Unclassified Quality Metal Additive Manufacturing (QUALITY MADE) EPE FY17-03 Proposed Pillar: Enterprise Platform Enablers (EPE) Primary POM-17 Gap: FY17-35: Naval Platform and Systems Operational Availability Secondary POM-17 Gap: FY17-34: Naval Platform and Systems Total Ownership Cost Billy Short – Code 30 _____________________ EC Manager ONR Code Distribution Statement D: Distribution authorized to the Department of Defense and Destruction Notice – For unclassified, limited documents, U.S. DoD contractors only; critical technology; December 2014. Other requests for this destroy by any method that will prevent disclosure of contents document shall be referred to the Office of Naval Research, 875 N. Randolph Street, or reconstruction of the document. Arlington, VA 22203-1995. Unclassified
UNCLASSIFIED Operational Problem Problem Description: Gap FY17-35 - Naval Platform and Systems Operational Availability: Decreased platform availability due to an increasing number of part challenges that PMs are facing. ① Challenges include very long Mean Logistics Delay Time for limited production parts. ② Lack of commercial interest in low volume complex fabrication work and significant delays in contracting and workflow. ③ Increasing pressure on organic manufacturing capability. As an example, Fleet Readiness Centers (FRCs) produce over 120,000 manufactured items per year . ④ Secondary Gap - FY17-34 - Naval Platform and Systems Total Ownership Cost: High cost for limited production runs to make problem parts; many of those are cast components. This may also include large investments to create special tooling and complex castings. • Common Issues Across all Platforms: • Ageing fleets with severe parts supply issues. Examples: Amphibious Assault Vehicle will be 51 years old at the end of service life & aircraft will have 14,000 hours & designed for 6,000 . • Higher failure rates; new failure modes; exigent parts demand for critical components • Systems down/deadlined for part obsolescence issues; decreasing vendor supply base • Increase in components that fail that were never expected to be repaired or replaced Stakeholders/Mission: Depots and FRCs are increasingly making parts to combat these challenges. FRC/Depots mission includes producing parts to improve maintenance efficiency. They need new technologies to enable the reliable and cost-effective production of low volume parts. Priority Documentation: • VADM Cullom’s interest in AM as a Navy Innovation and Disruptive Technology • Naval Additive Manufacturing Technology Interchange Recommendations report • NAVAIR AM IPT and NAVAIR AM Roadmap as key AM technology enabler • Key flag-level program endorsements 2 UNCLASSIFIED
Unclassified (U) EPE-FY17-03: Quality Metal Additive Manufacturing (QUALITY MADE) OPERATIONAL NEED (U) Objective: Ability to enable reliable and cost-effective production of additively manufactured metallic parts at Naval maintenance depots to significantly increase operational availability of applicable Naval systems and to reduce sustainment costs/delays by manufacturing “on demand.” (U) Value to Naval Warfighter: • Improve air, ground and sea platform operational availability by reducing supply chain delays; lower maintenance cost. ( ) Naval Input Source and Stoplight (U) Primary Gap # & Title: FY17-35: Naval Platform and Systems Operational Availability (U) Impact if Not Addressed: • Decreased Naval system operational availability • High system total lifecycle costs to manufacture limited BUSINESS CASE production parts that are currently cast. (U) Key Metrics: PROPOSED SOLUTION • Increase Platform Availability by reducing part acquisition (U) The Technology: time (Mean Logistics Delay Time) by 50% (T), 80% (O) for • Integrated Computational Materials Engineering (ICME) low volume parts that are currently cast. Design w/ Closed Loop Process Control (U) Proposed Funding ($K): (U) Similar/Related Projects: FY17 FY18 FY19 FY20 Total • ONR SBIRs, Direct Digital Manufacturing & Advanced ICME 5,275 8,680 9,125 7,632 30,712 • DARPA’s Open Manufacturing Program (U) Program of Record: COM FRC/NSWC (S&T Products); AAV, UH-1Y, H-53K, LPD-17 (Parts Demo) (U) TRL: Current (FY15): 4, Projected at End (FY20) 6 (U) Acquisition Sponsor: Mr. Balazs (NAVAIR/Logistics and (U) Major Goals/Schedule by Fiscal year: Industrial Ops), Mr. Perryman (PEO-A), Mr. Taylor (PEO-LS), • Process Controls by 2Q FY18 Mr. Droz (PMS 317) • ICME Model by 3Q-FY19 (U) Resource Sponsor: Mr. Hull/DC CD&I; N98; N4 • S&T Product Transitions to COM FRC/NSWC, Demo Parts (U) Fleet/Force Advocate: CAPT Futcher/N41 , Mr. Truba/I&L Transition to PEO-A, PEO-LS, PMS-317 in 4Q-FY20 . (U) ONR Contact: Mr. Billy Short / ONR 30 / 703.696.0842 / Unclassified 3 billy.short@navy.mil
UNCLASSIFIED EC Relationship to Other S&T Investments DARPA Open Manufacturing • Transition’s DARPA’s Boeing’s tiFAB (titanium additive manufacturing) • Leverage Penn State ARL’s Additive Manufacturing Demonstration Facility (also ONR performer) • Developing engineering models & design tools for titanium • Relating key mechanical properties to processing parameters and chemical/metallurgical variables to the product Program completes at end of FY16; TRL-5 for Ti process Builds from ONR Programs Advancing AM S&T • • Multiple discovery & invention programs M&S tools for digital design and manufacture for AM • Small Business Innovation Research • Closed-loop feedback control • Technique for rapid qualification Need an integrated program to TRL-6 for titanium, aluminum and steel Willing to work with other countries that will open up their AM system architecture to allow integration of closed loop quality controls. 4 UNCLASSIFIED
Products in the EC Unclassified Develop M&S and quality control tools & processes for 2 alloys (Ti-6Al-4V and Al-Mg-Si) using 2 metal AM processes (T), 3 alloys to include the addition of steel (O) M&S Tools: Integrated Closed Loop Computational Materials Process Controls Engineering (ICME) approach Transition Part Design Using ICME Start: TRL 4 Start: TRL 4 Models to NSWC/NAVAIR/Industry End: TRL 6 End: TRL 6 ONR 33 ONR 35 Transition Process / Control Suite to FRCs/Depots/Industry - Defects (T) match that of castings and (O) 25% - Microstructure-Property Prediction - Closed loop control process improvement capability: 2 σ for tensile properties with Capability as a function of process and or 𝑄 ≥ 95% ; (O) 3 σ or 𝑄 ≥ 99.7% - Mechanical properties: (T) match that of castings geometry: +/- 10% (T) and +/- 5% (O) and (O) meet or exceed AMS - Uniformity of Microstructure (by % - Fatigue Properties: (T) match that of castings volume): 90% (T) and 95% (O) and (O) match wrought Gap Level Metrics: (1) reducing part acquisition time from 8-28 months for low-volume production by 50% (T)* & (2) reduce time/cost to design and optimize AM replacements for cast components by 30% (T). 5 Unclassified
EPE-FY17-03 Unclassified Integrated Computational Materials Engineering (ICME) Design w/ Closed Loop Process Control Product Description: Modeling & simulation tools to rapidly design, optimize & build AM metallic parts. Process control tools to support AM process fabrication & qualification. M&S tools and process quality control sensors developed, installed & demonstrated at Naval centers/depots via fabrication of metallic parts. TRL at Start: 4/5 TRL at Transition: 6 Planned Demos/Transition Warfighting Payoff: Enhancing the • Acquisition POR/Contact: COM FRC, AAV, quality and reliability of metal Additive UH-1Y, H-53K, LPD-17; Mr. Balazs Manufacturing will: (1) increase (NAVAIR/Logistics and Industrial Operations), operational availability of Naval systems Mr. Taylor (PEO-LS); Mr. Perryman (PEO-A); and (2) decrease sustainment costs by Mr. Droz, PMS-317 adopting AM processes for critical parts • Resource Contact: Mr. Hull (CD&I); N98, N4 that require low volume production runs • Key Demonstrations (Qtr/Yr): Controls: 2Q- and where maintenance and cost FY18; Models 3Q-FY19; Parts 4Q-FY20 efficiencies are achieved. • Final Transition (Yr): 4Q-FY20 FY17 FY18 FY19 FY20 . Product Funding ($K) 5,275 8,680 9,125 7,632 Demos - Transition - Distribution Statement D: Distribution authorized to the Department of Destruction Notice – For unclassified, limited documents, Defense and U.S. DoD contractors only; critical technology; 1 Dec 2014. Other destroy by any method that will prevent disclosure of contents requests for this document shall be referred to the Office of Naval Research, or reconstruction of the document. 6 875 N. Randolph Street, Arlington, VA 22203-1995. Unclassified
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