Joint Technology Exchange Group
CMTC Brief
November 05, 2003
Gary W. Schuerfeld
Chairman, The Composites Consortium
This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing
Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
• Scheduled Topics
– Overview of Composites Manufacturing
Technology Center (CMTC)
– Overview of Ongoing Projects at the
CMTC
– Overview of Future Composites
Applications and Vision for the US Navy
This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing
Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
Composites Manufacturing
Technology Center
Overview
This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing
Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
Composites Manufacturing
Technology Center
 One of Nine US Navy MANTECH Centers
• Managed by SCRA’s Applied Research and
Development Institute (ARDI)
• Technical Work Performed by The Composite
Consortium (TCC)
• Wide Scope of Activities Possible:
Science and Technology
MANTECH
This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing
Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
Composites Manufacturing
Technology Center
• Sponsor:
ONR MANTECH Program
• Award Date:
October 2000
• Contract Period:
5 Years
• Contract Amount:
Contract Ceiling :
$120M
ONR Core Funding : $ 60M
• Contract Type:
Cooperative Agreement
This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing
Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
US Navy Centers of
Excellence (COE)
National Center for Excellence in
Metalworking Technology
(NCEMT)
Johnstown, PA
Electro-Optics Center
(EOC)
Kittanning, PA
Institute for Manufacturing and
Sustainment Technologies
(IMAST)
Penn State, PA
Electronics Manufacturing
Productivity Facility (EMPF)
Philadelphia, PA
Best Manufacturing
Practices Center of
Excellence (BMP)
College Park, MD
Navy Joining Center
(NJC)
Columbus, OH
Energetics Manufacturing
Technology Center (EMTC)
Indian Head, MD
Center for Naval
Shipbuilding Technology
(CNST)
Charleston, SC
Seneca, SC
This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing
Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
Composites Manufacturing
Technology Center
SCRA
Corporate
Offices
This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing
Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
Composites Manufacturing
Technology Center
• Personnel
•
•
•
•
•
•
•
•
•
•
Henry E. Watson
Jim Sabo
Skip Wharton
Jada Gates
Rhett Cheatham
Ivan Snell
Gary Schuerfeld
Lillian Rumsey
Lesley Morrison
Dr. Art West
- ARDI and CMTC: Executive Director
- CMTC: Technical Director
- ARDI: Director of Finance and Procurement
- ARDI: Senior Contracts Manager
- ARDI: Projects Administrator
- CMTC: Director, Special Programs
- CMTC: Chairman, The Composites Consortium
- ARDI: Coordinator
- ARDI: Administrative Assistant
- ARDI: Technical Director
• Headquarters
934-D Old Clemson Highway
Eagles Landing Professional Park
Seneca, South Carolina 29672
Phone: 864-653-7590
Fax: 864-653-7434
This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing
Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
CMTC/TCC Structure
Through a cooperative agreement with the Office of Naval
Research (ONR), the Applied Research and Development
Institute (ARDI), an operating unit of the South Carolina
Research Authority (SCRA), manages the Composites
Manufacturing Technology Center (CMTC) located in Seneca,
South Carolina.
The CMTC chairs The Composites Consortium (TCC), an
organization of industry-focused, balanced team of prime
contractors, composites industry suppliers, universities, and
institutes. Through the Navy’s Manufacturing Technology
Program (MANTECH), as well as other directed DoD funding,
TCC members are able to perform on a wide range of
Government projects across all service branches.
This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing
Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
CMTC/TCC Structure
Technical Advisory Board
(TAB)
Executive Steering Committee
(ESC)
This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing
Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
TCC Technical
Advisory Board (TAB)
–What is the Technical Advisory Board?
• The Technical Advisory Board (TAB) is an assemblage of key
composites technical experts from within The Composites
Consortium (TCC). Each TCC member organization appoints
one technical representative to the board.
–What does the Technical Advisory Board do?
• The TAB assists in the development of a Composites
Manufacturing Technology Center technical strategic plan,
advises and assists the Center’s Technical Director with the
process of MANTECH project development, attends reviews of
projects within their area of expertise, consults on technical
issues within a specific area of expertise, and by identifying
composites manufacturing technology needs and priorities. In
addition, the TAB may assist the CMTC in the selection of
proposals if multiple proposals are received for a given project.
This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing
Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
TCC Technical
Advisory Board (TAB)
Alliant Aerospace Company
Michael Blair
Atlantic Research Corporation
John Sparks
ARC Technologies, Inc.
Judith Snow
Bell Helicopter-TEXTRON, Inc.
Ken Nunn
The Boeing Company
Randy Southmayd
Clemson University
Larry Dooley
Composite Solutions, Inc.
James Lovejoy
General Dynamics
Dr. Jeff Hall
(Electric Boat, Land Systems,
Bath Iron Works)
Goodrich Corporation
Ron Kestler
Lockheed Martin Corporation
Morris Scales
Mississippi State University
Wayne Bennet
210 State Route 956
M/S: WV01-10
Rocket Center, WV 26726-3548
5945 Wellington Road
Gainesville, VA 20155
11 Chestnut Street
Amesbury, Mass 01913
PO Box 482
Plt 1, Drop 1701
Ft. Worth, TX 76101
Advanced Mfg. Research &
Development Phantom Works
PO Box 516
Mail Code S2761007
St. Louis, MS 63166-0516
College of Engineering and Science
Riggs Hall
Clemson University
1940 Old Dunbar Road
West Columbia, SC 29172
General Dynamics Electric Boat
Dept. 341, Sta. J88-9
75 Eastern Point Road
Groton, CT 06340
11120 S. Norwalk Blvd
Santa Fe Springs, CA 90670
PO Box 748
Fort Worth, TX 76101
College of Engineering
Mississippi State University
PO Box 9544
Mississippi State, MS 39762
(801) 775-1722
michael_blair@atk.com
(703) 754-5371
john.sparks@arceng.com
(978) 388-2993
jsnow@arc-tech.com
(817) 280-3435
knunn@bellhelicopter.textron.com
(314) 232-4770
randy.a.southmayd@boeing.com
(864) 656-3200
dooley@clemson.edu
(803) 822-8493
jlovejoy@csisc.com
(860) 433-7300
jhall@ebmail.gdeb.com
(562) 906-7356
ron.kestler@goodrich.com
(817) 935-1761
morris.r.scales@lmco.com
(662) 325-2270
wayne@engr.msstate.edu
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Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
TCC Technical
Advisory Board (TAB)
Northrop Grumman Newport News
Chris Duer
Northrop Grumman Integrated
Systems
Eric Barnes
Northrop Grumman Ship Systems
Walter Whitehead
Pennsylvania State University –
Applied Research Laboratory
Raytheon Company
Kevin Koudela
Robert C. Byrd Institute (RCBI)
Tom Minnich
Sikorsky Aircraft Corporation
Stephen Varanay
SPARTA Composites, Inc.
Joel Zuieback
Specialty Materials, Inc.
Rich Caruso
Structural Composites, Inc.
Eric Greene
Touchstone Research Laboratory
Michael Brown
Bill Scheck
Dept E30, Bldg 1744-5
4101 Washington Avenue
Newport News, VA 23607
One Hornet Way, 9L20/W2
El Segundo, CA 90245-2804
(757) 688-0430
Chris.duer@ngc.com
(310) 331-3753
eric.barnes@ngc.con
PO Box 149
Mail Station 7000-02
Pascagoula, MS 39568
PO Box 30
State College, PA 16804-0030
1151 E. Hermans Road
PO Box 11337
Bldg. 805, M/S D4
Tucson, AZ 85734-1337
1050 Fourth Avenue
Huntington, WV 25701
6900 Main Street
PO Box 9729
Stratford, CT 06615-9129
10540 Heater Court
San Diego, CA 92121
1449 Middlesex Street
Lowell, MA 01851
86 River Drive
Annapolis, MD 21403
The Millennium Centre
R.D. 1, Box 100 B
Triadelphia, WV 26059-9707
(228) 872-7312
john.whitehead@ngc.com
(814) 863-4351
klk121@psu.edu
(520) 794-1018
wgscheck@raytheon.com
(800) 469-7224
tminnich@rcbi.org
(203) 386-4351
svaranay@sikorsky.com
(858) 455-1650
Joel_zuieback@sparta.com
(508) 393-7868
rcaruso@specmaterials.com
(410) 263-1348
EGASSOC@aol.com
(304) 547-5800
mlb@trl.com
This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing
Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
TCC Technical
Advisory Board (TAB)
Virginia Polytechnic Institute and
State University
Wake Forest
York Technical College
Al Loos
Dr. David Carroll
Ed Duffy
Virginia Tech Center for Composite
Materials and Structures
Department of Engineering Science
and Mechanics
Mail Code 0219
320 Norris Hall
Blacksburg, VA 24061
Wake Forest University
214 Olin Physical Laboratory
PO Box 7507
Winston Salem, NC 27199
452 South Anderson Road
Rock Hill, SC 29730
(540) 231-4713
(336) 758-5530
(803) 327-8012
aloos@vt.edu
carrolld@wfu.edu
duffy@york.tec.sc.us
This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing
Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
Executive Steering
Committee (ESC)
- What is the Executive Steering Committee?
• The Executive Steering Committee (ESC) is a group of senior level managers from
within the Composites Consortium (TCC). The 8-member ESC is composed of two
TCC representatives from each of the following four groups:
– Members who are primarily aerospace contractors,
– Members who are primarily shipbuilding or ocean structures contractors,
– Members who are research universities/institutes/laboratories, and
– Members who are primarily supplier contractors or technology suppliers.
• ESC members are nominated and elected by member companies of The Composites
Consortium (TCC).
- What does the Executive Steering Committee Do?
• The ESC provides overall coordination for technical reviews and technology
transfer. In addition, the ESC (1) Reviews all CMTC issues to be submitted to the
Navy MANTECH database, (2) Assists in the development of the technical strategic
plan for TCC, and (3) Assists the Executive Director of the CMTC in maintaining and
coordinating support for TCC, identifying additional sources of funding, marketing
TCC to potential customers,
This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing
Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
Executive Steering
Committee (ESC)
ESC Company
ESC Member
Alliant Aerospace Company
Michael Blair
Bell Helicopter-TEXTRON, Inc.
Walter
Sonneborn
Northrop Grumman Newport News
David P Rice
Northrop Grumman Integrated Systems
Company Address
Phone
E-mail
210 State Route 956
M/S: WV01-10
Rocket Center, WV 26726-3548
(801) 775-1722
michael_blair@atk.com
PO Box 482
MS: 1322
Ft. Worth, TX 76101
(817) 280-2107
wsonneborn@bellhelicopter.textron.
com
4101 Washington Avenue
B905/7
Newport News, VA 23607
(757) 688-1762
David.Rice@ngc.com
George
Rodgers
One Hornet Way, 9L20/W5
El Segundo, CA 90245-2804
(310) 331-7101
rodgege@mail.northgrum.com
Northrop Grumman Ship Systems
William
Solitario
Chair - Naval Postgraduate School
777 Dyer Rd
M/S 97
Monterey, CA 93943
(831) 656-2546
wasolita@nps.navy.mil
SPARTA Composites, Inc.
Joel Zuieback
10540 Heater Court
San Diego, CA 92121
(858) 455-1650
Joel_zuieback@sparta.com
(304) 547-5800
mlb@trl.com
(803) 325-2865
kosak@yorktech.com
Touchstone Research Laboratory
Michael Brown The Millennium Centre
(ESC Chairman)
York Technical College
Bob Kosak
R.D. 1, Box 100 B
Triadelphia, WV 26059-9707
452 South Anderson Road
Rock Hill, SC 29730
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Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
Current TCC Status
• The Composites Consortium
– 25 Current Members
•
•
•
•
•
Research Universities
Weapons Platform Primes
Specialty Fabricators
University Affiliated Research Centers (UARC)
Training & Education Organizations
– Supports All Weapon Platforms
•
•
•
•
•
Aerospace (Including Unmanned Vehicles)
Surface Ships and Vehicles
Undersea
Land Vehicles
Space Structures
This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing
Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
Current TCC Members
• Alliant Aerospace Company
• Northrop Grumman Ship Systems
• Atlantic Research Corporation
• Pennsylvania State University - Applied
Research Laboratory
 ARC Technologies, Inc.
• Bell Helicopter – TEXTRON, Inc.
• The Boeing Company
• Clemson University
• Composite Solutions, Inc.
• General Dynamics Corporation
(Bath Iron Works, Electric Boat, Land Systems)
• Raytheon Company
 Robert C. Byrd Institute (RCBI)
• Sikorsky Aircraft Corporation
• SPARTA Composites, Inc.
 Specialty Materials, Inc
• Structural Composites, Inc.
• Goodrich Corporation
• Touchstone Research Laboratory
• Lockheed Martin Corporation
• Mississippi State University
• Virginia Polytechnic Institute and State
University
• Northrop Grumman Newport News
 Wake Forest University
• Northrop Grumman Integrated Systems
• York Technical College
 New Members
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Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
TCC Member Locations
GD-Bath Iron Works
Alliant Aerospace
ARC Technologies
Specialty Materials
Boeing
Sikorsky
GD-Land Systems
Boeing
ARL/PSU
NGIS
RCBI
Goodrich
GD-Electric Boat
TRL
NGNN
Virginia Tech
Atlantic Research
Wake Forest
York Tech
NGIS
Composite Solutions
SPARTA
Clemson Univ.
Goodrich
Raytheon
SCI
Bell Helicopter
NGSS
Mississippi State
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Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
CMTC Website
http://cmtc.scra.org
TCC Info
Page
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Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
Composites Manufacturing
Technology Center
Ongoing Projects
Distribution Statement D: Distribution authorized to U.S. DOD and U.S. DOD Contractors only, for administrative and operational use. WARNING - This
document contains technical data whose export is restricted by the Arms Export Control Act (Title 22, U.S.C. SEC 2751 et seq.) or the Export Administration
Act of 1979, as amended, Title 50, U.S.C., App 2401, et seq. Violations of these export laws are subject to severe criminal penalties. Disseminate in accordance
with the provisions of DOD Directive 5230.25 and OPNAVINST 5510.161.
The Marine Composites Technology Center
West Melbourne, Florida
Spence Center for Composites Technology
Columbia, South Carolina
TECHNOLOGY TRANSFER CENTERS
York Technical College
York, South Carolina
TTC THRUST
Transfer innovative, defense-critical
composites manufacturing
technology skills from development
programs to widespread applications,
and to assist in ensuring the
affordability of composites for Navy
use
Technology Transfer
Centers
• Accomplishments
– York Technical College
• Developing a New Navy Training Course
“Introduction to Composites” Aimed at
Maintenance/Repair Personnel
• Performed a Survey of Existing Navy Composites
Training and Certification Programs at Three Main
Aviation Maintenance Depot Locations
• Conducted DACUM’s (Develop A CUrriculuM) for
Composite Repair Training and Certification
Programs at Cherry Point, North Island and Oceana
Naval Air Stations.
This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing
Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
Technology Transfer
Centers
• Accomplishments
– Spence Center for Composite Technology
• Sponsored a Conference Entitled “NavyCommercial Partnerships for World Class
Manufacturing.”
• Developed a Training Manual for the Safe Handling,
Use, and Disposal of Composites Materials
• Developed Manufacturing Processes for the
Production of Radomes using Flouroalaphatic
Cyanate Resin and Astroquartz Fiber
This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing
Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
Technology Transfer
Centers
• Accomplishments
– Marine Composite Technology Center
• Conducted A Resin Infusion Demonstration at the
Composite Fabricators Association (CFA)
International Symposium on Vacuum Infusion
Processing and Resin Transfer Molding
• Developed Booklet: “Alternative Approaches to
Closed Molding”, a Primer of VARTM-type Infusion
Processing Methods
• Developed Booklet: “Potential Composite
Applications for Oliver Hazard Perry Class Frigates”,
detailing Composites Solutions for Fleet Corrosion
Issues.
This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing
Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
PROJECT OBJECTIVE
Develop, demonstrate and
document improvements to the
wet filament winding process as
applied to pressure vessel
fabrication
AIM-9X
COMPOSITE PRESSURE VESSEL FABRICATION
PROJECT TEAM
Atlantic Research Corporation
ROI = 24:1
Composite Pressure
Vessel Fabrication
•
Project Number: A0937
•
Performing Activity: Atlantic Research Corporation
•
Start/End Dates: 04/99 – 12/03
•
Primary Benefit: Provides manufacturing technologies that will substantially
reduce the costs of high-performance composite pressure vessels to a level where
they will be competitive with metal pressure vessel alternatives.
•
Objective: Develop, demonstrate and document improvements to the wet filament
winding technology as applied to pressure vessel fabrication.
•
MANTECH Cost: $1,789K Cost Share: $267K
•
Implementation Cost: None
•
Systems Impacted: AIM-9 SIDEWINDER, RAM, SM, HELLFIRE
•
Implementation: ARC to provide improved WFW technology prior to AIM-9X
EMD
Benefit Analysis/ROI
• The Fiber Damage Assessment task, a precursor to fiber wetout, was completed.
• Investment
– ManTech Program: $1.79M
• Unit Cost Analysis
– GFE MK-36 Steel Motors: $8000
– Upgrade to AIM-9X: $6823
– Motor Unit Cost: $14,823
– Projected Procurement of 6680 AIM9X and 1500 RAM (USN & FMS)
– Total Cost Avoidance: $37.5M
• Warfighting Return
– IM Compliance
• Lives Saved
• $2.5B Past Carrier Damage
– Composite Case Required to Meet
Missile Performance Goals
• The fiber tensioner, spreader, and resin bath systems integrated
system was delivered and mounted onto an ARC filament
winder and is functional.
• NDC Corp. traveled to ARC for installation and calibration of
a gamma gage system.
Status:
• CECMT issued stop work order February 2001
• Project restarted under CMTC January 2002.
• The extended interruption in the contract is requiring
some duplication of effort to relearn programming of the
new control software and to restart the project.
Expected Unit Cost ROI = 24:1
40
Millions Saved
Technical Achievements:
30
20
10
MANTECH cost = $1.79M
FY1 FY2 FY3 FY4 FY5
Fiscal Year
Composite Pressure Vessel
Composite Pressure Vessel Fabrication
• 4” JANNAF Tubes
– Testing of Tubes from the Baseline Winder
Completed.
– Three Tubes from the ManTech Winder
Tested. Additional Tubes Being Fabricated
for Test
– Statistical Analysis After All Tubes Tested
• 6” Hydroburst Bottles
– Two ManTech Winder Bottles
Wound/Prepared for Hydroburst
– Additional Bottles Being Fabricated
• Problems With ManTech Winder Delayed
Project Approximately 2 Months
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Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
Gantry Trolley
Composite Gantry/Trolley Type Structures
• At the NSWC/CSS Station in Panama City, FL
• Composite Barge Was Being Considered for Test Pond
• Customer Determined Composite Barge to be High
Technical, Cost & Schedule Risk
• Customer Specified Steel Barge
• Barge/Building Installation Completed: Dedication
Ceremony 09 September 2003
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Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
Gantry Trolley
Aerial View of
Acoustic Test Facility
Old Barge 26’x38’
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Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
Gantry Trolley
New Barge (30’ x 60’) w/Building
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Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
Gantry Trolley
New Barge (30’ x 60’) w/Building
This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing
Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
PROJECT OBJECTIVE
Automate the Z-fiber installation
process eliminating the concerns
of manual insertion and provide
additional cost savings to the
F/A-18E/F.
AUTOMATED INSERTION OF Z-FIBER FOR COMPLEX SHAPES
PROJECT TEAM
Northrop Grumman
Aztex, Inc.
ROI = 1.4 w/o Partial Depth
Automated Insertion of
Z-Fiber for Complex Shapes
• Project Number: A1007
Prototype
Automated
Insertion Head
(End-Effector)
• Performing Activity: Northrop Grumman Corp., El Segundo, CA; Aztex
• Start/End Dates: 10/01 – 01/04
• Primary Benefit: Significant improvements in composites affordability and
increased system performance for advanced composite structures.
• Objective: To automate the Z-fiber insertion process on F/A-18 E/F
eliminating production and quality assurance concerns related to the manual
insertion variability and fatigue.
Current Manual
Insertion Head
• MANTECH Cost: $2.68M Cost Share: $721K
• Implementation Cost: TBD
• Systems Impacted: F/A - 18 E/F and derivatives, other vehicles with joined
composite parts
• Implementation: Initially a/c FF- 108 (5 parts), fully a/c FE-120 (all 37 parts)
Technical Achievements:
Benefit Analysis/ROI
• Prototype end-effector head designed, fabricated and
delivered for concept proofing and troubleshooting.
• Benefit Analysis Assumptions
• Initial coupon testing displays promising results for a
maturing technology.
Status:
• Machine systems/customer requirements document
finalized.
• Automated machine builder procurement specification
contract currently in bidding process.
• Makes a/c effectivity
• All identified parts captured
6
• 400 total aircraft purchased
• Increase in aircraft build from
36/yr. to 48/yr. for FY 05.
• Benefit Analysis Results
$Million
s
• Prototype end-effector head demonstrated on flat panel
hat-stiffened composite parts.
Expected ROI = 4.5:1
8
• Initially $12K saved per a/c
ultimately $30K saved per a/c
4
MANTECH cost =
$2.68M
2
• ROI calculation
• Significant savings over projected
a/c program lifetime with partial
depth insertion implemented.
FY04
FY05 FY06 FY07 FY08
Fiscal Year
Z-FIBER AUTOMATED
INSERTION
Mechanical Fastener Attachment
Requires:
• Pre-Curing of Multiple Details
• Drilling/Countersinking of Fastener Holes
• Application of Liquid Shim
• Wet Installation of Fasteners
Advanced Attachment with “Z-Pins”
Requires:
• Integration of Composite Lay-ups
• Installation of Z-Pins Prior to Cure
• Backside OML Sealing
Pre-Cured Composite
Radius Block
Co-Cured Composite
Hat Stiffener
Pre-Cured
Composite Skin
Co-Cured
Composite Skin
Demonstrated Benefits






.011” Dia. GR/BMI Z-Pins
(420 pins/in2)
Reduced Touch Labor
Reduced Weight
Reduced Part Count
Reduced Defect Count
Increased Interlaminar Capability
Improved Damage Tolerance
This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing
Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
Z-FIBER AUTOMATED
INSERTION
Complex
Curvature
Components
This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing
Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
Z-FIBER AUTOMATED
INSERTION
6-Axis
Gantry
Automated
Insertion
Equipment
This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing
Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
PROJECT OBJECTIVE
Improve the affordability of SiC-C
composite engine exhaust
components by streamlining and
optimizing the manufacturing
production process.
F- 414 Engine
SiC-C COMPOSITE FLAPS AND SEALS
PROJECT TEAM
Goodrich Corporation
ROI = 6.58
Manufacturing Technology for SiC-C
Composite Flaps and Seals
•
•
•
•
Project Number: A1013
Performing Activity: Goodrich Corporation
Start/End Dates: 09/02 – 08/04
Primary Benefit: Reduced Cost for F414 Engine Exhaust and Seal Components
• Objective: Identify, and Validate for Production, a Lower Cost SiC Fiber/Prepreg
Resin System and Develop Process Modifications That Will Reduce the Cost and
Cycle Time of the Carbon Vapor Deposition (CVD) Process.
• MANTECH Cost: $856K
• Implementation Cost: TBD
• Systems Impacted: F/A-18 Hornet
• Implementation: Process Changes Will Be Submitted to GEAE Engineering for
Review. GE Will Fund Engine Testing Under Their F414 Development Engine
Testing Program. Commitment has been obtained from NAVAIR F414 IPT to
Support Engine Qualification Tests
Status:
• Anticipated Project start September 2002
Project Tasks:
• Task 1: Reduce CVD Cycle Time
– Combine Pyrolysis and Carbonization Steps
– Measure The Effect Upon Composite Densities And
Mechanical Properties
• Task 2: Substitute Low Cost Fiber and Alternate Resin/Filler
System
• Task 3: Validate Process Improvements
– Manufacture Engine Hardware Panels
– Generate Mechanical Properties
• Task 4: Manufacture a Set of Engine Hardware
• Task 5: Engine Test Hardware (GEAE Funded)
Benefit Analysis/ROI
• Benefit Analysis Assumptions
– Based on 520 Engine Sets
– Estimated Cost Savings of $9.8K Per Engine
– Spare Parts Are Not Included in Analysis
• Benefit Analysis Results
– Cost Savings of $5,078K Over 520 Engines
• ROI = ($9,768 X 520) / $856,000 = 5.93
PROJECT OBJECTIVE
Develop an improved composite
protection layer for ship main
propulsion shafts that will afford
corrosion protection over a
twelve-year docking cycle.
PROPULSION SHAFT COMPOSITE SURFACE TREATMENT
PROJECT TEAM
Newport News Shipbuilding
NSWC Carderock Division
Norfolk Naval Shipyard
Portsmouth Naval Shipyard
Puget Sound Naval Shipyard
ROI = >10:1 Over 5 Year Cycle
Propulsion Shaft Composite
Surface Treatment
•
•
•
•
•
•
•
•
•
Project Number: S1012
Performing Activity: Northrop Grumman Newport News; NSWCCD; Puget Sound,
Portsmouth and Norfolk Naval Shipyards
Start/End Dates: 09/02 – 05/05
Primary Benefit: An Improved Shaft Coating System Will Help the Navy Achieve
a 12-year Docking Cycle while Reducing Shaft Life Cycle Costs.
Objective: Develop an Improved Composite Protection Layer for Ship Main
Propulsion Shafts That Will Afford Corrosion Protection for Twelve Years.
MANTECH Cost: $1,441,700
Implementation Cost: $16,460 - $49,500 Fabrication Cost Increase Per Shaft
Systems Impacted: CVN 68 Class Nuclear Aircraft Carrier; CVN77 & CVNX Next
Generation Nuclear Aircraft Carriers; DDG-51
Implementation: Approvals Secured From SEA 05Z12, SEA 05Z2, NSWCCD
SSESDET / Code 9323, SEA 05M1, PMS 312D, CNAP N43 for the CVN-70
RCOH availability. Tech Transfer/Training to Navy Shipyards
Status:
Benefit Analysis/ROI
• Anticipated Project start September 2002
• Benefit Analysis Assumptions
Project Tasks:
• Task 1 - Manufacturing Process Development
• Task 2 - Peel Testing/Environmental Conditioning
• Task 3 – Manufacturing Trials & Scale Test Shaft Fabrication
• Task 4 - NSWCCD Testing of Scale Shafts
– Repair Cost Extrapolated From Shipyard Repair Cost Estimates for Current
Shaft Covering Practices (Does Not Include Submarines).
– 383 Shafts on Surface Ships Replaced or Repaired Every 7 Years (on Average).
– $64,000 - $192,450 Repair Cost (Relative to the Shaft Size) Per Shaft Every 7
Years ($33,966,825 Total Estimated Repair Cost Savings Every 7 Years)
– $16,460 - $49,500 Fabrication Cost Increase Per Shaft ($519,730 Total
Fabrication Cost Increase Every 7 Years)
• Task 5 – Planning for RCOH 70 and CVN 77
• Benefit Analysis Results
• Task 6 – Repair Procedure Development
• $34 Million Cost Avoidance Over 7 Years
• Task 7 – Technology Transfer to Navy Shipyards
• 5-Year ROI = 5/7 x ($33,966,825 – $519,730)/$1,395,000 = 16
PROPULSION SHAFT
SURFACE TREATMENT
Polysulfide Coating Application
Application of GRP Overwrap
Polysulfide Coating Application
Application of GRP Overwrap
This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing
Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
PROPULSION SHAFT
SURFACE TREATMENT
Carderock Development of
Scale Shaft Evaluation
Progress Continues on the
“Four Square” Test
Apparatus and Test Facility
This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing
Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
PROJECT OBJECTIVE
Develop a manufacturing
process to incorporate
composite structural armor into
the EFV troop ramp door
reducing the weight by 20%
and eliminating the costly
appliqué armor system
EXPEDITIONARY FIGHTING VEHICLE TROOP DOOR
PROJECT TEAM
General Dynamics Land
Systems
ARL Penn State
ROI = 14.3 : 1
EXPEDITIONARY FIGHTING
VEHICLE TROOP DOOR
• Project Number: C1011
• Performing Activity: General Dynamics Land Systems; ARL Penn State
• Start/End Dates: 08/02 – 06/04
• Primary Benefit: Reduced Cost and Reduced Weight for the EFV Rear Door
Assembly.
• Objective: Develop a Manufacturing Process to Incorporate Composite Structural
Armor Into the EFV Troop Ramp Door Reducing the Weight by 20% and Eliminating
the Costly Appliqué Armor System
• MANTECH Cost: $ 920K Cost Share: $ 325K
• Implementation Cost: The Manufacturing Technology Developed Is Not Expected
to Require New Facilities.
• Systems Impacted: Expeditionary Fighting Vehicle (EFV)
• Implementation: A commitment has been obtained from the EFV Hull Mechanical
Systems IPT Lead (Mr. Michael Lange) to support the installation and testing of the
prototype assemblies on EMD vehicles E2, 3 and 5.
Status:
Benefit Analysis/ROI
• Anticipated Project start August 2002
• Benefit Analysis Assumptions
Project Tasks:
– Number of Vehicles = 1013
• Task 1 – Redesign & Analysis (Cost Share Task)
– Cost Savings of $5K per Door
• Task 2 – Manufacturing Process Development
– Value of Weight Savings = $100 per Pound x 80 lbs/door = $8,000
• Task 3 – Machining, Assembly, and Quality
Assurance/Inspection
– Assembly, Logistics and Other Potential Cost Savings Not Included
• Benefit Analysis Results: Total Cost Savings of $13,169K
• Task 4 – Ballistic Testing (Cost Share Task)
• ROI = (1013 vehicles x $13,000 per vehicle)/ $919,500 = 14.3
• Task 5 – Fabrication of Prototype #1
• Task 6 – Process Optimization
• Task 7-9 – EMD Vehicle E2, E3 and E5 Hardware Fabrication
PROJECT OBJECTIVE
Develop affordable and reliable
manufacturing process that
address the specific embedment
fabrication issues while
concurrently assessing the
process impact on structural
and electrical performance.
AFFORDABLE INTEGRATED STRUCTURAL APERTURES
PROJECT TEAM
Northrop Grumman AEW/EW
Northrop Grumman Ship
Systems
ROI = 7.53:1
Affordable Integrated
Structural Apertures
• Project Number: A1042
• Performing Activity: Northrop Grumman Integrated Systems
• Start/End Dates: May 2003 – January 2006
• Primary Benefit: Reduced Cost and Reduced Weight for the Satellite Communications
Antenna System for the E-2C Aircraft
• Objective: Develop Affordable And Reliable Low-pressure Autoclave And Vacuum Bag
Cure Hand Lay-up Manufacturing Processes That Address Specific Embedment
Fabrication Issues While Concurrently Assessing The Process Impact On Structural And
Electrical Performance.
• MANTECH Cost: $ 1,980K Cost Share: $ 600K
• Implementation Cost: Est. $5M E-2C Program Production Non-recurring Cost
• Systems Impacted: E-2C Hawkeye
• Implementation: This Project Is Part Of The E-2C (PMA231) Technology Insertion
Plan To Enhance The Overall Airborne Early Warning Capability For Advanced
Hawkeye Program.
Status:
Benefit Analysis/ROI
• Project Started 20 May 2003; Kickoff Meeting 04 June 2003
• Benefit Analysis Assumptions
– Number of Vehicles = 223 (Includes Spares & Retrofits)
Project Tasks:
– Acquisition Cost Savings of $50K per Aircraft
• Task 1: Embedded Antenna Type Downselect
– Value of Weight Savings = $300 per Pound x 20 lbs/Unit = $6K
• Task 2: Manufacturing Development
– Recurring Cost Savings of $20K per Year (Maintenance Labor Savings and
Reduced Fuel Consumption)
• Task 3: Subcomponent Fabrication
• Task 4: Demonstrate Repairability, Electrical Performance
• Task 5: Fabricate 2 Full-Scale Articles
• Task 6: Validate Cost/Weight Benefits
– 10 Year Service Life
– $5,000K E-2C Program Non-Recurring Cost
• Benefit Analysis Results: Total Cost Savings of $57,100K
• ROI =$57,100K/($2,580K + $5,000K) = 7.53
Affordable Integrated
Structural Apertures
Embedded Antenna Secondary Embodiment:
Advanced Hawkeye Embedded IFF Elements
This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing
Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
Affordable Integrated
Structural Apertures
1/5 Scale Advanced
Hawkeye Rotodome
Mockup
Radar Elements
Graphite/Epoxy Skin
Fiberglas Skin
This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing
Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
PROJECT OBJECTIVE
Address the need for a more
affordable, carrier-capable
airframe leading to an
alternate, low risk, more
affordable J-UCAS airframe
product.
J-UCAS CONCEPT EXPLORATION
REQUIREMENT
Current airframe designs and
manufacturing capabilities must
be improved in order to meet JUCAS affordability goals.
PROJECT PERFORMERS
Boeing Company
Northrop Grumman
CAI Phase III – J-UCAS
Concept Exploration
• Performing Activity: The Boeing Company
Northrop Grumman Corporation
Start/End Dates: 11/02 – 12/03
• Primary Benefit: Improved airframe design and manufacturing
capabilities to meet UCAV-N affordability goals
• Objective: Competing contractor teams compete to identify promising
design concepts, manufacturing and assembly approaches
• Project Cost: $635,170 (Combined Northrop and Boeing Project Cost
Including Cost Share)
• Systems Impacted: A new family of unmanned aerial vehicles
• Implementation: Technologies developed and partially demonstrated
on the MANTECH project will be further validated, qualified, and certified
during execution of the J-UCAS SDD program
Problem:
Project Tasks:
The U.S. Navy plans to develop and field a new family of unmanned
aerial vehicles to fulfill a variety of mission needs including long
range surveillance, communications node, and deep precision strike.
While considerable attention is being given to technologies such as
integrated avionics, communication capabilities, and sensor suites,
very little is being done to address the need for a more affordable,
carrier-capable airframe. Current airframe designs and
manufacturing capabilities such as those employed on the F/A-18
E/F and JSF must be improved in order to meet J-UCAS
affordability goal
• Documentation of J-UCAS product requirements (this defines the
engineering requirements for J-UCAS products)
• Documentation of J-UCAS baseline (this defines the cost and weight
metric to which progress will be measured and compared
• Identification of alternate design, manufacturing and assembly concepts of
the airframe
• Development of maturation plans for candidate technologies required in
order to realize the alternate concepts
• Documentation of detailed plans for further development and demonstration
of the most promising candidates (this will be the Project Planning
Document for the follow-on SDMD effort)
J-UCAS CONCEPT
EXPLORATION
J-UCAS Concept Exploration
• Task Order Issued to Boeing on 02 January 2003
- Kickoff Meeting Held 09 January 2003 at NAVAIR, Pax River
- Customer Outbrief Held 21 May at Boeing, St. Louis
- Final Report Submitted 30 June 2003
• Task Order Issued to NG on 4 April 2003
• Kickoff Meeting Held 14 May 2003 at NAVAIR, Pax River
• CE Phase Completion Date 15 December 2003
J-UCAS Systems Design and Manufacturing Development
• Project Planning Meeting Held 24 June, 2003 at NAVAIR, Pax
River
• CMTC Evaluating Boeing Proposal
• Mid- to Late-Q1 GFY04 Project Start Anticipated
This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing
Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
PROJECT OBJECTIVE
Develop and implement producible
and cost effective steel-tocomposite adhesive joining
technology meeting requirements
of the USS Zumwalt Class Land
Attack Destroyer
LARGE MARINE COMPOSITES-TO-STEEL JOINTS
PROJECT TEAM
• SCRA CMTC
– Boeing Company
– ARL Penn State
• NJC
Bolted Joint Used in
Composite Topside
Demonstration Program
DD21 Bonded
Joint Concept
– Bath Iron Works
– Northrop Grumman Ship Systems
LARGE MARINE COMPOSITES-toSTEEL JOINTS
• The composite deckhouse is a key component in the DD(X) design and
requires a composite to steel connection.
• Current composite-to-steel joints are accomplished by mechanical
fasteners. This attachment scheme has inherent performance and cost
deficiencies.
• Bonded joint identified in DD-21 Phase I by both Blue and Gold Teams as
needed technology to enhance design performance.
• A MANTECH project was proposed and approved by the LIPT to develop
an adhesive bonded joint for composite to steel material combinations.
This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing
Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
LARGE MARINE COMPOSITES-toSTEEL JOINTS
• Phase I: Assessment and Review of Composite-to-Steel Adhesive
Joints (Complete)
• Phase II: Joint Development (Complete)
• Phase III: Joining Process Validation/Qualification
• Phase IV: Adhesive Technology Implementation at Shipyards
E-Glass fabric/Vinyl
Ester facesheets
Key Project Development Activities
•
•
•
•
•
•
•
Design and Functional Requirements
Material characterization
Joint design and analysis
Manufacturing/ Process Development
Nondestructive Inspection Development
Repair Development
Technology Transfer/ Implementation
Outer
moldline
tool
surface
Balsa
Core
Machine
surface to fit
steel scarf
joint
Tool
Machine or grind surface
to mate steel joint
Composite
Part
Paste
adhesive
Weld from
this side
Steel “H”
section
Weld from
this side
Steel deck
stiffeners
This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing
Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
PROJECT OBJECTIVE
Meet advanced critical weight
and performance requirements
by developing processes to
manufacture and validate
integrated and bonded
airframe primary structures
CAI: INTEGRATED AND BONDED STRUCTURES VALIDATION
PROJECT TEAM
Boeing-St. Louis
Boeing-Seattle
Lockheed Martin
Bell-Textron
Northrop Grumman
PROJECT OBJECTIVE
Develop manufacturing/assembly
procedures for composite DDX
modules that satisfy structural and
electronic performance
requirements using a resin system
that meets fire, smoke and toxicity
requirements of MIL-STD 2031SH
MODULAR OUTFITTING TECHNOLOGY
PROJECT TEAM
Northrop Grumman Ship
Systems
Bath Iron Works
NSWCCD
Others?
Project Funding
MANTECH: $2.715M
Cost Share: $3.614M
Modular Outfitting Technology
• Project Number: S1048
• Performing Activity: Northrop Grumman Ship Systems; Bath Iron Works
• Start/End Dates: September 2003 – August 2004
• Primary Benefit:
• Objective: Develop a VARTM Process That Achieves Structural And Electronic
Performance Requirements Using A Resin System That Satisfies Fire, Smoke And
Toxicity (FST) Requirements of MIL-STD 2031SH
• MANTECH Cost: $ 2,715K Industry Investment: $ 3,614K
• Implementation Cost: The Manufacturing Technology Developed Is Not Expected
to Require New Facilities.
• Systems Impacted: DDX and Future Surface Combatants
• Implementation: As This Approach Is Baseline For The DDX Design, The Box-ina-box Modules Will Be Installed On The DDX Lead Ship.
Status: Anticipated Project Start Q4 GFY03
Benefits:
Problem Statement
• Benefits the Navy and industry. Like modules are less costly than
complex, unique modules used today;
Existing outfitting techniques involve installation of shipboard
electronic systems and habitability items individually during the
ship assembly process. This method is labor intensive, risks
damage to the equipment, and frequently requires multiple
assembly, testing, and disassembly of items (both at vendor and
then upon ship installation).
Solution:
The Box-in-a-Box concept is a revolutionary new approach to
ship construction, in which components could be installed and
tested in a standardized module at the vendor, and then
transported to the shipyard and installed as a complete unit.
• Streamlined supply chain - eliminates non-value added steps of repeated
assembly/test/disassembly;
• “Plug and Play” technology reduces man-hours required for technology
upgrades and retrofitting;
• System Integrator participation in the outfitting, and testing of electronic
combat system spaces;
• Reduced weight composite modules improve ship KG.
MODULAR OUTFITTING
TECHNOLOGY
Modular Outfitting Technology
• Surface Strike Affordability Initiative Funding
• 15 Month Duration Project Will be Conducted in Two Phases
– Phase 1: Module Design (Cost Share) and
Manufacturing Process Trials
– Phase 2 Go/No Go Decision
– Phase 2: Optimization of Down-Selected
Manufacturing Process and Testing (MANTECH and
Cost Share)
• Deliverables: Two Composite Modules
– Enclosure #1 For Equipment Installation And Ship
Integration Validation.
– Enclosure #2 For Qualification Testing And
Destructive Testing.
This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing
Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
PROJECT OBJECTIVE
Develop fabrication processes for
large scale, multifunctional
composite panels that incorporate
fire resistant materials and
ceramic armor solutions for
applications such as the
integrated MFR radar house/mast
and deck edge elevator doors.
CVN 21 WEIGHT REDUCTION
PROJECT TEAM
Northrop Grumman Newport News
Northrop Grumman Ship Systems
ARL Penn State
General Dynamics Land Systems
Project Funding
MANTECH: $900K
Cost Share: TBD
CVN 21 WEIGHT REDUCTION
CVN 21 Composites Applications for Weight Reduction
• Project Submitted by PEO Aircraft Carriers
• Project Duration 12 Months
• Tasks:
– Task 1: Design for Manufacturability
– Task 2: Process Development
– Task 3: Scaled-Fabrication Process Demonstration
– Task 4: Process Optimization
– Task 5: Full-scale Hybrid Panel Fabrication
• Implementation on CVN 21 and Possibly Backfit on
Nimitz Class During RCOH
This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing
Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
PROJECT OBJECTIVE
Develop and refine integrated
bleeding manufacturing
technology for the in-situ
fabrication of thick, doubly
curved submarine cover
plates.
SUBMARINE COVER PLATES
PROJECT TEAM
NG/Newport News
GD/ Electric Boat
Virginia Tech
ROI = 13:1
Composites Manufacturing Technology
for Low Cost Submarine Cover Plates
•
Project Number: S1023
•
Performing Activity: General Dynamics Electric Boat; Northrop Grumman
Newport News; Virginia Tech
•
Start/End Dates: 08/02 – 10/03
•
Primary Benefit: Reduced Acquisition Cost for Submarine Cover Plates and
Positive Impact on Shipyard Schedule.
•
Objective: Develop and Refine Integrated Bleeding Manufacturing Technology for
the In Situ Fabrication of Thick, Doubly Curved Submarine Cover Plates.
•
MANTECH Cost: $ 324K
•
Implementation Cost: The Manufacturing Technology Developed Is Not Expected
to Require New Facilities.
•
Systems Impacted: Virginia Class Submarines With Backfitting Potential to Los
Angeles, Ohio and Seawolf Class Submarines
•
Implementation: On the SSN774, First Ship of the VIRGINA Class. Implemented
As a Modification to the Existing Drawings, Material Specifications, and QC
Inspection Plans. NAVSEA PMS450 to Fund Qualification Testing.
Status:
Benefit Analysis/ROI
• Project Initiated 03 October 2002
• Benefit Analysis Assumptions
Project Tasks:
• Task 1 - Preliminary Material Evaluation (Cost Share Task)
• Task 2 - Manufacturing Process and Design Development
• Task 3 - Fabricate Manufacturing Prototype
• Task 4 - Manufacturing Evaluation of Prototype
• Task 5 - Limited Material Validation Testing (Cost Share Task)
• Task 6 - Qualification Testing (NAVSEA PMS450)
Cost Share: $ 49.4K
• Number of Submarines: 10
• Number of Large/Small Cover Plates: 5/15
• Cost Savings for Large/Small Cover Plates: $49,500/$12,500
• Benefit Analysis Results: $4 ,250K Cost Savings
• ROI = 10 x ((5 x $49,500) + (15 x $12,500))/ $324,000 = 13.1
SUBMARINE COVER PLATES
Submarine Cover Plates
• Cytec WR 24/754, a Single Sided Prepreg, Down-Selected and
Material Characterization Completed.
• GDEB Completed Finite Element Analysis Confirming that
Mechanical Properties Obtained from the Integrated Bleeding
Process Will Meet Design Requirements.
• NGNN Fabricated a Male Mold from a Dihedral Pod Splash
This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing
Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
SUBMARINE COVER PLATES
Submarine Cover Plates
• NGNN Fabricated 2 of 3
Prototype Manufacturing
Demonstration Articles.
• Virginia Tech Modified Their
3DINFIL Process Simulation
Software to Reflect
Integrated Bleeding
Fabrication Processing
Parameters.
• Optimized Processing
Parameters Developed from
the Simulation Model Will Be
Used During Manufacture of
the Third Prototype.
This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing
Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
Composites Manufacturing
Technology Center
Future Applications
This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing
Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
CURRENT COMPOSITES
IMPLEMENTATION
•
Examples of Wet Navy Composites
Implementation
– Topside Structure
– Ventilation Ducts
– LPD-17
This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing
Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
CURRENT COMPOSITES
IMPLEMENTATION
•
Examples of Wet Navy Composites
Implementation
– AEMS Mast
– Mine Hunter Rudder
– Joint Modular Lighter System
– Composite Sail
This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing
Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
Key Issues
SHIPBOARD APPLICATIONS
• Issues Related to the Application of Shipboard
Composites Technology
– Fire, Smoke, Toxicity (FST)
– EMI/Lightning Strike
– High Temperature Requirement
– Initial Costs
– Repair Technology
– Joining
• Composites to Composites
• Composites to Steel
– Ability to Inspect
This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing
Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
SHIPBOARD APPLICATIONS
This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing
Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
COMPOSITES IMPLEMENTATION
OPPORTUNITIES
• Composites Implementation Opportunities
– Near Term (1-2 Years)
• Composite Drains & Gratings
• Composite Pumps
• Composite Piping
• Composite Storage Tanks (Water, Fuel, Oil)
• Composite Ducts and Fans
• Composite Doors & Hatches
• Composite Galley Deck & Catwalk
from: CMTC Composites Technology Roadmap
This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing
Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
COMPOSITES IMPLEMENTATION
OPPORTUNITIES
• Composites Implementation Opportunities
– Intermediate Term (2-5 Years)
• Propulsion Components
– Rudders
– Shafts
– Propellers
• Radar Fences
• Bulkheads
• Blast Deflectors
– Long Term (5-8 Years)
• CVNX Carrier Island
• Virginia Class Advanced Sail
• DDX Topside
from: CMTC Composites Technology Roadmap
This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing
Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
FUTURE COMPOSITES
APPLICATIONS
New USN Interest in High Speed
• High Speed Craft
• High Speed Ships
Surface Combatants
Amphibious
Logistic
Range of Speed
Innovative Hull Forms
Lightweight Materials
• Composites
• Aluminum
Lightweight/High
Output Propulsion
Units
High Speed Transit (40 to 50 knots)
Amphibious
Logistics
High/Low Speed Operations (10 to 50 knots)
This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing
Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
FUTURE COMPOSITES
APPLICATIONS
AIRCRAFT TECHNOLOGY
Concept: Use of Aircraft Technology
on Small Fast Surface Combatants
- Weapons Against Small Boats
- Communications
- EW Systems
- Radars
This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing
Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
FUTURE COMPOSITES
APPLICATIONS
MODULAR MANNED AND UNMANNED SHIPS
MANNED
UN-MANNED
UN-MANNED
FUTURE COMPOSITES
APPLICATIONS
HYBRID HULL FORMS
Mission Station A
(57mm Gun)
Mission Station E
Mission Station D
16 Cell VLS Option
(Mission Station D)
Mission Station B
Mission Station C
CATAMARANS
Mission Station D (P/S)
Mission Station B (P/S)
Mission Station A
(57mm Gun)
Mission Station C
RAM Launcher
Mission Station D (P/S)
Mission Station B (P/S)
Aviation/UAV Payload
57mm Gun
16 Cell VLS
Aft Payload Midships Payload (Stbd & Port)
Payload Option
Fwd Payload
SURFACE EFFECT SHIPS (SES)
Mission Station A
Mission Station C
SMALL FAST SURFACE COMBATANT HULL FORMS
FUTURE COMPOSITES
APPLICATIONS
ANTENNA CONFIGURATIONS
EHF/GBS - Receive/Transmit
VHF Dipole Antennas
Ku Band - Receive/Transmit
GPS Antenna
ESM Antennas
Radar/JTIDS/HF Receive/UHF LOS Antennas
This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing
Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
CONCLUSIONS
– Composites Gaining Recognition as Necessary Technology
to Meet Mission Requirements on New Navy Platforms
– Historical Resistance to Implementation of Composites on
Navy Platforms is Being Replaced With Composites
Specified as Baseline in New Designs
– Advanced Manufacturing Methods Allowing Composites to
Approach Cost Equivalency to Conventional Metal
Structures
– Additional Work On-going Addressing Materials and
Design Issues Related to:
• FST
• Repair
• Inspection
This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing
Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
Contact Information:
Gary W. Schuerfeld
Composites Manufacturing Technology Center
934D Old Clemson Highway
Seneca, SC 29672
(864) 653-7590 x20
schuerfeld@scra.org
http://cmtc.scra.org
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