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April 2004
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 2004 CTMA
Working Symposium on Sustainment, held in Atlanta, March 29, 30
Thirty-two new project ideas resulted from the annual
Symposium which are summarized below. All of these projects are being
considered for funding in 2005. Project criteria includes:
-
What new manufacturing technologies will be developed to
meet the needs of industry and the Department of Defense (DoD) maintenance
facilities?
-
Is there cross-service involvement in the effort?
-
Do we exceed the 2:1 cost-share requirements from the
industrial participants?
What do you need to do?
Look through the project listing for those in which you are
interested in being a participant. Contact the NCMS track leader via e-mail
to indicate you want to be included on the project team and to help define
the project. We require both strong industrial collaboration and
active participation from DoD facilities on all projects.
Then what?
NCMS staff, working with the Office of the Secretary of
Defense, will start to cull down the project list based on fit to the CTMA
program criteria. We will pursue as many projects as future funding
will allow. We will have an indication of future funding later this year.
Notes and Caveats
1. Typically, the CTMA program has ample funding at
this time of the year to start to pursue project ideas coming out of the
Symposium. However, FY'04 funds were less than usual and are being
used for project ideas submitted over the previous year. Therefore,
projects resulting from this Symposium will not be funded until FY'05 funds
are received (in the April timeframe). We don't like to move this
slowly, but must do so under these circumstances.
2. Non-DoD participants in CTMA projects must be NCMS
members. NCMS member companies receive preference over non-member
companies in projects. Non-members can participate in defining the
project with the understanding they will become members. Go to the NCMS homepage,
www.ncms.org for more information.
Track 1: Metals (NCMS Contact – Tony Haynes,
tonyh@ncms.org, 734-995-4930)
1.
Project:
Smart Machines
Problem:
Machine
health status and process data is difficult to collect, especially from
legacy machines. Data if collected could be used to improve processes
and maintenance operations.
Solution:
Install
Freedom e-Log system to capture and process data. Evaluate data mining
techniques
DoD Participants:
Red
River Army Depot, Cherry Point NAVAIR
Industry
Participants:
Cincinnati Lamb, Caterpillar, NIST, IMS Center, Parker
Hannifin
2.
Project:
Laser Stripping of Coatings
a.
Example:
Laser paint stripping
Problem:
Current
paint removal processes (chemicals, particle sprays, etc.) are labor
intensive and not environmentally friendly.
Solution: Investigate
laser removal processes (followon to current project?)
DoD Participants:
Multi-service potential
Industry
Participants:
Power Laser
b.
Example:
Laser removal of thermal barrier
Problem:
Surface
coatings (paint) are often applied over a thermal barrier. Removal of
that barrier is difficult.
Solution:
Create
laser removal system
DoD Participants:
Multi-service potential
Industry
Participants:
General Lasertronics, others
c.
Example:
Removal of surface
coatings in confined spaces such as sealant removal from A-10 wing tank.
Problem:
Current
methods are labor intensive and difficult to the confined space.
Solution:
Create
laser removal system with fiber optic delivery system for use in
confined spaces
DoD Participants:
Multi-service potential: Ogden ALC expressed interest
Industry
Participants:
General Lasertronics, Lockheed Martin
3.
Project:
Digitized overhaul
Problem:
Replacement
or overhaul of shipboard systems often requires labor intensive
measurement and mapping of available space.
Solution:
Use 3D
scanning technology to construct surface map of existing structures
prior to replacement.
DoD Participants:
Navy: All shipyards
Industry
Participants:
possible extension of existing Opticam project?
4.
Project:
Acoustic Tile & Adhesive Removal
Problem:
Acoustic
tiles and adhesive residue difficult and costly to remove. Much hand
work.
Solution:
Handheld or
local mount laser
DoD Participants:
Navy:
- Dean Bensley –
Gary Mock, PHNSY
- Portsmouth,
Norfolk, Puget Sound possible
Industry
Participants:
Electric Boat? Power Laser?
5.
Project:
Plastics removal from items such as valve handwheels.
Problem:
Current
method (use of knife) is labor intensive and a safety hazard.
Solution:
Soak? Bake?
Peel off? Freeze?
DoD Participants:
All
four Naval shipyards plus private shipyards:
Gary Mock (808)
473-8000 x2643
Industry
Participants:
TBD
6.
Project:
Parts marking
a.
Example:Thermal
spray powders & wire for data symbol generation
Problem:
Current readers are expensive and require custom data collection s/w
Solution:
Study and
develop various metal combinations to create markings with high contrast
and durability.
DoD Participants:
Tri-Service - TBD
Industry Participants:
Jay Cantwell – Waterjet Technology - (314) 428-6900,
Schlumberger, Weatherford, Lufkin Ind., Grant Prideco
b.
Example:
Centralized 2D Dot Matrix Decode Platform
Problem:
Current readers are expensive and require custom data collection s/w
Solution:
Develop a
server based decode platform using digital cameras
DoD Participants:
Tri-Service - TBD
Industry Participants:
Jay Cantwell – Waterjet Technology - (314) 428-6900, Caterpillar,
Quality Electric Casting, Weatherford, Lufkin Ind., Grant Prideco
c.
Example:
Point-of-Cast 2D Dot Matrix Part Marking
Problem:
High value and safety critical parts need permanent markings to provide
lifecycle traceability.
Solution:
Cast the
barcode into the part at the point of manufacture
DoD Participants:
Tri-Service - TBD
Industry Participants:
Jay Cantwell – Waterjet Technology - (314) 428-6900, Caterpillar, Lufkin
Ind., Griffen Wheel, American Steel, Howmet, Quality Electric
d.
Example:
Under Paint Data Symbols
Problem:
Current dot matrix codes require contrast for decoding which typically
degrades over time or is painted over.
Solution:
Data
symbols made of iron loaded polyurethane can be painted over and read
thermally using low cost hand held induction heating and thermal imaging
DoD Participants:
Tri-Service - TBD
Industry Participants:
Jay Cantwell – Waterjet Technology - (314) 428-6900, Ajax Tocco, Boeing,
Lockheed Martin
e.
Example:
Rapid induction fusion of paste or spray applied data symbols
Problem:
Safety
critical parts require permanent data symbols that last the life of the
part.
Solution:
Fused-on
data symbols are permanent. Use of induction heating could provide a
non-invasive fused on data symbol.
DoD Participants:
Tri-Service - TBD
Industry Participants:
Jay Cantwell – Waterjet Technology - (314) 428-6900, Caterpillar, Grant
Prideco, Weatherford, Ajax Tocco, Griffen Wheel, Howmet
7.
Project:
Rapid Castings
a.
Example:
Patternless Sand Casting Manufacturing
Problem:
For depot
sand castings, quantities are usually low and often the original tooling
or patterns aren’t available. Creation of tooling or patterns is usually
the high cost, long-lead item in procuring parts.
Solution:
Develop and
implement a direct art to part process. Go direct from CAD file to 3D
mold/core.
DoD Participants:
All
depots – Keyport has expressed interest.
Industry Participants:
Extrude Hone lead (Dan Maas/Jeff McDaniel (800) 367-1109, other industry
might be Sikorsky, P&W, Raytheon, Honeywell KC, NASA, Caterpillar,
Kodak, …
b.
Example:
Low quantity, high complexity castings are very expensive and often have
long lead times.
Solution:
Work with Prometal Rapid Casting Technology to develop a system for DoD
foundary.
DoD Participants:
Navy, Kyle Morris – NUWC Keyport (360) 396-1939
Industry Participants:
Prometal, auto makers and suppliers
8.
Project:
Cold
spray metal deposition for corrosion protection
Problem:
Control of surface corrosion is a universal and costly problem for
depots and for industry.
Solution:
Investigate cold spray metal deposition processes and materials for
land-based vehicles
DoD Participants:
Multi-service potential
Industry Participants:
Delphi, Ford, Boeing
Ken Johnson (Delphi)
and Bob McCune (Ford) are co-champions
9.
Project:
Expansion of Marine Core armored vehicle project
Problem:
HMMVV, LAV and other land vehicles designed without armor for speed are
vulnerable to post-conflict urban attack.
Solution:
Create conversion kits for point-of-use attachment
DoD Participants:
USMC: Albany/Barstow
Industry Participants:
Auto makers, customizers
10.
Project:
Transient Liquid Phase repair of critical items
Problem:
Foreign object damage and leading edge wear on turbine blades is
difficult to repair.
Solution:
Investigate repair process using the transient liquid phase tip
replacement process developed by Siemens Westinghouse.
DoD Participants:
Red River Army Depot, Cherry Point NAVAIR, OC-ALC
Industry Participants:
Siemens Westinghouse
Track 2: Lightweight Structures and Advanced Testing (NCMS contact – Steve
Hale,
steveh@ncms.org, 734-995-2195)
1.
Project:
Evaluation of uses for UV-Cure pre-preg for use in field repairs.
Problem:
Find a faster, easier less expensive way to conduct hand-lay-up FRP
repairs
Solution:
Improved speed of repairs. Also, allow less-trained personnel to
produce fast, durable repairs.
DoD Participants:
TBD
Industry Participants:
UV Corrosion Control
2.
Project:
Cure State Management of PMC
Problem:
A: Thick laminate – differential cure/exotherm B: Dimensional distortion
C: Controlled atmosphere pressure resin
Solution:
”Smart” cure processing
DoD Participants:
OC-ALC, OD-ALC, CCAD
Industry Participants:
Vought, Boeing, General Atomics, Rockwell, Sikorski, US Army RDECOM
3.
Project:
Acoustic Thermography. Proj. A: Make “on-wing” insitu system. Proj. B:
make “teach-mode” capability to allow rapid testing of different/new
components.
Problem:
A: Current sys. is A: too large to insert in-frame or in-engine for
remote inspection. B: does not have self teach mode to develop new
component technique.
Solution:
A: Miniaturize energizing sys. B: Add hardware/software to system for
self teach capability.
DoD Participants:
Anniston Army Depot
Industry Participants:
Siemat Acoustic & Sikorski Aircraft
4.
Project:
”Grid-Lock” inspection using NDI for metal bonding of internal structures.
Problem:
Grid-Lock design components have replaced a majority of honeycomb-core
components on the F-15. There is currently no field level means to
accomplish reliable NDI on these components.
Solution:
Acoustic Thermography, Shearography, others.
DoD Participants:
WR-ALC
Industry Participants:
Siemens, Wayne State University, BF Goodrich, Boeing, Position Systems,
Inc.
5.
Project:
Maintenance Mentoring Systems (MMS) Combined with Delphi Sensors for
Maintenance on LAV
Problem:
LAV is currently developing on-board sensors for condition based
maintenance.
Solution:
MMS is an electronic technical maintenance manual that could receive
sensor information and provide repair procedures to the maintenance
tech.
DoD Participants:
PM LAV office, US Army Alaska
Industry Participants:
L-3 communications, MMS, Black & Rossi, Delphi, GSI, Siemens
Westinghouse, Positron Systems, Inc.
6.
Project:
Develop low cost portable turbine engine component NDI system that includes
all damage accumulation.
Problem:
No non destructive technology exists. Statistically modeled today at
high retirement cost.
Solution:
Develop portable Newton Induced Position Annihilation (NIPA) unit.
Thickness inspection to 2 inches.
DoD Participants:
Navy, Air Force, Propulsion units => NAVAR, AFRL, ARL
Industry Participants:
Siemens, DOE, Positron Systems.
7.
Project:
Low Cost Composites
Problem:
The cost of composite structures is typically large.
Solution:
Vector Composites rapid fiber pre-form technology delivers lower cost
composites. Additional costs for autoclave capitol and maintenance would
be avoided.
DoD Participants:
TBD
Industry Participants:
Vector Composites & Sikorski Aircraft
8.
Project:
Data Mining
Problem:
Use intelligent agents and data mining to locate problem parts for
re-engineering. Also, if located by serial number, a recurring part may
need to be removed from stock.
Solution:
There is considerable work at the university level and private companies
to consolidate information from large amounts of data, needed for
decision making.
DoD Participants:
TBD
Industry Participants:
TBD
9.
Project:
Manufacturing of Composite NDI Stds.
Problem:
There is no manufacturing composite inspection standards.
Solution:
Develop a standardized manufacturing method to input known part
delaminations.
DoD Participants:
WR-ALC, Ogden ALC
Industry Participants:
Nordan, FAA NDI Validation Center Sandia
Track 3: Electronics (NCMS
contact – Lee Patch,
leep@ncms.org, 734-995-4972)
1.
Project:
DMSMS Shortage Issues
Solution:
Develop reverse Eng. & Mfg of PWA/PWBs Using Field Programmable (FPGA)
Design and Production Capability at AF Depot, to include Modeling and
Qualification Testing
DoD Participants:
John Shawhan, WR-ALC
Industry Participants:
Georgia Tech, Teradyne, and others
2.
Project:
Electrostatic Discharge (ESD) event detection for PWAs
Problem:
Need a method for detecting static events.
Solution:
Use magneto-optical detector to record static events (resettable).
DoD Participants:
Larry Weber, TYAD
Industry Participants:
TBD
3.
Project:
Advanced electronics prognostics, system assessment & diagnostics
capabilities (alternative test capability)
Problem:
Need an ancillary, faster, easier test capability, without engineering
data
Solution:
DoD Participants:
Bruce Long - WPAFB
Industry Participants:
TBD
4.
Project:
On-board wiring fault detection/location/recording devices.
Problem:
In-flight mode faults – non recurring & intermittent fault detection.
Solution:
Continuous monitoring of conductive path.
DoD Participants:
Jerome Collins (301) 342-2187 NAVAIR 4.4.4.3, Andrew Yang (904) 542-2631
x103 NAVAIR JAX
Industry Participants:
Live Wire Test Labs (Utah), Eclypse, DIT-MCO.
Track 4: Advanced
Manufacturing and Environmental Issues (NCMS contact – Connie Philips,
conniep@ncms.org, 734-995-7051)
1. Project:
Laser Cladding (Powder) Process Monitoring Sensor
Problem:
Deployment of laser repair technology is impeded by the lack of
closed-loop process control. Process control is imperative for
consistent and sound repairs. No current COTS.
Solution:
real time, feedback loop, process sensing and control system monitoring
all critical process parameters such as: power variations, travel speed,
filler material flow/speed variations, aim of filler material into melt
pool, melt pool size, shape – thermal properties.
DoD Participants:
NUWC Keyport, PHNSY/PSNS, ANAD, OC-ALC
Industry Participants:
Fraunhofer USA – Center for Coating & Laser Applications, Knust SBO
(Drilling Industry), Optomec, Toolmen, University of Michigan
Champion:
Seandra Williams, NUWC Keyport, 360-396-2855,
williamssl@kpt.nuwc.navy.mil
2. Project Idea:
Reverse
Engineering
Problem:
Once a point cloud from scanning is created it is labor intensive to get
to 3D CAD surface or solid model.
Solution:
Better tools to
automate point cloud to surface/solid model are needed. Circularity
issues are key.
DoD Participants:
NAVSEA/Norfolk Naval Shipyard, PSSY
Industry Participants:
GLM, USG-PLM, SIS, RM&R Team
Champion:
Mitch Vickers, Norfolk
NSY, 757-396-5328,
VickersMA@nnsy.navy.mil
3. Project Idea:
Integration of Diagnostic (CBM) Information with Asset Management,
Inventory, and Workflow Management Systems
Problem:
Real time
(e.g. CBM) and off-line (e.g. I-POMX) diagnostics information can
predict and identify equipment failures; however, disparate information
systems impede responsive maintenance actions.
Solution:
Leverage
industry standards (for CBM and enterprise integration) to define
information exchange standards for asset management, inventory
management, and workflow management systems. Define information
structure and schema. Utilize web services to access information from
on-board (shop floor) and off-line systems.
DoD Participants:
DLA, OC-ALC
Industry Participants:
Rockwell Automation, IMES Inc., SIS, UGS, Cincinnati Lamb, University of
Michigan/IMS
Champion:
Dan Carnahan, Rockwell Automation, 440-646-7321,
dlcarnahan@ra.rockwell.com
4. Project Idea: a)
Aircraft
Laser depainting integrated with Aerial Multiplatform and a vision system
b)
Depaint and Preparation for Combat Vehicles and Artillery (tanks).
Problem:
Eliminate environmental issues from using blast media and the
maintenance of blast equipment. a) Challenge: Robotic depainting/strip
KC-135 in one hour.
Solution:
Automated or Robotic Depainting to eliminate use of blast media.
Waterjet, laser or other methods. Scalable from WRL laser. Must be
economical and environmentally friendly. Funds from P-2.
DoD Participants:
AFRL, WR Labs, OC-ALC/MAB, ANAD
Industry Participants:
SWRI,
University of Michigan, Toolmen, Fraunhofer, AMP, PLM, Airlines?,
Aircraft Companies?, CTA, VSI, SIS
Champions: a)
Lt. Col. Ed
Laverdure, OC-ALC, 405-734-4523,
edward.laverdure@tinker.af.mil; b) Fred Burns, ANAD,
256-235-7716,
fred.burns@us.army.mil
5. Project Idea:
Parts Marking Technology Selection Tool.
Problem:
Depots are facing unclear objectives and hurdles to overcome prior to
successful implementation of parts marking technologies. Hurdles such
as tech evals and material analyses plus documentation changes are the
minor issues, process integration is the real challenge.
Solution:
A software
management tool for parts marking technical analysis and technology
insertion. Clearly defined guidance on:
-
Material analysis
-
Process insertion
and communication
-
Size, location and
construct of the mark
-
Drawing changes,
data storage
-
Changes to
standards, QA and ISO documents
-
Validation and
verification of mark
-
Selection of the
appropriate marking technology CAI, etc. etc.
DoD Participants:
OC-ALC, MC3 Albany
Industry Participants:
Pratt & Whitney
Champion:
Greg
Russell, MC3 Albany (AmDyne), 229-639-8072,
gregory.russell@nmci.usmc.mil
6. Project Idea:
Graphical Probe Programming – On-Machine Probing Implementation
Problem:
For widespread use of, contact probing must be made easier to implement
on the shop floor. This project would have two components:
1.
Implementation of probing commands in a graphical NC programming
environment such as Unigraphics
2.
Implementation of on-machine probing techniques on the shop floor at
various depots on high value applications where operator (human)
interaction with the manufacturing process should be minimized.
Solution:
Implement probing menus and commands into a graphical environment,
graphical tools to do set-up, programming, adjusting and inspection and
probing integration on shop floor with NC. P&W would be willing to
share their vast experience and knowledge of part and tool probing with
the various depots to improve their quality, reduce lead time and reduce
part cost.
DoD Participants:
ANAD, OC-ALC?
Industry Participants:
Pratt & Whitney, GE, Sikorsky, Unigraphics or other CAD/CAM providers,
TDA, Rockwell, BCT Technologies, Cincinnati Lamb
Champion:
Andy
Kilguss, Pratt & Whitney, 860-565-1375,
andrew.kilguss@pw.utc.com
7. Project Idea:
CAD Independent
Characteristic Identification and Extraction to Support First Article
Inspection
Problem:
Inconsistent and manual process is in use today for the identification
and extraction of key characteristics for use in first article
inspection. This process results in escapes and errors in the
inspection and manufacturing process.
Solution:
Develop
method of posting the extraction/identification process to create a CAD
neutral interface. Automated identification of critical characteristic
data and specifications from CATIA CAD data for downstream first article
inspection planning and execution.
DoD Participants:
TBD
Industry Participants:
Sikorsky, BCT Technology
Champion:
Bob Mann,
BCT Technology, 508-292-0906,
bmann@bct-technology.com
8. Project Idea:
Stand Alone Laser Repair Cell (Build-Up)
Problem:
Finishing work after laser rapid prototyping still high. Deposition rate
of laser process is low. Fixturing effort is high. Two machines required
so far.
Solution:
Integrated machine design that combines laser rapid prototyping plus an
arc deposition and milling machine working directly from CAD with the
output being the finished part. Advantages: reduce fixturing time and
effort, reduce finish work. first concepts have been developed by
Fraunhofer; targeted operation - submarine. Unit for on-board use would
have to be sailor proof, scaled down, and able to work from CAD model.
DoD Participants:
NUWC Keyport, C21 Group
Industry Participants:
Fraunhofer, University of Michigan, Toolmen
Champion:
Christian
Walz, Fraunhofer Institute, 734-354-6300 x 231,
cwalz@fraunhofer.org
9. Project Idea:
Suspended Abrasive Waterjet (SAW) Multi-hole Drilling in a One Piece Casting
Problem:
Large numbers of cooling holes are needed in the aerospace industry,
sometimes in confined spaces. to
Solution:
Create, test, and implement a suspended abrasive waterjet system with
various nozzle assemblies enabling one piece castings by providing the
capability to drill non-line of sight holes. Waterjet process allows
superior hole quality (.020 – 0.30” with consistency and multiple holes
(100/time)) through virtually any material.
DoD Participants:
Aerospace depots for high-value added. Any overhaul process where high
volume, high quality holes must be produced,
USMC
Industry Participants:
Pratt & Whitney, General Electric, Sikorsky, Any manufacturer
producing high volumes of small holes, Other aerospace manufacturing
companies, Toolmen
Champion:
Andy Kilguss, Pratt & Whitney, 860-565-1375,
andrew.kilguss@pw.utc.com
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. | 