick, MA 01760TN:AMSRD-NSC-ST-F, Natick, MA 01760

Lightweight, Affordable, High Performance Chemical/Biological Agent Resistant Shelter Fabric for Joint Expeditionary Collective ProtectionProviding Chemical, Biological, Radiological and Nuclear (CBRN) protection at a low mass, low cost in high volume for collective protection applications.

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OBJECTIVE / SOLUTIONDevelop a process for reducing the weight of a CBRN

laminate from 14oz/yd2 to 11oz/yd2. Based on suc-cesses with other laminate developments for Space and Missile Defense Command where mass is also critical, a Direct Roll process on the CBRN film substrate can be improved enough to reach the 11oz/yd2 target.

ACHIEVEMENTSNew project. Start date was September 2011.

BENEFITS•• Reduced logistic burden (weight, cube, cost)•• Reduced setup time (No need for liner system)•• Tents in field will have inherent CBRN protection

STATUSContract was awarded in September 2011.

WEAPON SYSTEMS / SECONDARY ITEMS IMPACTED•• Joint Expeditionary Collective Protection •• Chemical Biological Protective Shelter•• Legacy Collective Protection Shelters

POTENTIAL COST AVOIDANCE•• Return on Investment of 133.9 to 1 with a cost benefit of $286.8M

Chemical Biological Protective Shelter

Field Deployment of Chemical Biological Protective Shelter

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POC: Army ManTech Manager, U.S. Army Research, Development and Engineering Command (RDECOM), Armament Research, Development and Engineering Center (ARDEC), Energetic, Warheads and Environmental Technology Directorate, B321, ATTN: RDAR-MEE-P, Picatinny Arsenal, NJ 07806-5000

Net-Centric Model Based Enterprise (MBE) Data to Support Integrated Weapon System Life CycleThis research area will provide selected Army activities, PM’s, Arsenals, Depots, and RDECs with the capability to utilize a Network Centric Manufacturing (NCM) enterprise approach that creates and transfers information using a Model Based Environ-ment (MBE).

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OBJECTIVE / SOLUTIONThe pilot program(s) at each selected depot/arsenal will demon-

strate the ability to use a relational model-based environment in manufacturing and re-manufacturing planning activities, including:

― Ability to reuse 3D CAD data for downstream processes ― Model Based Definition (MBD) for product manufacturing

information (PMI), and manufacturing simulation on integrated product platforms

― Dynamic visual based electronic work instructions ― Ability to procure and manufacture or remanufacture items

from annotated models ― 3D Technical Publications with animation to increase user

friendliness and functionality.ACHIEVEMENTS•• Evaluated the current state of art in MBE tools for CAD, Visual-ization and Product Lifecycle Management (PLM)•• Initiated market survey and use-case demo of existing MBE technology: PLM-PLM interoperability•• Initiated integration of 3D published data into PLM environment. To include published MBDs. Survey existing projects focused on integrating logistical data into PLM systems•• Requirements Planning: Assess depot readiness, select depot partners, generate requirement documents and obtain signed TTAs/ endorsements

BENEFITS•• Reduce cycle time in all elements of the product development and management life-cycle•• Reduce risk of production delays•• Reduction in production planning time •• Reduction in product defects•• Improvement in the quality of Work Instructions and technical publications•• Provides interac-tive capability to reduce time to maintain product during mainte-nance activities

STATUS•• Developed first iteration of best practices and tools within the Model Based Defini-tion (MBD) to support the Model Based Environment (MBE)•• Developed process of using a light format for delivering work instructions, and work-ing with industry to improve next genera-tion of lightweight formats that can be integrated with PDF reader•• MBE Multi CAD/PLM Environment was in-stalled during Summer 2011 and is up and running at the National Institute of Science and Technology (NIST) •• Collaborating with standard organizations to develop a baseline Model Based Defini-tion schema and terminology•• Working with Program Manager (PM) of mproved Explosive Device Defeat (IEDD), Ground Combat Vehicle (GCV), and CH-47F Chinook Systems to develop FY12-14 Implementation strategy

WEAPON SYSTEMS / SECONDARY ITEMS IMPACTED•• All current and future tactical and ground combat vehicles requiring re-use of engineering data •• Improved Explosive Device Defeat (IEDD) Systems•• CH-47 Chinook Helicopter

POTENTIAL COST AVOIDANCE•• Return on Investment of of 92.0 to 1 with a cost benefit of $723M

CH-47 Chinook Helicopter

M2 Bradley Fighting Vehicle

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