April 2003

Welcome to The CTMA Connector, a monthly newsletter designed to provide news and ideas about the Commercial Technologies for Maintenance Activities (CTMA) program. The CTMA program is a joint Department of Defense/National Center for Manufacturing Sciences (DoD/NCMS) effort promoting collaborative technology development between industry and the DoD maintenance and repair facilities. This newsletter highlights ongoing projects, serves as a forum for promoting new project ideas, and provides other news of interest to the program. Our goal is to stimulate your participation and solicit your input. Feel free to submit items for the newsletter as well as any suggestions to make it more useful. More information about the program can be found at http://ctma.ncms.org/. To subscribe or unsubscribe to the CTMA Connector, send a message to listserv@listserv.ncms.org with "subscribe CTMANewsletter" or "unsubscribe CTMANewsletter" in the subject line.

 Results from the 2003 NCMS/CTMA Working Symposium on Sustainment.

The New Project Ideas below resulted from the workshop discussions at the 2003 Symposium held April 1,2 in Salt Lake City.  If you are interested in collaboration in any of these projects, please contact the NCMS staff indicated for each track.  The project ideas are presented in two forms.  The more detailed ideas under each track list interested participants from the Symposium.  At the end of each track is a listing of other project ideas that were identified in the workshop, but seen as lower priority by the Symposium participants. The first action is to cull down the project list to those of highest priority and participation.  The DoD/Industry teams for each project will then work together to define the effort for possible submission to the CTMA program.  For any general questions, please contact Chuck Ryan, chuckr@ncms.org, 734-995-4905.

I. New Project Ideas: Metals NCMS Contact: Steve Hale, steveh@ncms.org, 734-995-2195

  1. Laser Repair In-Situ Plating Alternatives and In-Situ Quality Monitoring

Interested Participants:  H&R Technologies, NUWC Keyport, Penn State (ARL), POM, Boeing (Titanium Alloys), Toolmen/SMU, Barstow MC3, Albany MC3

  1. Sheet Metal Fabrication PMO – Rapid Manufacturing Repairs, Prototype

Interested Participants:  Industrial Origami, Anniston Army Depot, Sikorsky, Caterpillar, Boeing, H&R Technologies, Solidworks, Metalsoft, U of M, NASA, OC-ALC, Pearl Harbor NSY, China Lake NAVAIR, Cherry Point NADEP, Barstow MC3 and Albany MC3

  1. Serialized Tracking (follow-on to Parts ID) including Avionics and Electronics (Predictive Analysis Tools is a step beyond)

Interested Participants: AES Total Quality Systems, Telesis, Boeing, Cherry Point NADEP, USMC, OC-ALC, Puget Sound NSY

  1. Coating Removal and Surface Prep

Interested Participants: Boeing, Penn State (ARL), Lasertronics, Sikorsky, Lockheed Martin, Pearl Harbor NSY, USMC, Anniston Army Depot

  1. 3D Technical Data (STEP) (Reverse Engineering)

Interested Participants: Anniston Army Depot, Cincinnati Machine, Boeing, Maxim-IT, Sikorsky, U of M, USMC, OC-ALC

  1. FSW – Friction Stir Welding

Interested Participants: Cincinnati Machine, Boeing, USMC

  1. Trivalent Chrome Replacement for Hexavalent Chrome

Interested Participants: Sikorsky, Boeing, Faraday Technology, Cherry Point NADEP, OC-ALC, USMC

  1. Residual Stress Management in Machined Parts (NCMS contact: Tony Haynes)

Interested Participants: Sikorsky, Boeing, Cincinnati Machine, Warner-Robins ALC, Oklahoma City ALC, Cherry Point NADEP

Additional Project Ideas (track 1 - metals):

  1. NDE Techniques/Skills                                                     

  2. Maintenance Mentoring                                                    

  3. Corrosion Issues/Methods Matrix of Solutions                  

  4. Halon Replacement                                                           

  5. Welding Fume Evacuation                                                 

  6. High Speed Machining Centers                                         

  7. In-situ Laser Repair Capability                                          

  8. NDI Internal Weld Spatter                                                

  9. Low Temperature/Multi-Color Powder Coating                  

  10. Robotic Painting

  11. Automated IC Engine Piston Carbon Removal                  

  12. Laser Shot Peening                                                           

  13. Air Frames – Doors/Floor Panel Fabrication                     

  14. Serialized Tracking and Predictive Analysis Tools              

  15. Modeling/Simulation Fatigue Cracking                               

  16. Corrosion Modeling                                                          

  17. NDE                                                                                                                             

  18. Coating Removal                                                              

  19. Coatings/Primerless Topcoats

  20. Cadmium Replacement                                                  

  21. Turbine Blade Coatings (Russian Proprietary Coatings)     

  22. Elimination of VOC’s in Coatings                                      

  23. Biodegradable A/C Deicing Materials                               

  24. Leaky Fuel Tanks – Sealants

II. New Project Ideas: Composites and Lightweight Structures NCMS Contacts: Connie Philips, conniep@ncms.org, 734-995-7051, Manish Mehta, manishm@ncms.org, 734-995-4938

  1. Sealants/Coating (Parts:  Bladder/fuel tank/access panels)

  • Leak Detection

    • Helium

    • Photo acoustics/UT

    • Gas imaging

  • Rejuvenation

    • Chemical catalyst/activator

    • Laser

  • Removal/Restoration

    • Laser

    • Waterjet/Drop blast

    • Chemical

Interested Participants:  Boeing, OC-ALC, WR-ALC, Elixair, Helitech, Lasertronics, OO-ALC

  1. Thick Composite Structural Repair (>2 inches thick)

(Future combat systems and DDX—future naval combatants) 

  • Multiple Functionality Structural Composites

  • Multiple Bond Lines

  • Real Time Cure Knowledge

  • Innovative Processes/Tooling (VARTM/liquid molding)

  • Preform Processing/Handling

Interested Participants:  United Defense, General Dynamics Land Systems, Boeing (FCS System Integrator with SAIC), Northrop/Grumman, Bath Iron Works, Army/Navy Mantech, AvPro, Siemans Composites, Anniston Army Depot, University of Delaware- Center for Composite Materials (CCM), SCRA – Navy Mantech

  1. Overhaul and Repair Using Composites

  • Material Substitution

  • Low Temperature Cure

  • Low Cost Tooling

  • Real Time Process Control

  •  Integrate NDE Technologies into Process Controls

  • Repair Design Analysis (process)

  • Inspection (NDI)

  • Modification Process

  • Paint Removal

  • Certification

Interested Participants: Advance Processing Technology, Boeing, Sikorsky, Lastertronics, Cherry Point NADEP, OO-ALC, CCAD, GE Engines

Additional Project Ideas (track 2 - Composites and Lightweight Structures):

  1. Weight Reduction (Recapitalization)

  2. Composite Armor and Aircraft Repair Tech. (e.g., FCS, Boeing and Aircraft Repair) - Multiple Bond Line Repair

  3. Non Destructive Evaluation and Inspection Criteria

  4. Composite Degradation: New Processes and Materials studies to Repair

  5. Joining of Composites (Similar and Dissimilar)

  6. Parts Tracking for Composites

  7. Low Observables (LO) Capabilities at Depots

  8. Repair, Paint, Test/Verify

  9. Predictive Analysis and Maintenance Capabilities

  10. Repair Methods for Joint Strike Fighter (Unique Issues)

  11. Cosmetic/Touch-up Training in Composites Technology/Kits

  12. Composite Superstructures

  13. Fire Retardant Technology

  14. Corrosion and Substitution Materials

  15. Lower Temperature Cure Film Adhesives

  16. Real Time Composite Cure Monitoring

  17. Reconfigurable Tooling (e.g. 2Phase project) and RM/RT

  18. Effort and Handling Reduction via Automation in Depots

III. New Project Ideas: Electronics  NCMS Contact: Lee Patch, leep@ncms.org, 734-995-4972 

  1. Automated Test Equipment Software Analysis and Test Program Set Translation Tool

  • Minimize recurring cost when migrating test program set (TPS) to new automated test equipment (ATE) platform(s)

  • Develop automated methods for extracting test requirements from legacy ATE/TPS

  • Develop “Middleware” to generate new TPS on modern system(s)

  • Enable data collection for trend analysis and Knowledge Base

Interested Participants: WR-ALC, OO-ALC, OC-ALC, Tobyhanna Army Depot, NUWC Keyport, Teradyne, Honeywell, Agilent

  1. Synthetic Instrumentation Insertion for Automated Test Equipment (ATE)

  • Address Instrumentation Obsolescence

  • Develop multi-use, software-configurable, test instrument technology

  • Provide a path for common test platform

  • Include Boundary Scan capability

  • Minimize upgrade costs

Interested Participants: Warner Robins ALC, Oklahoma City ALC, Ogden ALC, Tobyhanna Army Depot, NUWC Keyport, Teradyne, Honeywell, Agilent

Additional Project Ideas (track 3 - Electronics):

  1. Automated conformal coating removal

  2. Predictive Maintenance Tools

  3. SIM modeling for T&E

  4. Automated contact cleaning (pin & finger)

  5. Infra Red (IR) imaging of phased array antenna emissions

  6. Wireless monitoring of harness/cable status on shipyard cranes

IV. New Project Ideas: Advanced Manufacturing and Best Business Practices  NCMS Contacts: Mike Gnam, mikeg@ncms.org, 734-995-4971, Tony Haynes, tonyh@ncms.org, 734-995-4930 

  1. Serialized Tracking Systems

Interested Participants: Oklahoma Air Logistics Center

  1. Remote Inspection of Confined Spaces

Interested Participants: PSNS, PHNSY, PNS, NNS, Penn State ARL, Ford, GM, Ethereal, Ogden ALC, AES  Total Quality Systems

  1. Predictive Analysis

Interested Participants: OC-ALC, OO-ALC, NUWC Keyport, RLW, Cincinnati Machine

  1.  Obsolescence Tracking

Interested Participants: NUWC Keyport, DLA, OC-ALC, OO-ALC, NSWC Crane

  1.  Non-skid coatings

Interested Participants: Penn State (ARL),Puget Sound NSY, Norfolk NSY, H&R Technologies, POM

  1.  Reverse Engineering

Interested Participants: Boeing, NUWC Keyport, USMC

  1.  Rapid Manufacturing & Repair

Interested Participants: NUWC Keyport, USMC, PHNSY, PSNS, Extrude Hone, POM

  1.  Automated Test Equipment (self-diagnosis, mobile, and reconfigurable)

Interested Participants: Ogden ALC, NUWC Keyport, TYAD, Teradyne, Honeywell

  1.  High Performance Motion Control Devices

Interested Participants: IQL, Warner Robins ALC, Caterpillar, Boeing, Honeywell, Cincinnati Machine 

Additional Project Ideas (track 4 - Advanced Manufacturing):

  1. HAZMAT Reduction

  2. Fuel System Prob reduction

  3. Performance-based Acquisition

  4. Parts Tracking

  5. Predictive Analysis Tools

  6. Flow Day Reductions

  7. Roadmapping

  8. Coatings

  9. Fuel Cells

  10. Maintenance Mentoring Systems

  11. Process Flow modeling

  12. Configuration Management

  13. Knowledge Management

  14. Transition to Lean

  15. Microchip Tracking

  16. Loft foil to CAD conversion

We appreciate your feedback. Please contact Chuck Ryan with suggestions or input on other topics that would be of interest to you in this newsletter. The CTMA Program is sponsored by the Department of Defense; the content of this newsletter does not necessarily reflect the position or policy of the government; no official endorsement should be inferred.


Copyright 2003
National Center for Manufacturing Sciences