Proposal Title Company Amount

Transcription

1 Proposal Title Company Amount Automated Assembly of U.S. Military Optics Keystone Applied Technologies $456, Mass Fabricated Micro-Initiator Boards for Gun Launch MEMS-based S&A Devices Integrated Circuit Emulation Manufacturing Design Capability Improvements Integrated Circuit Emulation Manufacturing Test Capability Improvements Tanner Research, Inc. $1,000, Sarnoff $946, Sarnoff $788, Manufacturing Capability for Spray Cooled Vehicle Power Control and Distribution System Isothermal Systems Research, Inc., $844, US Based GaN Limiter MMIC Supplier for Naval & Ground Based Radars Lockheed Martin $999, Advanced Process Engineering for Cost-Effective Composite Battery Manufacturing of 6T Microcell Batteries Firefly Energy $985, Development and Implementation of a Fast Braze Process for Aero Engine Components Intensive Quenching Technology for Critical Artillery Components Incremental Sheet Forming for Aging Department of Defense Asset Sustainment Woodward FST Inc. $492, NexTec Corporation $852, The Boeing Company $949, Development and Transition of Optimized Transformation Processes for ATl 500-MIL Auto- Tempered High Hard Steel National Center for Defense Mfg. & Machining $540, Preservation and Manufacturing of Legacy Components Rolls-Royce $887, Cost-Effective Grinding of Nickel-Based Alloys for Quality Production of Propulsion and U.S. Defense Weapon Systems Components TechSolve, Inc. $700, Implementation of Innovative Metal Casting Technologies To Lower DoD Procurement Costs and Reduce Lead Times buycastings.com $997,174.00

2 Advanced Process Engineering for Cost-Effective Composite Battery Manufacturing of 6T Microcell Batteries Firefly Energy, Inc. proposes a 12-month advanced Process Engineering and Product Integration effort to bring its microcellular foam-based lead acid battery adapted for military applications (6T-NRG) to full commercialization. Prototypes of the Firefly 6T-NRG military battery have been developed for military applications under a contract with the U.S. Army s Tank, Automotive and Armaments Command (contract W56HZV-07-C-0184 CLIN0001) for use in combat vehicle applications as a high-performance replacement for the 6T-size battery, currently used in 95% of Army vehicles. Intensive Quenching Technology for Critical Artillery Components The goal of the proposed project is to implement a patented heat treatment, known as Intensive Quenching (IQ), into production of gun barrels for the families of light (M249) and medium (M240) machine guns. In addition to the proposed implementation project IQ technology has broader application potential on aerospace and other military vehicle components, such as helicopter transmission gears, tank transmission shafts, and ground vehicle armor. Improved material structure and high residual surface compressive stresses produced by the IQ process will increase the damage tolerance in these critical components, as well as life of the component. Manufacturing Capability for Spray Cooled Vehicle Power Control and Distribution System The M109AG Paladin self-propelled howitzer is the primary target for a SprayCool Vehicle Power Control and Distribution System (VPCDS). BAE Systems, Johnson City is currently under contract by the US Army s PIM Paladin/FAASV to develop the system for the Paladin. Similar power distribution and control systems built today are often accomplished using rugged conduction cooled VME cards. Conduction cooled electronics are often thought to be the only approach to integrating electronics applications on harsh ground vehicle platforms such as the Paladin. Unfortunately, the cost of rugged, conduction cooled cards is often as much as 1.8 times their commercial equivalents so there is considerable motivation for being able to leverage commercial cards. Mass Fabricated Micro-Initiator Boards for Gun- Launch MEMS-based S&A Devices Technologies developed by the Army to achieve lethality enhancement and weight/cost reduction resulted in fabricating a gun-launch MEMS-based Safe & Arm (S&A) device capable of significantly enhancing the performance of most munition systems. The MEMS-based S&A device benefitted from a $10+ Million ManTech program that did not include mass fabricating the key-enabling plug-in micro-initiator board (MIB) used to start a complex ordnance train. ARDEC Fuze Division is purchasing individual MIB devices from Tanner Research in small quantities at more than $70 each. Buy Castings Aging Weapons, Shrinking Supply Chain and Increased Cost: Years of war have taken a toll on DoD weapon systems. Wear and tear from the wars in Iraq and Afghanistan have rapidly increased costs to maintain and replace aging systems. Simultaneously, operational costs have soared and development costs for new weapon systems such as the F-22 and F-35 skyrocketed over the original estimates. These factors

3 have lead to DoDs mounting challenge to avail our war fighters with the best possible equipment and operational capability. Several recent examples have highlighted the critical and urgent need to replenish our weapon systems. The Air Force had to ground all F-15 fighters in November 2007 for inspections after a catastrophic mishap of an F-15 in Missouri. This is not an isolated case. Aircraft, including the C- 5, B-52, C-130, and KC-135s have been in the inventory for over four decades and are scheduled to fly for decades to come. These Air Force examples are only a sampler of the growing DoD-wide challenge to maintain and replace aging weapons systems. To exacerbate rising costs and maintenance problems the global economic downturn has forced closures and consolidation of OEMs and suppliers, making it difficult to obtain replacement parts on a reliable basis. In some cases, the original manufacturers or suppliers have significant advantages that prevent competitors from entering the market. For example, in the investment casting industry, current suppliers have already invested resources to make their own tooling and molds for replacement parts. New suppliers would have to invest significant sums to reverse engineer, manufacture the tooling/molds, engineer the process, and qualify/certify the product all before manufacturing a single part. These market barriers have made entering the defense supply market an unattractive proposition for many small and medium size businesses. Further, many parts drawings for legacy parts and systems no longer exist, so the DoD customers rely heavily on the sole supplier s drawings and specifications. According to the DLA, only 1% of their non-commodity replacement parts have a full list of drawings and specifications that can be sent to multiple suppliers for bid. In addition, the U.S. investment casting industry is running close to maximum capacity, between 60-90%. As a result, many foundries are not responding to procurement orders from DoD. These market forces are reducing competition and DLA has witnessed dramatic increases in replacement part prices and lead times. Finding a solution (i.e. lower costs, more suppliers, and shorter lead times) is a cross-cutting challenge for all DoD departments. Cost Effective Grinding of Nickel-Based Alloys for Quality Production of Propulsion and U.S. Defense Weapon Systems Components In this proposal we are focusing on cost-effective grinding of nickel-based alloys (Rene N5 and N6). The initial implementation of this program is planned for turbine airfoil grinding for the T700 high-pressure turbine blade. The T700 high-pressure turbine blade is used in a variety of USAF, USN and US Army rotary aircraft. This program will be especially beneficial to new advanced airfoils such as the ones in the JSF s F136 engine. Development and Implementation of a Fast Braze Process for Aero Engine Components The objective of this project is the optimization of the high temperature joining process for the F119 and F135 fuel augmentor spraybar injectors. These injectors are used on the F22 and F35 series military fighters respectively. Results from the optimization are expected to reduce the total manufacturing time while simultaneously decreasing scrap and rework rates, thus yielding better manufacturing throughput capabilities. It is expected that these improvements can be leveraged to increase Woodward s throughput for other critical war fighter applications such as the F100 sprayrings (F-15 and F-16 aircraft) and the TR33 fuel manifolds (B-52, AWACS, and JSTARS aircraft). Therefore, it is anticipated that the manufacturing enhancements derived from this project will permit Woodward to better meet any surge in procurement for these crucial military programs. Automated Assembly of U.S. Military Optics In this program, KATI plans to transition a prototype robotic lens assembly cell developed in conjunction with the National Center for Defense Manufacturing and Machining (NCDMM) onto the floor of its associated lens manufacturing facility (operated by Optical Systems Technology, Inc. (OSTI)).

4 This lens manufacturing facility is currently employing robotics to fabricate the glass elements that go into lens assemblies. However, strictly manual techniques are being used to assemble these glass elements into operational lenses. Industrial Base Innovation Fund Integrated Circuit Emulation Manufacturing Design Capability Improvements The objective of this proposal is to implement an integrated design system which is composed of physical devices (workstations and servers) and software from a single vendor to form a costeffective CAD suite of tools on a single platform that is flexible and customizable for all of the manufacturing processes and technologies supported under DLA s emulation programs. Industrial Base Innovation Fund Integrated Circuit Emulation Manufacturing Test Capability Improvements The objective of this proposal is to enhance the current microcircuit testing capability to improve testing performance and sustainability via deployment of more current supportable, reliable, and robust ATE test system for the emulation programs. The proposal has three tasks: 1) development and validation of a migration path to a modern test system, 2) installation and validation of a parallel testing capability of multiple microcircuits, and 3) installation and validation of an enhanced wafer testing/sorting capability. The cost to complete this project is within the $1 million ceiling guidance contained in BAA The program schedule has been planned in detail to produce demonstrable results within 11 months after contract award. The proposal is submitted for evaluation in the electronics category benefiting multiple supply chains aviation, land, maritime. Preservation and Manufacturing of Legacy Components This proposed 12 month project, however, addresses the DLA needs for accelerating the surge production of legacy components likely to be required in near term military operations so as not to compromise the readiness from possibly diminishing critical defense industrial base. The main benefit of this development is to bridge the technology generation gap between the relatively older legacy parts and the current efficient design and manufacturing processes. US Based GaN Limiter MMIC Supplier for Naval & Ground Based RADARs Lockheed Martin, teamed with Cree, propose on this IBIF MANTECH program to finalize the high power GaN limiter process development, qualify the process for product release, and complete development on the 100 Watt GaN limiter MMIC for insertion into the EQ-36 and VSR T/R Modules. Lockheed Martin will demonstrate the GaN limiter process in both the VSR and EQ-36 T/R modules verifying performance and perform life tests on the modules verifying reliability. Incremental Sheet Forming for Aging Department of Defense Asset Sustainment Boeing s plan to successfully deploy the technology to the domestic supply chain is designed with four sequential tasks. We will work with the DLA and Depot partners to identify representative geometries from the vertical lift, tactical, and airlift airframe segments will be in the first task. The second is to demonstrate the process on a variety of test geometries, mechanically test the properties of the as-formed test geometries, and compare the resulting data to the MMPDS allowables data in order to prove equivalency. Working with the Depots the third task will be identifying two airframe geometries to demonstrate, produce reverse engineering techniques/data for the selected geometries, produce the

5 selected geometries, and validate the results dimensionally with both scan data and a fit check. Task four will be to develop a transition plan to implement the process and technology at an approved aerospace products supplier. Development and Transition of Optimized Transformation Processes for ATI 500-MIL Auto-Tempered High Hard Steel The proposed collaborative effort will be led by the National Center for Defense Manufacturing and Machining (NCDMM) (Cage Code # 3RXG4) and will also include ATI Defense, a marketsector team of Allegheny Technologies Inc. and Concurrent Technologies Corporation (CTC). This collective team of world class material and manufacturing process experts will conduct extensive manufacturing studies which will lead to comprehensive processing plans and optimized manufacturing standards for the drilling, milling, forming, and welding of ATI 500- MIL auto-tempered high hardness steel. In order to assure transition to the widest possible population of the defense industrial base the project s results will be formalized into a training package that will be designed and delivered by NCDMM s established Training group.