joint technology exchange group cmtc brief november 05, 2003 gary w. schuerfeld chairman, the...

Joint Technology Exchange Joint Technology Exchange GroupGroup

CMTC BriefCMTC Brief

November 05, 2003Gary 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 TopicsScheduled 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


Composites Composites Manufacturing Technology Manufacturing Technology

CenterCenterOverviewOverview



Composites Composites Manufacturing Manufacturing

Technology CenterTechnology 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


• Sponsor:

• Award Date:

• Contract Period:

• Contract Amount:

• Contract Type:

ONR MANTECH Program

October 2000

5 Years

Contract Ceiling : $120MONR Core Funding : $ 60M

Cooperative Agreement


Technology CenterTechnology Center


US Navy Centers of US Navy Centers of Excellence (COE)Excellence (COE)

Institute for Manufacturing and Sustainment Technologies(IMAST)Penn State, PA

National Center for Excellence in Metalworking Technology(NCEMT) Johnstown, PA

Electro-Optics Center(EOC)Kittanning, PA

Center for Naval Shipbuilding Technology(CNST)Charleston, SC

Navy Joining Center (NJC)Columbus, OH

Best Manufacturing Practices Center of Excellence (BMP) College Park, MD

Energetics Manufacturing Technology Center (EMTC)Indian Head, MD

Electronics Manufacturing Productivity Facility (EMPF)Philadelphia, PA

Seneca, SCSeneca, SC



Technology CenterTechnology CenterSCRA

Corporate Offices



Technology CenterTechnology Center• Personnel

• Henry E. Watson - ARDI and CMTC: Executive Director• Jim Sabo - CMTC: Technical Director• Skip Wharton - ARDI: Director of Finance and Procurement• Jada Gates - ARDI: Senior Contracts Manager• Rhett Cheatham - ARDI: Projects Administrator• Ivan Snell - CMTC: Director, Special Programs• Gary Schuerfeld - CMTC: Chairman, The Composites

Consortium• Lillian Rumsey - ARDI: Coordinator• Lesley Morrison - ARDI: Administrative Assistant• Dr. Art West - ARDI: Technical Director

• Headquarters934-D Old Clemson HighwayEagles Landing Professional Park Seneca, South Carolina 29672Phone: 864-653-7590 Fax: 864-653-7434


CMTC/TCC CMTC/TCC StructureStructure

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.


CMTC/TCC CMTC/TCC StructureStructure

Technical Advisory Board(TAB)

Executive Steering Committee

(ESC)

–What is the Technical Advisory BoardWhat 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 doWhat 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.


TCC Technical TCC Technical Advisory Board Advisory Board

(TAB)(TAB)



(TAB)(TAB)Alliant Aerospace Company

Michael Blair 210 State Route 956

M/S: WV01-10 Rocket Center, WV 26726-3548

(801) 775-1722 [email protected]

Atlantic Research Corporation John Sparks 5945 Wellington Road Gainesville, VA 20155


ARC Technologies, Inc. Judith Snow 11 Chestnut Street Amesbury, Mass 01913


Bell Helicopter-TEXTRON, Inc. Ken Nunn PO Box 482 Plt 1, Drop 1701 Ft. Worth, TX 76101


The Boeing Company Randy Southmayd Advanced Mfg. Research & Development Phantom Works PO Box 516 Mail Code S2761007 St. Louis, MS 63166-0516


Clemson University Larry Dooley College of Engineering and Science Riggs Hall Clemson University

(864) 656-3200

[email protected]

Composite Solutions, Inc. James Lovejoy 1940 Old Dunbar Road West Columbia, SC 29172


General Dynamics (Electric Boat, Land Systems,

Bath Iron Works)

Dr. Jeff Hall General Dynamics Electric Boat Dept. 341, Sta. J88-9 75 Eastern Point Road Groton, CT 06340


Goodrich Corporation Ron Kestler 11120 S. Norwalk Blvd Santa Fe Springs, CA 90670


Lockheed Martin Corporation Morris Scales PO Box 748 Fort Worth, TX 76101


Mississippi State University Wayne Bennet College of Engineering Mississippi State University PO Box 9544 Mississippi State, MS 39762



Northrop Grumman Newport News Chris Duer Dept E30, Bldg 1744-5 4101 Washington Avenue Newport News, VA 23607


Northrop Grumman Integrated Systems

Eric Barnes One Hornet Way, 9L20/W2 El Segundo, CA 90245-2804


Northrop Grumman Ship Systems Walter Whitehead

PO Box 149 Mail Station 7000-02 Pascagoula, MS 39568

(228) 872-7312

[email protected]

Pennsylvania State University – Applied Research Laboratory

Kevin Koudela PO Box 30 State College, PA 16804-0030


Raytheon Company Bill Scheck 1151 E. Hermans Road PO Box 11337 Bldg. 805, M/S D4 Tucson, AZ 85734-1337


Robert C. Byrd Institute (RCBI) Tom Minnich 1050 Fourth Avenue Huntington, WV 25701


Sikorsky Aircraft Corporation Stephen Varanay 6900 Main Street PO Box 9729 Stratford, CT 06615-9129


SPARTA Composites, Inc. Joel Zuieback 10540 Heater Court San Diego, CA 92121


Specialty Materials, Inc. Rich Caruso 1449 Middlesex Street Lowell, MA 01851


Structural Composites, Inc. Eric Greene 86 River Drive Annapolis, MD 21403


Touchstone Research Laboratory Michael Brown The Millennium Centre R.D. 1, Box 100 B Triadelphia, WV 26059-9707



(TAB)(TAB)


Virginia Polytechnic Institute and State University

Al Loos 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 Dr. David Carroll

Wake Forest University 214 Olin Physical Laboratory PO Box 7507 Winston Salem, NC 27199

(336) 758-5530

[email protected]

York Technical College Ed Duffy 452 South Anderson Road Rock Hill, SC 29730



(TAB)(TAB)

- What is the Executive Steering Committee?- 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?- 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,


Executive Steering Executive Steering Committee (ESC)Committee (ESC)


Executive Steering Executive Steering Committee (ESC)Committee (ESC)

ESC Company ESC Member Company Address Phone E-mail

Alliant Aerospace Company

Michael Blair 210 State Route 956 M/S: WV01-10 Rocket Center, WV 26726-3548


Bell Helicopter-TEXTRON, Inc. Walter Sonneborn

PO Box 482 MS: 1322 Ft. Worth, TX 76101


Northrop Grumman Newport News David P Rice 4101 Washington Avenue B905/7 Newport News, VA 23607


Northrop Grumman Integrated Systems George Rodgers

One Hornet Way, 9L20/W5 El Segundo, CA 90245-2804


Northrop Grumman Ship Systems William Solitario

Chair - Naval Postgraduate School 777 Dyer Rd M/S 97 Monterey, CA 93943


SPARTA Composites, Inc. Joel Zuieback 10540 Heater Court San Diego, CA 92121


Touchstone Research Laboratory Michael Brown (ESC Chairman)

The Millennium Centre R.D. 1, Box 100 B Triadelphia, WV 26059-9707


York Technical College Bob Kosak 452 South Anderson Road Rock Hill, SC 29730


• The Composites ConsortiumThe 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


Current TCC Current TCC StatusStatus


• Alliant Aerospace Company

• Atlantic Research Corporation 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)

• Goodrich Corporation

• Lockheed Martin Corporation

• Mississippi State University

• Northrop Grumman Newport News

• Northrop Grumman Integrated Systems

• Northrop Grumman Ship Systems

• Pennsylvania State University - Applied Research Laboratory

• Raytheon Company Robert C. Byrd Institute (RCBI)

• Sikorsky Aircraft Corporation

• SPARTA Composites, Inc. Specialty Materials, Inc

• Structural Composites, Inc.

• Touchstone Research Laboratory

• Virginia Polytechnic Institute and State University

Wake Forest University

• York Technical College New Members

Current TCC Current TCC MembersMembers


TCC Member TCC Member LocationsLocations

ARC Technologies

Atlantic Research

Alliant Aerospace

GD-Electric Boat

Clemson Univ.

Composite Solutions

York Tech

GD-Bath Iron Works

GD-Land Systems

Goodrich

Bell Helicopter

Boeing

Mississippi State

NGNN

NGIS

NGIS

NGSS

SPARTA

Goodrich

ARL/PSU

Raytheon

RCBI

Sikorsky

Specialty Materials

SCI

Virginia Tech

TRL

Boeing

Wake Forest


TCC Info Page

CMTC WebsiteCMTC Website

http://cmtc.scra.org


CenterCenterOngoing ProjectsOngoing 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 CenterWest Melbourne, Florida

York Technical CollegeYork, South Carolina

Spence Center for Composites TechnologyColumbia, South Carolina

TTC THRUSTTransfer 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 CENTERSTECHNOLOGY TRANSFER CENTERS


Technology Transfer Technology Transfer CentersCenters

•Accomplishments– York Technical CollegeYork 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.



•Accomplishments– Spence Center for Composite TechnologySpence Center for Composite Technology

• Sponsored a Conference Entitled “Navy-Commercial 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



•Accomplishments– Marine Composite Technology CenterMarine 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.

PROJECT OBJECTIVEDevelop, demonstrate and document improvements to the wet filament winding process as applied to pressure vessel fabrication

PROJECT TEAMAtlantic Research Corporation

ROI = 24:1

AIM-9X

COMPOSITE PRESSURE VESSEL FABRICATIONCOMPOSITE PRESSURE VESSEL FABRICATION

Composite PressureComposite PressureVessel FabricationVessel 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

Technical Achievements:• The Fiber Damage Assessment task, a precursor to fiber wet-

out, was completed.

• 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.

Benefit Analysis/ROI• 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 AIM-9X 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

Fiscal YearM

illio

ns S

aved

MANTECH cost = $1.79M

Expected Unit Cost ROI = 24:1

FY1 FY2 FY3 FY4 FY5

20

30

40

10


Composite Pressure VesselComposite 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


Gantry TrolleyGantry 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


Old Barge 26’x38’Aerial View of Acoustic Test

Facility



New Barge (30’ x 60’) w/BuildingNew Barge (30’ x 60’) w/Building


PROJECT OBJECTIVEAutomate the Z-fiber installation process eliminating the concerns of manual insertion and provide additional cost savings to the F/A-18E/F.

PROJECT TEAMNorthrop GrummanAztex, Inc.

ROI = 1.4 w/o Partial Depth

AUTOMATED INSERTION OF Z-FIBER FOR COMPLEX AUTOMATED INSERTION OF Z-FIBER FOR COMPLEX SHAPESSHAPES

Automated Insertion of Automated Insertion of Z-Fiber for Complex ShapesZ-Fiber for Complex Shapes

• Project Number: A1007• 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.

• 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)

Benefit Analysis/ROI• Benefit Analysis Assumptions

• Makes a/c effectivity• All identified parts captured• 400 total aircraft purchased• Increase in aircraft build from 36/yr. to 48/yr. for FY 05.

• Benefit Analysis Results• Initially $12K saved per a/c ultimately $30K saved per a/c

• ROI calculation• Significant savings over projected a/c program lifetime with partial depth insertion implemented.

Technical Achievements:• Prototype end-effector head designed, fabricated and

delivered for concept proofing and troubleshooting.• Prototype end-effector head demonstrated on flat panel

hat-stiffened composite parts.• Initial coupon testing displays promising results for a

maturing technology.

Fiscal Year

$Mill

ion

s

MANTECH cost = $2.68M

Expected ROI = 4.5:1

FY04 FY05 FY06 FY07 FY08

8

Prototype Automated

Insertion Head (End-Effector)

6

4

2Status:• Machine systems/customer requirements document

finalized.• Automated machine builder procurement specification

contract currently in bidding process.

Current Manual Insertion Head


Z-FIBER AUTOMATED Z-FIBER AUTOMATED INSERTIONINSERTION

Mechanical Fastener AttachmentMechanical Fastener Attachment Advanced Attachment with “Z-Advanced Attachment with “Z-Pins”Pins”

Reduced Touch LaborReduced Touch Labor Reduced WeightReduced Weight Reduced Part CountReduced Part Count Reduced Defect CountReduced Defect Count Increased Interlaminar CapabilityIncreased Interlaminar Capability Improved Damage ToleranceImproved Damage Tolerance

Demonstrated BenefitsDemonstrated Benefits

Requires:Requires:• Pre-Curing of Multiple DetailsPre-Curing of Multiple Details• Drilling/Countersinking of Fastener HolesDrilling/Countersinking of Fastener Holes• Application of Liquid ShimApplication of Liquid Shim• Wet Installation of FastenersWet Installation of Fasteners

Requires:Requires:• Integration of Composite Lay-upsIntegration of Composite Lay-ups• Installation of Z-Pins Prior to CureInstallation of Z-Pins Prior to Cure• Backside OML SealingBackside OML Sealing

Pre-Cured Pre-Cured Composite SkinComposite Skin

Co-Cured Composite Co-Cured Composite Hat StiffenerHat Stiffener

.011” Dia. GR/BMI Z-Pins.011” Dia. GR/BMI Z-Pins(420 pins/in(420 pins/in22))

Co-Cured Co-Cured Composite SkinComposite Skin

Pre-Cured Composite Pre-Cured Composite Radius BlockRadius Block



Complex Complex Curvature Curvature

ComponentComponentss


6-Axis 6-Axis Gantry Gantry

Automated Automated Insertion Insertion

EquipmentEquipment


PROJECT OBJECTIVEImprove the affordability of SiC-C composite engine exhaust components by streamlining and optimizing the manufacturing production process.

PROJECT TEAMGoodrich Corporation

ROI = 6.58

F- 414 Engine

SiC-C COMPOSITE FLAPS AND SEALSSiC-C COMPOSITE FLAPS AND SEALS

Manufacturing Technology for Manufacturing Technology for SiC-C Composite Flaps and SealsSiC-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

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

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)

PROJECT OBJECTIVEDevelop an improved composite protection layer for ship main propulsion shafts that will afford corrosion protection over a twelve-year docking cycle.

PROJECT TEAMNewport News ShipbuildingNSWC Carderock DivisionNorfolk Naval ShipyardPortsmouth Naval ShipyardPuget Sound Naval Shipyard

ROI = >10:1 Over 5 Year Cycle

PROPULSION SHAFT COMPOSITE SURFACE TREATMENTPROPULSION SHAFT COMPOSITE SURFACE TREATMENT

Status:• Anticipated Project start September 2002

Propulsion Shaft Composite Propulsion Shaft Composite Surface TreatmentSurface 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


– 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)• Benefit Analysis Results• $34 Million Cost Avoidance Over 7 Years• 5-Year ROI = 5/7 x ($33,966,825 – $519,730)/$1,395,000 = 16

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• Task 5 – Planning for RCOH 70 and CVN 77• Task 6 – Repair Procedure Development• Task 7 – Technology Transfer to Navy Shipyards


PROPULSION SHAFT PROPULSION SHAFT SURFACE TREATMENTSURFACE TREATMENT

Polysulfide Coating Application Polysulfide Coating Application

Application of GRP Overwrap Application of GRP Overwrap


PROPULSION SHAFT PROPULSION SHAFT SURFACE TREATMENTSURFACE TREATMENT

Carderock Development of Scale Shaft Evaluation Progress Continues on the “Four Square” Test Apparatus and Test Facility

PROJECT TEAMGeneral Dynamics Land

SystemsARL Penn State

ROI = 14.3 : 1

PROJECT OBJECTIVEDevelop 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 DOOREXPEDITIONARY FIGHTING VEHICLE TROOP DOOR

EXPEDITIONARY FIGHTING EXPEDITIONARY FIGHTING VEHICLE TROOP DOORVEHICLE 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.


– Number of Vehicles = 1013– Cost Savings of $5K per Door– Value of Weight Savings = $100 per Pound x 80 lbs/door = $8,000– Assembly, Logistics and Other Potential Cost Savings Not Included

• Benefit Analysis Results: Total Cost Savings of $13,169K• ROI = (1013 vehicles x $13,000 per vehicle)/ $919,500 = 14.3

Project Tasks:• Task 1 – Redesign & Analysis (Cost Share Task)• Task 2 – Manufacturing Process Development • Task 3 – Machining, Assembly, and Quality

Assurance/Inspection • Task 4 – Ballistic Testing (Cost Share Task)• Task 5 – Fabrication of Prototype #1 • Task 6 – Process Optimization • Task 7-9 – EMD Vehicle E2, E3 and E5 Hardware Fabrication

Status:• Anticipated Project start August 2002

PROJECT OBJECTIVEDevelop affordable and reliable manufacturing process that address the specific embedment fabrication issues while concurrently assessing the process impact on structural and electrical performance.

PROJECT TEAMNorthrop Grumman AEW/EW

Northrop Grumman Ship Systems

ROI = 7.53:1

AFFORDABLE INTEGRATED STRUCTURAL APERTURESAFFORDABLE INTEGRATED STRUCTURAL APERTURES

Affordable Integrated Affordable Integrated Structural AperturesStructural 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.


– Number of Vehicles = 223 (Includes Spares & Retrofits)– Acquisition Cost Savings of $50K per Aircraft– Value of Weight Savings = $300 per Pound x 20 lbs/Unit = $6K– Recurring Cost Savings of $20K per Year (Maintenance Labor Savings and

Reduced Fuel Consumption)– 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

Project Tasks:• Task 1: Embedded Antenna Type Downselect

• Task 2: Manufacturing Development

• Task 3: Subcomponent Fabrication

• Task 4: Demonstrate Repairability, Electrical Performance

• Task 5: Fabricate 2 Full-Scale Articles

• Task 6: Validate Cost/Weight Benefits

Status:• Project Started 20 May 2003; Kickoff Meeting 04 June 2003



Embedded Antenna Secondary Embodiment: Advanced Hawkeye Embedded IFF Elements



1/5 Scale Advanced Hawkeye Rotodome

Mockup

Graphite/Epoxy Skin

Fiberglas Skin

Radar Elements

J-UCAS CONCEPT EXPLORATIONJ-UCAS CONCEPT EXPLORATION

PROJECT PERFORMERSBoeing Company

Northrop Grumman

PROJECT OBJECTIVE

Address the need for a more affordable, carrier-capable airframe leading to an alternate, low risk, more affordable J-UCAS airframe product.

REQUIREMENTCurrent airframe designs and manufacturing capabilities must be improved in order to meet J-UCAS affordability goals.

CAI Phase III – J-UCASCAI Phase III – J-UCASConcept ExplorationConcept 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

Project Tasks:• 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)

Problem: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


J-UCAS CONCEPT J-UCAS CONCEPT EXPLORATIONEXPLORATION

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

LARGE MARINE COMPOSITES-TO-STEEL JOINTSLARGE MARINE COMPOSITES-TO-STEEL JOINTS

PROJECT OBJECTIVEDevelop and implement producible and cost effective steel-to-composite adhesive joining technology meeting requirements of the USS Zumwalt Class Land Attack Destroyer

PROJECT TEAM• SCRA CMTC

– Boeing Company– ARL Penn State

• NJC– Bath Iron Works– Northrop Grumman Ship Systems

Bolted Joint Used in Composite Topside

Demonstration Program

DD21 BondedJoint Concept


LARGE MARINE COMPOSITES-to-LARGE MARINE COMPOSITES-to-STEEL JOINTSSTEEL 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.


LARGE MARINE COMPOSITES-to-LARGE MARINE COMPOSITES-to-STEEL JOINTSSTEEL 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

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

Pasteadhesive

CompositePart

Steel “H” section

Weld from this side

Steel deckstiffeners

Machine surface to fit steel scarf joint

E-Glass fabric/Vinyl Ester facesheets

Machine or grind surfaceto mate steel joint

Outer moldline tool surface

BalsaCore

Tool

Weld from this side

CAI: INTEGRATED AND BONDED STRUCTURES CAI: INTEGRATED AND BONDED STRUCTURES VALIDATIONVALIDATION

PROJECT TEAMBoeing-St. LouisBoeing-Seattle

Lockheed MartinBell-Textron

Northrop Grumman

PROJECT OBJECTIVEMeet advanced critical weight and performance requirements by developing processes to manufacture and validate integrated and bonded airframe primary structures

MODULAR OUTFITTING TECHNOLOGYMODULAR OUTFITTING TECHNOLOGY

PROJECT OBJECTIVEDevelop 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

PROJECT TEAMNorthrop Grumman Ship

SystemsBath Iron Works

NSWCCDOthers?

Project Funding MANTECH: $2.715MCost Share: $3.614M

Modular Outfitting Modular Outfitting TechnologyTechnology

• 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-in-

a-box Modules Will Be Installed On The DDX Lead Ship.

Benefits:• Benefits the Navy and industry. Like modules are less costly than

complex, unique modules used today;• 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.

Problem StatementExisting 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).

Status: Anticipated Project Start Q4 GFY03

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.


MODULAR OUTFITTING MODULAR OUTFITTING TECHNOLOGYTECHNOLOGY

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.

CVN 21 WEIGHT REDUCTIONCVN 21 WEIGHT REDUCTION

PROJECT TEAMNorthrop Grumman Newport

News Northrop Grumman Ship Systems

ARL Penn StateGeneral Dynamics Land

Systems

Project Funding MANTECH: $900KCost Share: TBD

PROJECT OBJECTIVEDevelop 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 REDUCTIONCVN 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

SUBMARINE COVER PLATESSUBMARINE COVER PLATES

PROJECT TEAMNG/Newport News GD/ Electric Boat

Virginia Tech

ROI = 13:1

PROJECT OBJECTIVEDevelop and refine integrated bleeding manufacturing technology for the in-situ fabrication of thick, doubly curved submarine cover plates.

Composites Manufacturing Composites Manufacturing Technology for Low Cost Technology for Low Cost Submarine Cover PlatesSubmarine 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 Cost Share: $ 49.4K• 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.


• 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

Status:• Project Initiated 03 October 2002

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)



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



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.


CenterCenterFuture ApplicationsFuture Applications



CURRENT COMPOSITES CURRENT COMPOSITES IMPLEMENTATIONIMPLEMENTATION

• Examples of Wet Navy Composites Implementation– Topside Structure– Ventilation Ducts– LPD-17


• Examples of Wet Navy Composites Implementation– AEMS Mast– Mine Hunter Rudder– Joint Modular Lighter System – Composite Sail

CURRENT COMPOSITES CURRENT COMPOSITES IMPLEMENTATIONIMPLEMENTATION


SHIPBOARD APPLICATIONSSHIPBOARD 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

Key

Issu

es


SHIPBOARD APPLICATIONSSHIPBOARD APPLICATIONS


COMPOSITES IMPLEMENTATION COMPOSITES IMPLEMENTATION OPPORTUNITIESOPPORTUNITIES

• 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


• 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

COMPOSITES IMPLEMENTATION COMPOSITES IMPLEMENTATION OPPORTUNITIESOPPORTUNITIES

from: CMTC Composites Technology Roadmap


FUTURE COMPOSITES FUTURE COMPOSITES APPLICATIONSAPPLICATIONS

New USN Interest in High Speed• High Speed Craft• High Speed Ships

Surface Combatants Amphibious Logistic

Range of SpeedHigh Speed Transit (40 to 50 knots)

AmphibiousLogistics

High/Low Speed Operations (10 to 50 knots)

Innovative Hull FormsLightweight Materials

• Composites• Aluminum

Lightweight/High Output Propulsion Units



Concept: Use of Aircraft Technology on Small Fast Surface Combatants

- Weapons Against Small Boats- Communications- EW Systems- Radars

AIRCRAFT TECHNOLOGYAIRCRAFT TECHNOLOGY

MANNED

UN-MANNED

UN-MANNED

MODULAR MANNED AND UNMANNED SHIPSMODULAR MANNED AND UNMANNED SHIPS



16 Cell VLS Option(Mission Station D)

Mission Station BMission Station C

Mission Station D

Mission Station E

Mission Station A(57mm Gun)

Mission Station C

Mission Station C Mission Station A(57mm Gun)

Mission Station B (P/S)

Mission Station A

Mission Station B (P/S)

Mission Station D (P/S)

Mission Station D (P/S)

16 Cell VLSPayload Option

Fwd PayloadMidships Payload (Stbd & Port)

Aviation/UAV Payload

Aft Payload

RAM Launcher 57mm Gun

HYBRID HULL FORMS

CATAMARANS

SURFACE EFFECT SHIPS (SES)

SMALL FAST SURFACE COMBATANT HULL FORMSSMALL FAST SURFACE COMBATANT HULL FORMS



EHF/GBS - Receive/Transmit

Ku Band - Receive/Transmit

ESM Antennas Radar/JTIDS/HF Receive/UHF LOS Antennas

GPS Antenna

VHF Dipole Antennas

ANTENNA CONFIGURATIONSANTENNA CONFIGURATIONS


– 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

CONCLUSIONSCONCLUSIONS

Questions…Questions… Discussion…Discussion…

Contact InformationContact Information::Gary W. SchuerfeldGary W. SchuerfeldComposites Manufacturing Technology Composites Manufacturing Technology CenterCenter934D Old Clemson Highway934D Old Clemson HighwaySeneca, SC 29672Seneca, SC 29672(864) 653-7590 x20(864) 653-7590 [email protected]@scra.org

http://cmtc.scra.orghttp://cmtc.scra.org

joint technology exchange group cmtc brief november 05, 2003 gary w. schuerfeld chairman, the...

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