Project ProfileNCEMT Demonstrates

Low-Cost, Single-Melt TitaniumAlloy for LW155 Howitzer

In Use in IndustryU.S. Navy is Implementing

Improved Phalanx PenetratorDeveloped Under NCEMT

What’s NewNCEMT Selected as Lead

to Develop ATPFPrototype for DD(X)

Project ProfileNCEMT Demonstrates

Low-Cost, Single-Melt TitaniumAlloy for LW155 Howitzer

In Use in IndustryU.S. Navy is Implementing

Improved Phalanx PenetratorDeveloped Under NCEMT

What’s NewNCEMT Selected as Lead

to Develop ATPFPrototype for DD(X)

Update

Advanced Metalworking Solutions for Naval Systems that Go in Harm’s Way

Fall 2004

METALWORKINGTECHNOLOGY

Page 3

Project Profile ............................ 3NCEMT Demonstrates Low-Cost, Single-Melt TitaniumAlloy for LW155 Howitzer

In Use in Industry ...................... 3U.S. Navy is ImplementingImproved Phalanx PenetratorDeveloped Under NCEMT

A Face Behind the NCEMTName .......................................... 4Paul J. Konkol

What’s New ................................ 4NCEMT Selected as Leadto Develop ATPF Prototypefor DD(X)

Letter from theProgram Director ....................... 5

NCEMT in Print ........................... 6Conference Papers/Presentations, PublishedJournal Articles

Out and About ............................ 6DD(X) LIPT MeetingShipTech 2005

C o n t e n t sMetalworking Technology Update

Page 4

Page 6

NCEMT Program DirectorDaniel L. Winterscheidt, Ph.D.

Center Operations ManagerDenise Piastrelli

WritersDebbie Roman EisenbergKelly H. Klug

Design and ProductionAmy J. StawarzProduction AssistantDonald Cekada

Concurrent Technologies Corporation (CTC)operates the National Center for Excellence inMetalworking Technology (NCEMT) for the U.S.Navy Manufacturing Technology (ManTech)Program. The NCEMT serves as a national resourcefor developing and disseminating advancedtechnologies for metalworking products andprocesses. The NCEMT applies these technologiesto solve productivity problems in support of theNavy and Department of Defense needs.

CTC is committed to assisting industry andgovernment achieve world-class competitiveness.Through a unique concurrent engineeringframework, CTC provides comprehensive solutionsthat improve our clients’ product quality,productivity, and cost effectiveness. The professionalstaff of CTC has the requisite experience,knowledge, and resources to rapidly and effectivelymeet the diverse needs of our clients by transitioningappropriate science, technology, and managementapplications.

For further information about topics in thispublication or about CTC, please contact717-565-4405.

Metalworking Technology Update is published byConcurrent Technologies Corporation, 100 CTCDrive, Johnstown, PA 15904-1935.

CTC is an independent, nonprofit, applied researchand development professional services organizationproviding management and technology-basedsolutions to a wide array of clients representingstate and federal government as well as the privatesector. Established in 1988, CTC operates frommore than 35 locations with a staff of over 1,300employees. For more information about CTC, pleasevisit www.ctc.com.

2 A ManTech Center of Excellence

Mark Your CalendarsNCEMT-Facilitated EventsShipTech 2005, Beau Rivage Resort, Biloxi, MississippiMarch 1–2, 2005 (rescheduled from January 19–20)

Advanced Materials for Ship and Ground Vehicle Applications,Rosen Centre Hotel, Orlando, Florida, February 1–2, 2005

Friction Stir Welding Technology Workshop, Columbus, OhioAugust 2005

Watch for Our ExhibitDefense Manufacturing Conference (DMC ’04)Bally’s, Las Vegas, Nevada, November 29–December 2, 2004

Stay tuned for more information.

Visit Our Web Site at www.ncemt.ctc.com

This publication was prepared by the National Center for Excellence inMetalworking Technology, operated by Concurrent Technologies Corporation (CTC),under Contract No. N00014-00-C-0544 to the Office of Naval Research as part of the

Navy ManTech Program. Approved for public release; distribution is unlimited.

© 2004 Concurrent Technologies Corporation. All rights reserved.

The cover image of the DD(X) is courtesy of Raytheon.

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www.ncemt.ctc.com

U.S. Navy is Implementing Improved PhalanxPenetrator Developed Under NCEMT

In Use in Industry

Proj

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3 A ManTech Center of Excellence

NCEMT Demonstrates Low-Cost, Single-Melt TitaniumAlloy for LW155 HowitzerUnder the Joint Program ManagementOffice (JPMO), the NCEMT madesignificant contributions to the U.S.Navy ManTech program through theSingle-Melt Process for Reduced-CostTitanium Alloys project.To reduce the cost of Ti-6Al-4V(Ti-6-4) alloy ingots by improving theingot surface finish, the NCEMToptimized the single-melt (SM) plasmaarc cold hearth melting (PAM)process. It aimed to demonstrate themechanical properties of forgingsmanufactured from single-melt Ti-6-4ingots that are produced using lower-cost feedstock material. The NCEMT

sought to determine the effect of oxygencontent on the SM PAM material propertiesbecause further cost reduction is achievablewith use of more high-oxygen content chargealloy material. For the LW155 howitzer, theNCEMT focused on manufacturing, testing,and field-evaluating bell housing forgings.The LW155 JPMO andBAE Systems willperform field-testingof bell housingforgings in FY05.The NCEMTsuccessfullydemonstrated the trialproduction of PAMingots and themanufacturing of bellhousings for theLW155 howitzer bynear-net-shape forging of SM PAM Ti-6-4alloy with 0.16, 0.20, and 0.24 wt% oxygenlevels and double vacuum arc remelted(2XVAR) Ti-6-4 with 0.17 wt% oxygen levelbase line alloy. In addition, the NCEMTperformed and analyzed tensile, fatigue,fracture, impact, and microstructure testingresults on the SM PAM Ti-6-4 forged bellhousings and delivered a machined andanodized Ti-6-4 bell housing to the JPMO forfield-testing.The NCEMT demonstrated an improved SMPAM ingot surface finish of sufficient qualitythat no surface machining is required prior toforging. Through extensive testing andevaluations, the NCEMT also showed thatmechanical properties met performancerequirements. As a result, the baselineproperties of SM PAM vs. 2XVAR Ti-6-4 alloywere established. Based on the testing andcharacterization results, forgings that weremade using SM PAM Ti-6-4 alloy up to 0.24wt% oxygen are now viable for LW155howitzer applications and other Marine Corpsapplications. ■

One of the first initiatives ever ventured by the NCEMT was toinvestigate the use of tungsten-heavy alloys (WHAs) to replacedepleted uranium penetrators in the Phalanx Close-In WeaponsSystems (CIWS). Now, the improved Phalanx penetrators thatwere developed by the NCEMT and its industrial partners arebeing implemented by the U.S. Navy.

The Phalanx CIWS, the last line of defensefor ships, rapidly fires armor-piercingpenetrators (projectiles) at enemy missiles.It’s an effective weapon system that isfrequently made from depleted uranium, anenvironmentally hazardous material thatloses mass during penetration. Cleanup ofdepleted uranium is costly and time-consuming, and the hazard is greater andmore pervasive when the penetrators aredischarged from ships because they cannotbe recovered.

Previously, Phalanx penetrators were manufactured from bothdepleted uranium and a tungsten-nickel-iron alloy, which havethe high density required for kinetic energy penetrators.Depleted uranium is used as a kinetic energy penetrator for itsability to penetrate thick sections of armor. However, themechanism that allows depleted uranium to penetrate thickarmor also causes it to lose mass when penetrating plate array-type targets that represent missiles. Thus, depleted uraniumperforms poorly in the CIWS. The work performed under theNCEMT program focused on developing penetrators that couldwithstand impact stresses at impact velocities greater than 5,000feet per second—retaining a higher remnant mass. Pursuant tothis, modifications in alloy composition and processingconditions were investigated.

After extensive evaluation and analysis of WHA compositions,mechanical properties, and ballistic performance, the NCEMTpartnered with a major tungsten manufacturer to create aprojectile that is made from a tungsten, nickel, and cobalt (W-Ni-Co) alloy. The NCEMT and its team of industry partnersfound that the W-Ni-Co alloy composition showed a 50%increase in both impact energy and remnant mass retention overthe tungsten-nickel-iron alloy at impact velocities over 5,000feet per second. Also, the cobalt-bearing alloy performed betterthan depleted uranium in the CIWS. Current powdermetallurgy manufacturing processes are used to produce largevolumes of the new WHA penetrators. This new alloy has a 50%improved ballistic performance as compared to existingtungsten alloy penetrators that are currently used in the fleet,and approximately 100% improvement in remnant massretention over depleted uranium. Reduced production costs andincreased efficiencies now result.

The Naval Surface Warfare Center - Dahlgren Division hasincorporated the W-Ni-Co composition and NCEMT WHAprocessing technology into modified ammunition specs. Also,the alloy that was chosen for the 20mm MK 244 Mod 0 ArmorPiercing Discarding Sabot Enhanced Lethality Cartridge wasselected from numerous alloys that were tested based onfracture toughness, which translates into superior terminalballistic performance. Additional cartridge designs have also usedthe W-Ni-Co alloy, including the 30mm MK 258 Mods 0 and 1. ■

Ti-6-4 alloy bell housing forthe LW155 howitzer

Phalanx penetrator

What’s New

4 A ManTech Center of Excellence

The NCEMT recognizesthat its organization isonly as strong as itspeople, the individualswho work every day to

solve current metalworking problems andimprove weapons systems for the U.S. Navyand DoD. The NCEMT would like toacknowledge the people who support theprogram and are committed to the successof its projects.

Paul Konkol is a Principal WeldingEngineer, Materials Processing Departmentand a registered Professional Engineer.He’s been working at CTC in support ofthe NCEMT Program since 1994. For mostof his career, he’s worked with steels andwelding. His versatile background, skills,and knowledge allow him to wear manyhats in support of NCEMT projects,serving as project manager, task leader,project engineer, and lead engineer. As theproject manager for the HSLA-65Weldment Characterization project, Paulhelped to certify a new steel, HSLA-65, foraircraft carriers. The U.S. Navy iscurrently implementing this steel for useon CVN 77 and the design of the new CVN21. When Paul was the task leader for theCombat Vehicle Research project, he andDr. Joseph R. Pickens, Chief Scientist, andDirector, Science & Technology at CTC,were the first to demonstrate the feasibilityof friction stir welding of HSLA-65 andother steels, which the Navy is currentlyevaluating for shipbuilding applications.

Paul’s affiliations to many councils andorganizations provide valuable networkingopportunities that keep him up-to-date onthe latest industry needs and futuredirection, which enhances his contributionsto NCEMT projects. Paul is frequentlycalled upon to be a team member/advisorfor the development of new NCEMTshipbuilding projects, assist in technologytransfer through papers and presentations,and help organize workshops andconferences. While working at U.S. Steel’sDivision of USX Corporation inMonroeville, Pennsylvania, Paul wasawarded two steel patents: No. 3,370,994,Method of Softening Steels; andNo. 3,502,462, Nickel, Cobalt, ChromiumSteel, also known as HY-180.

Paul earned a B.S. and M.S. inMetallurgical Engineering from CarnegieMellon University. ■

A Face Behindthe Name:Paul J. Konkol

NCEMT Selected as Lead Center for theDevelopment of a Prototype Automated Thermal

Plate Forming System for DD(X) Hull ApplicationsThe DD(X) Leadership Integrated Project Team has identified theAutomated Thermal Plate Forming (ATPF) project as a high priority forthe DD(X) ManTech Program. Complex hull curvatures presentlyrequire the application of a combination of mechanical (roller andbrake press) and thermal (oxy-fuel) inputs to form hull plates. Thesemethods of manual forming and reproducibility are highly dependanton operator skill and experience. To reduce variability in formed hullplate geometry and to reduce direct labor forming hours, rework andtime required to fabricate DD(X) advanced multi-mission destroyer andother Navy combatants hull structures, the NCEMT was tasked to leadthe development of a prototype ATPF system. The prototype systemwill be designed to operate in a harsh shipyard productionenvironment and will be delivered to a shipyard for production use atthe completion of this project.

To address these challenges, the NCEMT formed an Integrated ProjectTeam (IPT) comprised of Northrop Grumman Ship Systems, Bath IronWorks, the Navy Joining Center (NJC), the Institute for Manufacturingand Sustainment Technologies (iMAST) and the Naval SurfaceWarfare Center – Carderock Division (NSWCCD). Combining theexpertise of these organizations, the IPT will address the following taskrequirements:

• Verify that induction heating is an appropriate heat source forthermal plate forming, and optimize induction heating and coolingparameters for the range of plate thickness and grades required forDD(X) application.

• Develop a thermal model to predict the thermal profiles associatedwith plate heating and cooling during thermal forming operations.

• Qualify the thermal forming process by a combination ofmechanical and microstructure evaluations aimed at verifying thatthermally formed plate materials remain in compliance to requiredhull plate specifications.

• Develop a path planning software system that can plan heat linepaths and patterns to achieve desired 3D shape (from a CAD file).The initial shape, before thermal forming, may be either flat ormechanically formed.

• Design a plate holding system capable of supporting both flat andformed plates.

• Select an automated measurement system that can measure initial,formed and final plate geometry to the required dimensionaltolerance accuracy.

• Construct and integrate a prototype ATPF system that can processplates within a 12-foot wide by 20-foot long by 3-foot high workingenvelope. The system must include plate holding, inductionheating and quenching, path planning, automated measurement,and heating and cooling manipulation systems.

• Develop a technical specification for a full-size ATFP system thatcan process plates within a 12-foot wide by 56-foot long by 5-foothigh working envelope.

An ATPF system has the potential to increase quality and reduce costsand production time compared to the present manual methods to formhull plates. Target objective benefits for DD(X) application include100% increase in throughput, 80% reduction in rework, 50% reductionin direct labor costs and 75% reduction in support labor costs. TheATPF technology developed in this project is also expected to providebenefits and additional cost avoidance to other naval ship programssuch as LHD, LPD and CVN 21. ■

Northrop Grumman’s DD(X)

Letter from the Program DirectorDaniel L. Winterscheidt

5 A ManTech Center of Excellence

“We realize that oursuccess as a program isdirectly bound to ourability to discern the needsof the weapon systemprogram offices and toimplement metalworkingsolutions to meet the needsof ships and weaponsystems that must go inharm’s way.”

One of the guiding principles of the NCEMT Program is our understandingthat ManTech’s customers—the weapon system program offices—are thedriving force behind everything that we do. All of the technology and businessactions undertaken by the NCEMT—be it our technical approaches, our projectexecution, or our partnerships and affiliations—are driven by an underlyingunderstanding of what the program offices want to accomplish.

To meet the program office needs, we “partner with the primes.” The weaponsystem prime contractors act as customers because they receive themetalworking technology or solution, and frequently serve as subcontractorsto CTC in the execution of NCEMT projects. Since I became ProgramDirector last October, NCEMT project development has focused primarily onthe needs of the program offices and prime contractors of three weaponsystems: the 21st Century aircraft carrier CVN 21, the next-generationdestroyer DD(X), and the joint unmanned aircraft J-UCAS.

Reducing the ship’s weight and lowering its center of gravity are key prioritiesfor the CVN 21 Program Office. Working with the program office and primecontractor Northrop Grumman Newport News, the NCEMT has initiated threeprojects—10Ni Steel, LASCOR, and Titanium—to address the need for a lightercarrier with a lower center of gravity. Three welding-related projects will alsoenhance production effectiveness and efficiency. In total, the NCEMT hasdeveloped over $15M worth of CVN 21 projects that meet the Navy’s need formaneuverability and survivability.

To meet the need for innovative manufacturing approaches for ship hulls, theNCEMT is working with the DD(X) design agent Northrop Grumman ShipSystems (NGSS) to undertake projects prioritized by the DD(X) LeadershipIntegrated Project Team (LIPT) (see p. 6). The NCEMT and the Navy JoiningCenter (NJC) developed an Automated Thermal Plate Forming (ATPF) projectto meet the shipyards’ needs to accurately form steel plate corresponding tothe hull geometry of the DD(X) design (see p. 4). Another top priority for theLIPT is a project to address a special hull treatment for the DD(X). TheNCEMT is working with an IPT consisting of the DD(X) Program Office,NSWC Carderock Division, NJC, NGSS and Bath Iron Works to supportthis effort.

In support of the J-UCAS Program, the NCEMT has been working with teamsfrom both Boeing and Northrop Grumman to develop metalworking projectsto meet the manufacturing needs of each team’s J-UCAS design.

The M777 LW Howitzer is an NCEMT project where meeting stakeholderneeds is a critical success factor. The NCEMT has been an active participant inthe development of innovate manufacturing approaches for this titanium-intensive weapon that will be used by both the Marine Corps and Army.Working with the Joint Program Management Office and the prime contractor,BAE Systems, the NCEMT has reduced the part count, manufacturing cost,and waste for the howitzer by developing single-piece investment cast spadesand saddle, and by pursuing novel production methods, such as flowforming,for the cradle tube.

The NCEMT recognizes the significance of understanding and acting onstakeholder needs. We realize that our success as a program is directly boundto our ability to discern the needs of the weapon system program offices and toimplement metalworking solutions to meet the needs of ships and weaponsystems that must go in harm’s way.

Daniel L. Winterscheidt, Ph.D.Program DirectorNational Center for Excellence inMetalworking Technology

Out and About

NCEM

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6 A ManTech Center of Excellence

NCEMT Hosts DD(X) LIPT MeetingThe NCEMT hosted thequarterly meeting of the DD(X)Leadership Integrated ProjectTeam (LIPT) at ConcurrentTechnologies Corporation (CTC)headquarters in Johnstown,Pennsylvania, May 4–5.Representatives from ONR’sManTech Program, the NavalSurface Warfare Center –Carderock Division, NorthropGrumman Ship Systems, BathIron Works, the Navy JoiningCenter (NJC), and the Institutefor Manufacturing andSustainment Technologies (iMAST) participated in the two-day meetingintended to review and coordinate ManTech technology projects insupport of the DD(X), the Advanced Multi-Mission Destroyer with 21stCentury National Security Capabilities.

While at the meeting, participants toured CTC’s ManufacturingTechnology Facility and Environmental Technology Facility, andobserved a project demonstration in each facility including a submergedarc welding process that the NCEMT is supporting in conjunction withthe NJC, and a demo of the NCEMT friction stir welding machine—oneof the largest systems of its kind in the world, designed to accommodatea full-sized combat vehicle.

Currently, the NCEMT is supporting three projects for DD(X):Automated Thermal Plate Forming (see p. 4), Advanced BondingMethods for Steel Structures, and Manufacturing Large MarineStructrures, which is in its initial phase. ■

ShipTech 2005 Set for March 1–2 in Biloxi, MississippiShipTech 2005: A Shipbuilding Technologies Information Exchange willbe held at the Beau Rivage Resort & Casino in Biloxi, Mississippi, onMarch 1–2, 2005. The event will again be cosponsored by the Office ofNaval Research – Manufacturing Technology Program (ONR ManTech)and the National Shipbuilding Research Program (NSRP), and facilitatedby the NCEMT.

The two-day event is the seventh such NCEMT-developed forum that isintended for the domestic shipbuilding industry, its supplier base, theU.S. Navy Program Offices, and the U.S. Navy-sponsored shipbuildingresearch programs. Organized to exchange information on shipbuildingtechnology developments, ShipTech 2005 will feature advances that aregenerated respectively by the NSRP and the Navy ManTech Programthrough its Centers of Excellence and related shipbuilding initiatives.The overriding objective of the information exchange is to reduce totalownership costs of naval ships while enhancing the competitiveness ofthe domestic shipbuilding industry. General session presentations willprovide a high-level overview of naval shipbuilding programs as seen bythe Naval Sea Systems Command, ONR, and the NSRP ExecutiveControl Board. Concurrent technical sessions will feature completedand ongoing projects that are focused on production processes, productdesign and materials, business processes, and systems technologies. Theevent will conclude with a plenary panel discussion that addressestechnology transition from ManTech to industry.

Updated information can be found on the NCEMT Web site atwww.ncemt.ctc.com. For additional information, contact Tricia Wright,Event Coordinator, at 814-269-2567 or wright@ctc.com. ■

Conference Papers/PresentationsLaurentiu Nastac,Frank Spadafora (RMITitanium Company),Ernie M. Crist (RMITitanium Company).CFD Modeling andSimulation Applicationsfor PAM-Assisted Castingof Ti-6Al-4V Ingots andSlabs. TMS AnnualMeeting, Charlotte, NC,March 14–18, 2004.

Ibrahim Ucok, MehmetGungor, Kevin L. Klug,Joseph R. Pickens.

Improving Wear Resistance ofAlloy Ti-6Al-4V. TMS AnnualMeeting, Charlotte, NC,March 14–18, 2004.

Mustafa Guclu, Ibrahim Ucok,Joseph R. Pickens. Effect ofOxygen Content on Properties ofCast Alloy Ti-6Al-4V. TMSAnnual Meeting, Charlotte, NC,March 14–18, 2004.

Charles A. Meglio. InjectionMolded Rhenium: TechnicalSummary. JANNAF 23rd RocketNozzle Technology SubcommitteeMeeting, New Orleans, LA,March 30–April 1, 2004.

Conference PresentationKevin Klug, Mehmet Gungor,Ibrahim Ucok, Lawrence Kramer.Affordable Ti-6Al-4V Castings.TMS Annual Meeting, Charlotte,NC, March 14–18, 2004.

Published Journal ArticlesLaurentiu Nastac. “The CFDModeling of the EB-PVD of SiC/Ti-6Al-4V Coatings.” Journal ofMetals, Vol. 56, No. 3, March 2004,pp. 49–53.

Laurentiu Nastac. “Modeling andSimulation Engineering Processeswith Computational FluidDynamics.” Journal of Metals,Vol. 56, No. 3, March 2004, p. 43

Joseph R. Pickens. “Low-CostTitanium for Ships and Tanks.”Advanced Materials & Processes,Vol. 162, No. 5, May 2004,pp. 37–39.

Authors are from the NCEMT unlessotherwise noted by a companyname in parentheses.

LIPT participants observe a demonstration of thefriction stir welding machine while touring CTC’sEnvironmental Technology Facility in Johnstown,Pennsylvania.