1. Portable Water Filtration System (Randy Baisden, PSNS)
   1. Contaminants cannot be directly disposed to water system. 
   2. Hydro blasting (closed/open) cycle. Copper content is a problem.
   3. Washing the exterior hull, tanks (MBTs), heat exchangers, dry-dock floors are problem areas.
2. Containments (Bob Vozzela, PNS)
   1. Current containments are single use, with a lot of pre-build, tear down time averaging 30,000 man-hours per structure.  Containments could be made from air structures, rather than current structural members and  (staging) shrink wrap.
3. Mold-In-Place (MIP) SHT (Alan Orr, PSNS)
   1. There is no procedure for removing Mold-In-Place (MIP), from composites other than with hand tools.
   2. Development of a procedure is necessary, using methods such as the 3M Smart tool.
4. MIP/SHT Removal from Hull (Maxie McCowan, PSNS)
   1. Costly and difficult to precisely remove MIP.  Possible solutions may be water jet blasting with abrasive, laser coating removal, or cryogenic freezing.
5. Damping Tile Removal (Maxie McCowan, PSNS and Max Shinkawa, PHNSY)
   1. Breaking adhesive bonds is difficult, and can cause damage to hull, which then require welding repair.  Chipping guns can also cause ergonomic injury.
   2. Induction heating is a possible solution.
6. MIP/SHT Replacement Tile Installation (Adhesion) (Alan Orr, PSNS)
   1. Expensive environmental controls are required to successfully apply tiles.  The current 21-day flow-time (blast, paint, QA) is too long.
   2. What is needed is a faster setting adhesive which is not sensitive to temperature and humidity levels.
7. Develop Sampling and Inspection Software System (Dan Craig, PSNS)
   1. The existing database is going away (MS Access), and data cannot be shared between the shipyards.  So sampling inspection can be done multiple times.
   2. The project would develop an automated sampling and inspection system that can be used and shared by all the shipyards.
8. Paint Hose Temperature Control (Randy Baisden, PSNS)
   1. Electrically heated hose is not currently safe, and must meet NFPA Class 1, Division 1 (explosion proof), and 8,000 psi requirements.
   2. Design paint hose that maintains temperature tolerances for correctly maintaining paint viscosity.
9. Non-Skid removal on MIP/SHT (Randy Baisden, PSNS)
   1. Procedures need to be developed to remove non-skid without damaging MIP/SHT.  No solutions currently exist.
10. Portable Laser Crawler to Remove Coatings (Randy Baisden, PSNS)
    1. Expensive to dispose of processed waste and hazardous materials.
    2. Develop a portable laser crawler system to remove coatings.
11. Replace Radiographic Weld Inspection for Volumetric Inspection of Shipboard Piping (Rob Gorman, PSNS)
    1. TP-278 requires RT as the only method for volumetric inspection of critical piping, pressure vessel and machinery welds.  RT is too cumbersome and expensive shipboard, as outlined by Rob Gorman’s presentation.   Problems are crew size, disruption of other work (impact on schedule), speed of inspection and radiological safety.  
    2. Currently 5 up to 30 man days required for a single weld joint inspection (not including interpretation).
    3. Implement Phased Array (PA) ultrasonic inspection of welds.  The solution needs to be applicable to shipboard piping sizes and material.
12. Submarine Battery Layout and Placement (Mark Kougl, PSNS)
    1. Current template-based layout and placement methods for hold down rails are subject to excessive tolerance mismatch and accumulation, variation in as-built configuration of battery compartments, and excessive time.  Layout and placement of studs have similar issues. Welding of rails introduces distortion.
    2. A possible solution for development is a new process using laser-based 3D metrology of as-built space; CAD modeling; optical layout aids; and real-time laser based aid to maintain dimensional tolerances during  welding.
13. Cleaner Ripout (Mark Kougl, PSNS)
    1. Current techniques require excessive handwork and high likelihood of damage to structure requiring rework.
    2. The project would develop cleaner methods of cutting steel in tight configurations and subject to temperature and environmental constraints.
14. Low Heat Input Welding Techniques (Mark Kougl, PSNS)
    1. Current welding techniques induce distortions in parts and cause potential excessive heat input resulting in unacceptable effects on coatings and adjacent lead bins, with excessive process time required to stay within limits. Problem will become more severe in future scheduled refits with thinner steel material.
    2. The project would investigate alternative welding technologies for performance and adaptability to battery room conditions.
15. Remote Monitoring of Equipment and Processes (Dana Ellis, Epsilon System Solutions, Inc.)
    1. Currently there are no low cost means to monitor remote equipment – HPAC’s etc.
    2. The project would develop secure wireless and software that monitors and analyzes operational parameters of various equipment, i.e., lube oil pressure, bearing temperature, discharge pressure, etc.  Once a low or high condition is met, output is linked to a repair recommendation or condition-based maintenance.
16. Material Management Container Location & Movement Tracking (Don Adams, I.D. Systems, Inc.)
    1. It is difficult tracking containers moved by vehicles.
    2. The project would build off the current CTMA project, CFAMS, to integrate and record RFID tag and reader to confirm what has been moved when, where and by whom.
17. Point Cloud to CAD File Translation Tool (Kyle Morris, NUWC Keyport)
    1. The current data translation process is very labor intensive.
    2. The project would reduce reverse engineering lead time and associated cost by developing a software system.
18. Machined Parts/Knowledge Management (Tom McClure TechSoLVE, Allen Carrier PSNS)
    1. Lead time for critical spares is unacceptable, and there are limited sources of suppliers able to provide short runs/prototyping.
    2. Lack of corporate wide knowledge of existing DoD or Vendor suppliers.

    3. The project would develop:

                                                              i.      Improved SW tools to reduce NC programming,

                                                             ii.      Establish a DoD/Vendor knowledge management tool,

                                                           iii.      Supplier Capabilities Database (DoD/Vendor)

19. Condition Monitoring of Temporary Services Assets (Peter Sisa, RLW, Inc.)

    1. Currently reactive response – run to failure maintenance of high value equipment for temperature services.

    2. The project would demonstrate/implement condition monitoring capability for Shop 99 selected key assets.  This capability should integrate with eFem and trigger standard work orders and parts ordering.

20. Maintenance and Repair Associated Funding Strategy Plan (Paula Kramer, Tooele Army Depot)

    1. Funding for maintenance and repair is a problem.

                                                              i.      No-one in maintenance writes SBIR topics for maintenance issues.

                                                             ii.      No SPONSORSHIP (no 6.x or 7.x series)

                                                           iii.      Looking at a budget series number “Maintenance” is What is the DoD funding pot?

                                                          iv.      Lack of Contracts vehicle. 

2. The project would develop a technology trajectory for maintenance and repair generic topics.

                                                              i.      “Top 5” drives coordination between 04X’s of DoD, R&D and Funding Decision Makers.

                                                             ii.      Contract Vehicles put in place.

21. Central Repository for PLM i.e. CAD drawings etc. (Kyle Morris, NUWC Keyport)
    1. CAD data is managed locally within different DoD facilities.
    2. The project would develop a secure, digital, on-line system, a “JDMICS on steroids”

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New Project Approval:  Inspection and Repair Preparation Cell (IRPC)

DoD Participants: Warner Robins Air Logistics Center (ALC), Oklahoma City ALC, Ogden ALC, Norfolk Naval Shipyard - Philadelphia Detachment

Polymeric composite materials are seeing increasing usage in weapon systems due to their superior weight/performance advantages and resistance to corrosion.  However, repair equipment and processes for composite materials are only now being developed to address the increasing workload coming into the DoD maintenance and repair facilities.  This project is focusing upon C-130 Radomes, F-15 Radomes and F-15 Speed Brakes, which are large complex structures, with a high volume repair rates. The current Radome, and other composite component, inspection and repair processes are performed manually by artisans.  This project is developing technology to replace these manual methods with automated systems.  The first phase of this program will be devoted to qualifying individual processes on a stand alone basis, but performing the function of each technology using the targeted components to qualify the technologies.  Upon success, a phase will be utilized for performing the functions required, employing the individual processes in the machine tool/work environment and constraints.  These technologies will also be applicable to the other services repairing composites parts.  However, the current focus of this project will be on Air Force Radomes where the benefits can be quickly realized.

The NCMS Contact is Bill Waddell, Wwadd49648@aol.com, 231-264-9774.