Materials Directorate Aerospace Materials and Processes ... · Aerospace Materials and Processes Technology Transfer ... - Aerospace Structures Marine Structures Commercial - - Sporting

Materials Directorate Aerospace Materials and Processes

Technology Transfer

r Lawrence N. Hjelm Phone: 51 3-255-9830

E-Mail: [email protected] FAX: 51 3-255-9792

mailto:[email protected]

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Aerospace Materials and Processes Technology Transfer

Metals and Ceramics

Metals, Intermetallics and MMCs

- Aluminum Metal Matrix Composites

- Titanium Metal Matrix Composites

- Gamma Titanium Aluminides

Structural Ceramics


Technology Transfer Topics

Metal and Ceramic Material Processinq Controlled Dwell Extrusion

Controlled Dwell Forging

Consolidation Modeling - MMC and CMC

Material Behavior Modeling - Processing Maps - Constitutive Equations

Analytical Modeling - Deformation - Solidification - Densification - Fluid Flow

Aerospace Materials and Processes Technology Transfer I Technology Transfer

Topics

Nondestructive Evaluation

Computed Tomography

Large Area Composite Inspection

High Resolution Radioscopy

Materials and Processes echnology Transfer I Technology Transfer

Topics

behavior / Life Prediction

Titanium, Titanium Aluminide and Ceramic Matrix Composites

Gamma Titanium Aluminide

NASP Specific Materials

IHPTET Specific Materials

I

ace Materials and Processes Technology Transfer

t Nonme allic Structural Materials Carbqn-Carbon Composites for Electronic Packaging

Carbon-Carbon Composites for BrakeslClutches

Carbon-Carbon Composites as Graphite Replacement

Carbon-Carbon Composites for Space Structures or Thermal Management

Advanced Composites for Infrastructure

Light Weight, Low Cost Composites for Automotive Applications

High Temperature Organic Composites for Industrial, Automotive Applications

Smart Materials & Structures for Infrastructure, Transportation

Composites for Offshore Petroleum Operations

Aeros ace Materials and Processes Technology Transfer P

Nonstructural Materials

Nonflammable Hydrau I ic Flu id

Fire Resistant Hydraulic Fluid

Electronic Coolant

Cooperative Specialty Fluid & Lubricant Development

Self-Lubricating Aluminum Metal Matrix Composites

Ceramic Bearing Technology

Diamond Coated Ball Bearings

Pulsed Laser Deposition Technology


New Oraanic Materials

High Temperature Organic Electro-Optic Materials

High Temperature Thermoplastic Polymers


Mechanics & Surface Interactions I

1 GaAs Materials and Processing Technology

Hard Coating Materials and Processing Technology

Molecular Beam Epitaxy Processing Science and Control

Characterization of Materials Surfaces and Thin Films

Real Time Damage Monitoring

Efficient, 3-D, Numerical Methods for Composite Response - Micromechanics Including Fracture - Laminate Mechanics

Exact Solutions and Analytical Methods for Composite Materials

Unique Experimental Capabilities

- Baseline Solutions for Complex Problems

- Micro/Macro/lnterfaciaI Failure Modes

Aeros ace Materials and Processes P Technology Transfer I Technology Transfer Topics

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I I

Eledtronic. Optical and Hardened Materials Technoloaies Materials for High Temperature Electronics - SIC

InP for Electronics and Opto-Electronics

NLO Materials

HT-SC Materials & Processes

Thin Film Process Monitoring and Control

New Optical Filters - Rugates

Biotechnology for Optical Materials

Laser R&D Facilities

Aeros ace Materials and Processes echnology Transfer c

Manbfacturina Science I Rapid Foundry Tooling System 1 - Integrated Product/Process Design System for Cast Parts

rapid Design System - Integrated Product/Process Design for Machined Parts

- Integrated Process Design and Control for Composite Parts

- NonLinear, Open-Loop Control of Hot Deformation Processes

Advanced Control Software for Molecular Beam Epitaxy

Self-Directed Control Software for Pulsed Laser Deposition (PLD)

QPALII

, Innovative Forming Technologies

I

Self-Directed Control Software for Chemical Vapor Deposition (CVD)

Automated Materials Research - Electro-Optical Materials

Aerosiace Materials and Processes I Technology Transfer I Technology Transfer

Topics

Svstem Technolouies

Pollution Prevention

Aging Aircraft

Corrosion Prevention Methods

Metal-Matrix Aerospace Materials and Processes Technology Transfer

Readiness Standardized products available for SIC particulate reinforced aluminum composite - Title 111 Program - Manufacturers

- Products

- DWA, Chatsworth, California - ACMC, Greer, South Carolina

- Extrusions, sheet, plate Casting and highly loaded infiltrated components are are production ready Spray deposition is available Production experience for fiber mat preforms - Small and large diesel engine pistons - Squeeze cast to infiltrate preform

Unique Features Particulate: - High modulus (stiffness) - Low coefficient of thermal expansion

- High specific strength - Wear resistant Prefurm: - Increased use temperature

Current I Future Uses

Department of Defense Commercial > Varies as a function of reinforcement type

Point of Contact: Mr. Gerald Petrak, WUMLLM, 513-255-1304


Readin ss - Under tanding of the metallurgical and mechanical behavior of several continuous-fiber reinforced TMC s stems has been established - Fractu e-mechanics based life prediction methodologies are being developed for critical aircraft compo i ents

I Unique1 Features - High sbecific strength and stiffness - Higher temperature use than monolithic titanium without superalloy weight

Current / Future Uses

Department of Defense - Airframe components for advanced hypersonic aircraft - Su4port Structures (links, struts, strods, exhaust nozzle liners) for near-term turbine engines - Blaped rings for advanced turbine engine compression systems

- Critical components and support structures in gas turbine engines - Others?

Commercial

Point of Contact: Ms. Katherine Williams, WUMLLM, 513-255-1348

Aerospace Materials and Processes Technology Transfer I Gamma Titanium

Aluminides

Readiness - Need lighter weight I high temperature material to replace steel and superalloys - Knowledge of reproducible microstructure and properties, but technology has reached critical juncture - Cast technology is transitioned to vendor base

- Lighter weight than superalloys and titanium - Better high temperature properties (strength, modulus) than superalloys - Better oxidation and burn resistance than titanium

Unique Features


Department of Defense - Gas Turbine Engines - Near Term: Combustion swirler, high-pressure compressor stators, ,.Jde outer air Seals,

- Mid Term: Compressor and turbine cases, compressor blades nozzle liner tiles

Commercial - Near Term: Cast automotive exhaust valves - Mid Term: Wrought gamma valves, impellers, turbochargers, commercial land-based turbine components, commercial aircraft turbine engine components, and others.

Point of Contact: Capt. David Lee, WUMLLM, 513-255-1379


Reddiness I

- Stdte-of-the-art Structural Ceramics Have Matured to the Point of Real Application Insertion

Unique Features

- High Strength, Stiffness - LowDensity - Operating Capability to ~2000'F - Low Thermal Expansion Coefficient - Thermal Shock Resistance - Corrosion, Oxidation Resistance

- Erosion, Wear Resistance - Tailorable Electrical Properties - Non-strategic Constituent Materials - Fabricable by a Variety of Methods - Resistance to Catastrophic

Failure (Toughened Ceramics)

(Continued)

Materials and Processes echnology Transfer

C rrent / Future Uses

partment of Defense c Gas Turbine Engines 1 - I Aeropropulsion

Auxiliary Power Units I - Reciprocating Engines Automotives (Diesel)

Commercial

- Gas Turbine Engines Aeropropulsion Auxiliary Power Units Automotives Land Based Power Generation

Automotives - Reciprocating Engines

- Hot Aerostructure - Armor - Space Structures - Rocket Propulsion - Wear Parts

- Hot Aerostructure - Heat Recovery Sys-lms - Burners, Combustors - Chemical Process Equipment - Dies, Tooling - Wear Parts - Cutting Tools, Shears

Point of Contact: Dr. Allan Katz. WUMLLM. 513-255-9824

ace Materials and Processes Technology Transfer I Process Modeling

Technology

odeling Technology for the Design of Processes to Produce Metallic and

Readin@ - WidelylUsed Proven Technology Forging Extrupion Roilidg Casting

- Finite Element Based Computer Models - Applicable to Complex Geometries and Advanced Materials - Material Behavior Models - Fluid Flow

Unique Features


Department Of Defense - Advanced Propulsion Systems

Cof"cial - Commercial Aerospace

- Advanced Airframe Systems - Space Systems

- Automotive - Machine Tool - Space I

Point of Contact: Mr. James Moraan, WL/MLLN, 51 3-255-9835

Aerospace Materials and Processes Technology Transfer I Processing Science

Methodology

Analytical Modeling

- Deformation - Densification - Solidification - Fluid Flow

Material Behavior Modeling

- Processing Maps - Constitutive Equations

Physical Modeling

- Visioplasticity - Pilot-Scale Production


qigh Resolution Real-Time X-Ray Radioscopy

0 Readiness - Advanced Development hardware being developed - FY94 Demo planned of developmental system

Current I Future Uses

Department of Defense

Commercial

- Replace film radiography - Field I Depot Use

- Civil Aircraft Inspection - Medical - Mammography - Dental

Point of Contact: Mr. Mark Blodgett, WUMLLP, 51 3-255-9805

Aerospace Materials and Processes Technology Transfer I X-ray Computed

Tomography

X-ray Computed Tomography

Readiness - Advanced development applications program finishing FY93

Cost advantages demonstrated - reported


Department of Defense - Inspect castings, closed systems - Depot use, airframe, solid rocket motors

Commercial - Castings - Medical - Advanced mammography - Automotive

I Point of Contact: Mr. Charles Buynak, WUMLLP, 51 3-255-9807


Readiness - Concept has been demonstrated - Low cost options available

Unique Features - Very high thermal conductivity - Low, tailorable coeff icient-of-thermal-expansion (CTE) - Metallic & ceramic coatings/plating developed/demonstrated


Department of Defense -Thermal planes, heat sinks, heat sink fins - Multichtp module (MCM) & PWB substrates - Matched chiphubstrate CTE - Thermally conductive tie-down for components

Commercial - Same as Department of Defense

Point of Contact: Ken Davidson, WUMLBC, 513-255-9067

Aerospace Materials and Processes Technology Transfer I Advanced Composites

for Infrastructure

Readiness - Structural Applications Since Mid 1960's - MateriallMfg Data Base, Industrial Base

- Weight Savings - Tailorable Properties

Unique Features

i - Corrosion I Fatigue Resistance


0 Department of Defense - Aerospace Structures - Marine Structures

Commercial - Sporting Goods - Medical Equipment - Infrastructure

Point of Contact: Roger Griswold, WUMLBC, 51 3-255-9068

1 Readiness I - Structural Applications Since Mid 1960's - MateriallMfg Data Base, Industrial Base - Major DoD, NASA Cost Reduction Activity

Unique Features - Weight Savings - Ease Of Assembly/Repair - Corrosion/Fatigue Resistance - Energy Absorbing


Department of Defense - Aerospace Structures - Marine Structures

Commercial - Sporting Goods - Medical Equipment

- Automotive ! - infrastructure

Point of Contact: Roger Griswold, WUMLBC, 513-255-9068

Aerospace

- Engine, Airframe Structures - Current Flight Testing

- Weight Savings - High Temperature Capability (700°F) - Corrosion I Fatigue Resistance

Unique Features


High Temperature OMCs for Industrial & Automotive Materials and Processes

Technology Transfer Application -


Commercial

- Aircraft & Engine Structures

- Electronics - Automotive (Under The Hood, Exhaust) - Industrial (Power Generators, Engines) - Commercial Aircraft Engines

Point Of Contact: Roger Griswold, WUMLBC, 513-255-9068

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Structures for Infrastructure and Transportation

Aeros ace Materials and Processes Technology Transfer i

*I I - R ~ ~ ~ ~ ~ ~ n d u s t r y And Government Activity Since '80's , - Current Spacecraft/ Aircraft Testing And Demos - Civil Engineering Applications (Japan, Europe)

- Ability To Sense Vibrations, Strains - Structural Life Monitoring - Ability To Actively Control, Damp Vibrations

Unique Features


Department of Defense - Aircraft/Spacecraft/Submarine Structures - Intelligent Processing

Commercial - Automotive - Acoustic Noise Control For Cabin Interiors - Earthquake-Proof Buildings - Bridges - Oil Tankers, Pressure Vessels

0 ' Point Of Contact: Roger Griswold, WUMLBC, 51 3-255-9068

Aerospace Materials and Processes I Composites for Offshore Technology Transfer I Petroleum Operations 1

Readiness - Structural Applications Since Mid 1960's - MateriaVMfg Data Base, Industrial Base - Major DoD, NASA Cost Reduction Activity

- High Strengthlstiffness-To-Weight - Fatigue/Corrosion Resistance - Acoustic, Vibration & Energy Absorption - Processable In Very Long, Continuous Lengths

Unique Features

Currentlfuture Uses

Department of Defense - Aerospace Structures - Marine Structures

Commercial - Sporting Goods - Medical Equipment - Infrastructure - Automotive

Point Of Contact: Roger Griswold, WUMLBC, 513-255-9068

Aerospace Materials and Processes I Nonflammable Hydraulic Technology Transfer I Fluid MIL-H-53119 1

Readiness - A fully formulated hydraulic fluid, including the base fluid, antiwear additive and a rust inhibitor, has been developed. Validation in flight-worthy components with compatible elastomeric seals has been successfully completed.

Unique Features

Future / Current Uses

- The only truly nonflammable hydraulic fluid operating from -65°F to 350°F. 1

Department of Defense (currently in R&D programs) - US Army ground vehicles - Air Force brake systems - Electric hydraulic actuators

Commercial - Mining - Rapid transit, etc.

Point of Contact: C. E. Snyder, Jr., WUMLBT, 513-255-9036

Aerospace Materials and Processes I Fire Resistant Hydraulic h Technology Transfer L Fluid MIL-H-87257 I

Readiness - Developed as a replacement for flammable MIL-H-5606, this fluid has been successfully validated in the B-1 simulator.

Unique Features

Future Uses

- This fluid is the only drain-and-fill replacement for the very flammable hydraulic fluid that will operate down to -65°F for cold start applications.


Commercial

- This fluid will replace MIL-H-5606 in former SAC aircraft.

- Small commercial aircraft; industrial equipment.

Point of Contact: C. E. Snyder, Jr., WUMLBT, 513-255-9036


I Electronic Coolant I PAOCoolant 1

Readiness - This coolant has been successfully used since 1987 in the B-1 aircraft and since then has been converted to use in many DoD systems including Patriot missile, LANTIRN radar system and the F-18.

- This non-reactive PA0 coolant replaces a troublesome silicate ester coolant that reacted with water causing a gel and a flammable alcohol. - One-fourth the cost of the old coolant. - Environmentally friendly.

Unique Features


Department of Defense - Currently in many applications, future uses are in all systems using silicate ester coolants and some using silicone oils.

Commercial - Solar heat transfer fluid for energy savings. - Coolant for supercomputers.

Point of Contact: Lois Gschwender, WUMLBT, 513-255-7530


Point of Contact: C. E. Snyder, Jr.WL/MLBT, 51 3-255-9036 I

Readiness

- Tailored Fluid and Lubricant Development has successfully led to the development and transition of a wide variety of materials, - Fire resistant and nonflammable hydraulic fluids, P A 0 coolants,

specialty greases, gas turbine lubricants.

Unique Features

- This technology can be directly applied to non-DoD requirements, e.g., lubricants for new refrigeration systems, specialty fire resistant fluids and lubricants, replacements for mineral oil based products that are no longer available, etc.

- This approach is used when industry does not see either adequate volume or adequate assured market to warrant their investment of R&D resources to develop these specialized, tailored fluids and lubricants.

AerosF

- Long term friction tests (1M cycles) demonstrated self-lubricating nature. -I Steady state friction coefficient e.05 (dry) and e.1 (,50% humidity). Piness

Self-Lubricating Aluminum Metal ace Materials and Processes

Technology Transfer

Unique I Features - Extremely low wear rates; Smearing of AI eliminated. -I Lightweight (e3 g/cc) with tailorabie mechanical properties.

Current / Future Uses I Department of Defense

environments.

Commercial

- Self-lubricating bearing material for use in vacuum, dry and moist I

- Self-lubricating lightweight metal-based bearing material.

Point of Contact: K. R. Mecklenburg, WL/MLBT, 51 3-255-2465


Readiness Ceramic materials provide advanced performance in demanding ball and roller bearing applications.

Unique Features


Ceramic balls in steel races can provide long life and reduced wear.

Department of Defense Ball bearings for precision gimbals, turbine engines and for high and low temperature operation in air and vacuum.

Spindles for machine tools; corrosion resistant operation using ceramic balls and races; high vacuum; high speed and high and low temperature operation.

Commercial

Point of Contact: Karl R. Mecklenburg, WUMLBT, 51 3-255-2465

Aerospace Materials and Processes Technology Transfer I PLD of Thin-Film

Tribological Materials

Readiness - R&D for Deposition Technology Complete; Ready for Scale-up and Commercialization.

Unique Features


- Low Temperature Deposition; Extraordinary Film Properties, Environmentally Friendly Process.

Department of Defense - High Temperature Turbine Engine Components; Ball Bearings, Races, Gimbals, etc.; Space-borne components.

- Ball Bearings, Races, Components requiring solid lubrication/ hard coatings, etc.

i Commercial

Point of Contact: Dr. M. S. Donley, WUMLBT, 513-255-6485

Aerospace Materials and Processes Technology Transfer I Diamond Coatings

Ceramic Bearings

Readiness - Developmental Research Completed; Ready for Commercialization.

Unique Features


- Diamond is the Hardest Material Known; Excellent Microstructure and Surface Finish; Excellent Heat Conductor.

Department of Defense - Bail Bearings for Precision Applications (Gimbals, Sensors); High Temperature Corrosive Atmosphere Operations; Limited Lubricant Operations.

- Precision Bearings for Long Life, e.g., Dental Dri1is;Corrosive Environments; High Speed Operations; Limited Lubricant Availability.

Commercial

Point of Contact: Dr. M. S. Doniey, WUMLBT, 513-255-6485

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Readiness - Reproducible Synthesis Process

Unique Features - High Use Temperature (Up to 450°F max.) - Low Dielectric Properties (Good Insulaton) - Environmentai/Moisture Resistant (Less Swelling, Good Arc Resistance) - Tailorable Mechanical/lhermai Properties - Some Polymers Amenable To Spin Coating-Type Technologies


Department of Defense - New High Temperature CanopylSensor Material - Kapton Wire-Wrap Replacement - Dielectric Insulator For Electronic Packages - Thermal Barrier - Matrix Phase for Electro-optic Polymers

Commercial - Sensors - Wire Insulation - Electronic Packaging

Point of Contact: Marilyn Unroe, WUMLBP, 51 3-255-9145


Readiness - These materials offer a substantial improvement in properties over state-of-the-art, second-order, organic electro-optic materials.

Unique Features - Large 2nd-Order Activity - High transparency at visible light wavelengths - Increased Thermal Stability - Low dielectric constant


Department of Defense - Increased recording capacity for CDs via laser light manipulation. - Higher density of interconnects using E-0 materials. - Improved thermal management of electronic devices.

Commercial - Same as above.

Point of Contact: Bruce Reinhardt, WUMLBP, 51 3-255-91 62


I MBE Process Control I ofLowTempGaAs 1

I Fllipsometer equipped MBE providing real time process control

* Readiness

I I

1 - Ellipsometer has been developed providing process control of Low Temperature GaAs deposition at 25OOC by controlling the temperature of the As source, stochlometry and growth rate in real time.


Department of Defense - Phased Array Radar - Infra Red Detectors for Surveillance - High Temperature Electronics

Commercial - High Definition Tv Components - Direct Broadcasting Satellites - Ultra High Speed Computers - Low Power Consumption Electronic Circuits

Point of Contact: Dr. Wayne Ward, WUMLBM, 513-255-3068


Readiness - Highlights of 20 years of research by Dr Pagano and associates at WUML have been Incorporated in the software package "Automated System for Composite Analysis (ASCA)." - Basis for user friendly numerical methods to describe composite laminates and predict their response.

- Fiber, matrix, coatings and interface conditions are property inputs. - Micromechanical analysis used to compute moduli of layers with n-directional fibers. - Calculates laminate properties and stresses including interlaminar stresses - Define stress fields due to free edges, curing, moisture, transverse cracks & debonding.

Unique Features



Commercial

- Designlanalysis of solid propellant rocket nozzles - Characterization of materials applications for air and space vehicles

- Composite materials designlselection for infrastructure, sporting goods, etc. - Validation of finite element programs/solution

Point of Contact: Dr. Wayne Ward, WUMLBM, 513-255-3068

I Materials for High Aerospace Materials and Processes k Technology Transfer 1 Temperature ElectFonics I

Materials for High Temperature Electronics - Sic

Readiness


- A new materials system - for application

Department of Defense - Turbine engine controls - T/R Modules for 10 GHz

. CQMMERCIAL - Automobile engine controls and sensors - Turbine engine controls

Point of Contact: Mr. Tom Kensky, WL/MLPO, 513-255-4588 Ext. 3218

Aerospace Materials and Processes Technology Transfer and Opto-Electronics 1 I

InP for Electronics 1

devices.

Readiness - Technology (bulk and epitaxial) has been demonstrated. - Devices produced, being inserted Into systems.


Department of Defense - Optoelectronics for computing, terrahertz communication. - High-speed signal processing. - I T/R radar modules

Commercial ~ - Cellular communlcations/satellite applications - Collision avoidance radar (automotive) - GPSradar

InP for Electronics and Opto-Electronics InP-based devices can operate at higher power and higher frequency than current SOA GaAs-based

Point of Contact: Ms. Laura Rea, WUMLPO, 51 3-255-4588, Ext. 321 3

Aerosdace Materials and Processes Nonlinear b Technology Transfer Optical Materials 1

Nonline r Optical Materials Materials f r new laser sources (optical wavelength conversion) and for electro-optic devices (optical wave guid s and spatial light modulators).

Curre i t / Future Uses

Dep e rtment of Defense - Elebtro-optic countermeasures

- Laqerradar - Optical signal processing (eg, target recognition) - Optical interconnects for electronic packages

- LID@

Commercial

- Medical lasers - Switching networks for communicatlons - Optical interconnects for electronic packages - Scientific instruments

- LIDAR

Point of Contact: Dr. Ken Hopkins, WUMLPO, 513-255-4588, Ext. 3219


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High T mperature Superconducting Materials & Processes


A new m d teriai - thin films have demonstrated potential for significant performance enhancement. I

Department of Defense - RF circuits for electronic warfare - Signal processing - IR detectors

- Bipmagnetic imaging - Nondestructive evaluation - Passive components for communication satellites - Sibnai processing - Multichip modules

Cotnmercial

Point of Contact: Mr. Tim Peterson, WL/MLPO, 513-255-4588, Ext. 3235

Materials Aeros ace Materials and Processes

Technology Transfer P lnnovati e Optical Materials Novel mat rials for optical applications - blomolecular materials for NLO films; liquid crystal siloxane polymers; I fullerene-based optical limiting solutions; photochromic films for laser dosimetry.

Uniqup Features

Current /Future Uses

- Molecular materials that are easily tailorable for specific optical applications - low optlcal threjholds, high speed response, transparent.

Dedartment of Defense

Commercial

- Laser protective visors - Electro-optic sensor protection

- Electro-optical devlces - Optical computing - Laser dosimeter badge

I Point of Contact: Dr. Robert Crane, WL/MLPJ, 513-255-2110, Ext. 3174

Filters Aerospace Materials and Processes

!Technology Transfer

New Optical Filters - Rugates

Readiness - Ten years of DoD sponsored R&D progress. - Example filters surpass current SOA technology.

- Unlimited freedom in the design and manufacturing of optical filters. Unique Features


Department of Defense - High power laser mirrors - Electro-optic sensor protection - Tailored high performance optical filters

- Lightwave telecommunication technology Commercial

Point of Contact: Mr. Walt Johnson, WUMLPJ, 513-255-2110, Ext. 3170


- Laser R&D and T&E Facilities The use of lasers for materials processing is becoming more prevalent in both DoD and commercial industries. Two state-of-the-art laser test facilities provide opportunities for proof-of-concept testing.

Laser Hirdened Materials Evaluation Laboratory (LHMEL) A nationally unique carbon dioxide laser test facility producing repeatable high quality beam profiles at powers up to 150 kW on target. Produces beams In both continuous wave and repetitively pulsed mode.


Department of Defense - Laser effect on materials - Thermal response of materials or components - Surface treatment and coating application

- Materials processing (drilling, cutting, welding) - Heat treatment or surface treatment - strength enhancement - Materials performance testing - simulation of application heat loads

Commercial

Point of Contact: Mr. Rob Hull, WUMLPJ, 51 3-255-2334, Ext. 31 65 I


Laser R&D and T&E Facilities (continued)

One Kilowatt Laser Laboratory Employs a 1 kW carbon dioxide laser operating in either continuous wave or repetitively pulsed mode. Extremely small spot sizes and CNC table provide precision beam positioning.


Department of Defense - Materials response testing - Manufacturing technology proof-of-concept testing - Susceptibility (damage level) testing

Cotnmercial - Materials processing (cutting, drilling, welding) - Precision laser machining or engraving - Surface treatment for strength enhancement

Points of Contact: Dr. Patrick Hood, WUMLPJ, 513-255-2334, Ext. 3168 Mr. Charles Lovett, WUMLPJ, 51 3-255-2334, Ext. 31 61

ace Materials and Processes Technology Transfer I Rapid Foundry

Tooling System

Rapid F undry Tooling System RFTS cou les feature-based design and an associative memory to augment pattern making and process p anning of mold and pattern (parting line, gates & risers, draft angle, number and location of

of en 4 biing technology. Developed and supported by commercial business (AIWARE, inc., Cleveland, OH) and built on top of their software product called CADChemm.

cores, run, 1 ers, etc.)

Readi ess - SUC ssful prototype implemented at Kelly AFB Foundry available for commercial use or spin-off

I

Uniqule Features


- ThreA dimensional associative mapping of geometry, to processing problems, to causes. - An algorithm (patent applied for) to automatically core a pattern.

DualUse - Pattern making for sand casting, pattern making for investment casting, pattern making for rubber molding.

- Pdttern making for medical prosthesis. Commercial

Point of Contact: Dr. Steve LeClair, WUMLIM, 51 3-255-8787


I Rapid Design System

Rapid Dbsign System RDS couples feature-based design and a deductive-inductive memory to augment the machinist in process planning of fabrication and inspection of machined parts and enables the system to automate numerical control and coordinate measurement machine code generation.

Readiness - Prototype implementation at the Developmental Manufacturing and Modification Facility (DMMF) at Wright-Patterson AFB and available for commercial use or spin-off of enabling technology. Devdoped and supported by commercial business (Technosoft, Inc., Cincinnati, OH) and built on top af their software product called CHISELSTM.

- Seif-improving process design system (patent pending) to augment designer/machinist in optimizing product and process (fabrication and inspection) design.

Uniqup Features


DuailUse - ProducVprocess design for machined parts, automatic fabrication plan, automatic inspection pian, set up configuration, and productldata exchange (STEP/PDES) standards.

Point Df Contact: Dr. Steve LeClair, WUMLIM, (51 3) 255-8787

Aeros ace Materials and Processes Technology Transfer P

QPAL I I Automatlon Language (QPAL) is a knowledge base methodology and for the control of dynamic, event-driven processes.

Implemented at Sacramento Air Logistics Center and at several commercial sites (formerly General Dynamics), and Honeywell. Original QPALm prototype

Alr Force and currently supported through (Lawrence Associates, Inc., Is being built on OPALm with slgnlflcantiy enhanced language and user

Interface.

Unique Features - Evedt-driven process development and control system (patent awarded). - Applicable to any non-llnear, sensor-based control environment. - Supports process planning and optimization.

Current Future Uses

DuqlUse - Productlprocess deslgn for composite curing, productlprocess design for any non-linear, sensor-based materials or product manufacturing process, broadly applicable to overall manufacturing process scheduling and control, applicable to other event-driven scenarios, not limited to manufacturing (e.g., routing, scheduling, order/inventory tracking and control, etc.).

Point of Contact: Dr. Steve LeClair, WL/MLIM, 513-255-8787

of Deformation Processes Aerospace Materials and Processes

Technology Transfer

NonLinear, Open-Loop Control of Hot Deformation Processes (Forging, extrusion and rolling) - Optimal control system design for producing net-shape components having controlled microstructures and properties.

Readiness - Materlal Behavior and Process Models involved have been experimentally verified. - With ohly partial implementation, some metal working industries are reporting 15 - 25% increase in productivity (e.g. Youngstown AI Extruder's Consortium). - Planned and current process control technologies could impact a wide range of metal working processes.

Uniquq Features - Practipal process engineering tool - - Control system design includes robustness and performance analyses Especially applicable to complex geometric shapes and difficult-to-process materials.


DualUse - Design of optimal control systems for deformation processes including forging, rolling, and extrusion; advanced control technology; hierarchical control strategies; sensor fusion; processing of diff icult-to-process materials (intermetallics); improved processing efficiencies.

Point of Contact: Dr. Jim Malas, WL/MLIM , 513- 255-8787

Aerospace Materials and Processes Technology Transfer I Advanced Control

Software for MBE

Advanced Control Software for Molecular Beam Epitaxy

Readiness

Improved ciontrol of thin-film composition and thickness is obtained via real-time control using advanced sensor technology and model based control of the flux.

- Successful prototype has been tested at the Air Force Materials Directorate. - Patent application has been submitted.

Unique Features - Automated process Identification. - Shutter opening flux transient compensation. - Adaptive gain/bandwldth control. - An artificial neural network is used for quick reduction of ellipsometry data. - The control system Is easy to understand and adjust.


DualUse - Control of processes for deposition of electronlc materials; improved electronic devices; compositional control; thickness control; advanced sensors; sensor fusion.

Point of Contact: Dr. Steve LeClair, WUMLIM, 513-255-8787

Software for PLD Aerospace Materials and Processes

Technology Transfer

Self-Directed Control Software for Pulsed Laser Deposition (PLD)

Readiness

Produces high quality solid lubricants and hard coatings through real time control of system parameters.

Control and monitoring of composition and microstructure during thin-film growth with PLD has been demonstrated.

Unique Features - High energy process gives good substrate adhesion. - Stachiometric growth of material without thermal damage to substrate (20 - 200° C). - Environmentally safe. - Easy to operate.


DualUse - Control of processes for deposition of solid lubricants; high temperature precision mold adherence reduction (440SS Teflon molds for laser surgery); machine tool industry hard coatings (mill and tool ends); gas turbine clearance control; vacuum lubricant applications (disk drives, robotics).

Point of Contact: Capt. Elizabeth Stark, WUMLIM, 51 3-255-8787

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Aerospace Materials and Processes I Self-Directed Control Technology Transfer of CVD I

Self-Directed Control of Chemical Vapor Deposition Produce digh quality fiber coatings with desired interface properties for fabrication of ceramic matrix composites.

Readiness - Planned and current process control technoiogles could impact a wide range of commercial coating applications.

Unique Features

Current /F Future Uses

- Confrol of deposition morphology allows desired fiber properties. - High purity, low internal stress coatings.

DualUse - Control of depositon processes for coating ceramic fibers; ceramic matrix composites; deposition of thermal barrier coatings.

Point of Contact: Capt. David Griffin, WUMLIM, 513-255-8787


Automated Materials Research: Electro-Optical Materials

Readiness

Unique Features

A memory-driven automated system for analyzing electro-optical materials data from the literature and other sources.

- Prototype developed by Materials Directorate for use in-house.

- Electro-Optical materials In simple database. - Highly efficient material characterization. - Sophisticated analyses possible with fewer experts. - Trend identification made simple. - Identification of candidate materials.


Dualuse - Ciaracterlzation of new materials, extension of this technology to other sophisticated materials and designs.

Automated Materials Research:

- Electro-Optical Materials

Point of Contact: Dr. Steve LeClair, WUMLIM, 513-255-8787

Aerospace Materials and Processes Technology Transfer I Pollution Prevention

R&D

POLLUTION PREVENTION R&D The ML pallution prevention R&D program is focused on the elimination of water, VOC and ODC waste streams. Through the development and transfer of advanced materials and processes the Air Force will eliminate these waste streams from the manufacture and maintenance of its weapon systems

Readiness

Majorjthrusts

- The& are new FY93 projects still in the R&D Phase.

- Non chemical metal surface preparation - VOC compliant coating systems - Super critical C02 cleaning - Non-TOWHAZ anti-ice/de-ice for aircratt - Advanced fire extinguishing materiais I

Future Payoff - Eliminate the use of bad acting materials - Improve healthkafety of workers - Processes used universally by industry

Point of Contact: Ted J. Reinhart, WUMLSE, 513-255-3691

p&xGzq Aerospace Materials and Processes ,Technology Transfer

Aging Aircraft

Readiness

A large sqgment of the Air Force operational fleet is aged and deteriorated to the point where major refurbishments and retrofits are required to continue use.

I

- Life extensions a requirement. - The Klevelopment of new systems In the near term will be minimal. - Mission requirements likely to be increased.

Uniqthe Features - Environment/ missionlmaterial driven. - Applicable to numerous systems including trainers, bombers, and fighters. - lmpioved Inspection methods for corrosion and flaw detection,

impioved repair methods, etc.

Current / Future Uses I

DualUse - System enhancements applicable to commercial fleet.

1 Point of Contact: Mr. Ron Williams, WUMLSA, 513-255-3623

. I Aerospace Materials and Processes Corrosion Prevention C

Technology Transfer I Methods I

Corrosion Prevention Methods The need for materials/processes to manage corrosion of aircraft systems continues to be top priority. Introduction of substitutes has been driven by environmental, health, and safety issues.

Readiness - Current regulations reduce/eliminate the use of past, proven materials including inhibitors, platings, solvents, etc. - Quaiiflcation of acceptable substitutes needed immediately. - Drop-in are substitutes rare.

- Applicable to numerous uses. - Supplier/user vested interest.

Unique Features


DualUse - Qualified acceptable substitutes applicable to commercial aircraft, automotive Industry, medical devices, etc.

Point of Contact: Mr. Gary Stevenson, WUMLSA, 51 3-255-51 08

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