V Composite Manufacturing Technology Center 3f6t6t

t Technology Exchange Group CMTC Brief November 05, 2003 Gary W. Schuerfeld Chairman, The Composites Consortium

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• 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

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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

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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 ing 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 - CMTC: Director, Special Programs - CMTC: Chairman, The Composites Consortium - ARDI: Coordinator - ARDI: istrative 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 are able to perform on a wide range of Government projects across all service branches.

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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

[email protected]

(703) 754-5371

[email protected]

(978) 388-2993

[email protected]

(817) 280-3435

[email protected]

(314) 232-4770

[email protected]

(864) 656-3200

[email protected]

(803) 822-8493

[email protected]

(860) 433-7300

[email protected]

(562) 906-7356

[email protected]

(817) 935-1761

[email protected]

(662) 325-2270

[email protected]

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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

[email protected]

(310) 331-3753

[email protected]

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

[email protected]

(814) 863-4351

[email protected]

(520) 794-1018

[email protected]

(800) 469-7224

[email protected]

(203) 386-4351

[email protected]

(858) 455-1650

[email protected]

(508) 393-7868

[email protected]

(410) 263-1348

[email protected]

(304) 547-5800

[email protected]

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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

[email protected]

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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: – who are primarily aerospace contractors, – who are primarily shipbuilding or ocean structures contractors, – who are research universities/institutes/laboratories, and – who are primarily supplier contractors or technology suppliers. • ESC 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 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

[email protected]

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

(817) 280-2107

[email protected]. com

4101 Washington Avenue B905/7 Newport News, VA 23607

(757) 688-1762

[email protected]

George Rodgers

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

(310) 331-7101

[email protected]

Northrop Grumman Ship Systems

William Solitario

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

(831) 656-2546

[email protected]

SPARTA Composites, Inc.

Joel Zuieback

10540 Heater Court San Diego, CA 92121

(858) 455-1650

[email protected]

(304) 547-5800

[email protected]

(803) 325-2865

[email protected]

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

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 Status • The Composites Consortium – 25 Current • • • • •

Research Universities Weapons Platform Primes Specialty Fabricators University d Research Centers (UARC) Training & Education Organizations

– s 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 • 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

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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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CMTC Website http://cmtc.scra.org

TCC Info Page

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Composites Manufacturing Technology Center Ongoing Projects

Distribution Statement D: Distribution authorized to U.S. DOD and U.S. DOD Contractors only, for istrative 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 istration 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 – 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 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.

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

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.

Gantry Trolley

Aerial View of Acoustic Test Facility

Old Barge 26’x38’

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.

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.

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 ed 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 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 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 s – 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 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 ing technology meeting requirements of the USS Zumwalt Class Land Attack Destroyer

LARGE MARINE COMPOSITES-TO-STEEL TS PROJECT TEAM • SCRA CMTC – Boeing Company – ARL Penn State • NJC Bolted t Used in Composite Topside Demonstration Program

DD21 Bonded t Concept

– Bath Iron Works – Northrop Grumman Ship Systems

LARGE MARINE COMPOSITES-toSTEEL TS • The composite deckhouse is a key component in the DD(X) design and requires a composite to steel connection. • Current composite-to-steel ts are accomplished by mechanical fasteners. This attachment scheme has inherent performance and cost deficiencies. • Bonded t 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 t 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 TS • Phase I: Assessment and Review of Composite-to-Steel Adhesive ts (Complete) • Phase II: t Development (Complete) • Phase III: ing 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 t 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 t

Tool Machine or grind surface to mate steel t 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 s 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 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 – t 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 – ing • 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 Roap

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 Roap 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.

Information: Gary W. Schuerfeld Composites Manufacturing Technology Center 934D Old Clemson Highway Seneca, SC 29672 (864) 653-7590 x20 [email protected]

http://cmtc.scra.org

Questions… Discussion…