Naval Aviation Materials, Manufacturing and Maintenance Workshop: Accelerating

Technology Insertion

Air Vehicle Engineering Department

Naval Air Systems Command

William E. Frazier, Ph.D

30-31 Jan 2008

Southern Maryland Higher Education Center

California MD

Workshop Focus

Effect a 30% reduction in cost and a 30% increase in throughput, by accelerating the insertion of

extant and emerging Materials and Manufacturing Technologies.

We tasked the workshop participants to assist us in developing a path

to the answer.

Outline• Overview

– Organizers, Chairpersons, and Plenary Speakers

– Concept of Operation

– Participants

• Results

– Plenary: Technology Needs Summary

– Green Manufacturing

– Modeling and Simulation

– Rapid Prototyping

– Repair Technologies

– Transition Hurdles

Workshop Organizers

Organizers

• ARL Penn State– Dr. Tom Donnellan

• NAVAIR– Dr. William E. Frazier

– Dr. Eui Lee

• NAVMAR– Mr. Irv Shaffer

– Dr. Jeff Waldman

• Navy Metalworking Center(NMC)– Ms. Denise Piastrelli

– Dr. Daniel Winterscheidt

Chairpersons

• Rapid Prototyping– George Blasiole, Navy Metalworking Center

– Dr. Eui Lee, NAVAIR PAX Materials

• Repair Technologies– Robert Kestler, NAVAIR CP 4.0T

– Timothy D. Bair, ARL Penn State

• Green Manufacturing– Jose Jimenez, Ind. Compliance Dept. FRCSW

– Michele Pok, NAVAIR PAX Materials

– Ray Paulson, FRCSW

• Modeling and Simulation– Dr. Tom Donnellan, ARL Penn State

– Mark Traband, ARL Penn State

• Transition Hurdles– Dr. Jeff Waldman, NAVMAR

– Brian Riso, VLCOE CP

Plenary Speakers

• Mr. Richard Gilpin, NAVAIR AIR-4.3 Director, Air Vehicle Engineering Department

• Mr. John Johns, Deputy Commander Fleet Readiness Centers

• Mr. Thomas Laux, Program Executive Officer Air, ASW, Assault and Special Mission Programs

• Mr. Todd Mellon, NAVAIR AIR-6.7 Director, Industrial & Logistics Maintenance Planning / Sustainment

• Col. David Smith, Commanding Officer FRC East

• Mr. Greg Kilchenstein, Senior Sustainment Technology Policy Analyst, OSD(AT&L)

• Mr. John Carney, Director, Navy ManTech Program, Office of Naval Research

Aligned S&T Approach

• Sea Power 21

• NAE S&T Strategic Plan (July 2006)– Safety and Affordability Enablers (SAE) Capability Gap, STO-3

– Integrated Logistics Support (ILS) Capability Gap, STO-2

– Safety and Affordability Enablers (SAE) Capability Gap, STO-2

• NAVAIR Vision

• PEO(A) Rotorcraft Needs– Corrosion, Erosion, and Environmental Degradation were

identified as major O&S critical issues

Working Group CONOPS

• Five Discussion Groups

– Green Manufacturing

– Modeling & Simulation

– Rapid Prototyping

– Repair Technologies

– Transition Hurdles

• Led by Facilitator

– Selected audience (~20)

– Guided the discussion

GOAL

TECHNICALOBJECTIVES

TECHNICALCHALLENGES

RESEARCH APPROACHES

GOTChA Process

Navy Defined

Navy Defined, Workshop Validated

WorkshopDeveloped

• Prioritized list of technologies

• Viable approaches listed and prioritized for the near, mid, and far term.

< 5yrs; 5-10 yrs; > 10 yrs

Plenary

Working Groups

Idea Generation

& Prioritization

Post Workshop

Analysis & Synthesis

Technical

Needs,

Challenges,

and

Approaches

Product Generation

• Group output was consensus of experts

– Industry, Government, Academia

• Validated list of technical objectives

• For each Objective, specific challenges were defined

• For each challenge, potential technology approaches were proposed

Working Group Outputs

Attendance

Government Industry Industry Academia

•Air Force

•ARMY

•DARPA

•JSF

•NIST

•OSD

•ONR

•PEO(A)

• NAVAIR

•FRC

•3M Aerospace

•ALCOA Defense

•Battelle Memorial Institute

•Bell Helicopter

•Boeing

•Carpenter Technology

•CTC

•Dynamics Research Corp

•GE Aviation

•JENTEK

•KBSI

•Lockheed Martin

•METBLAST

•NanoTechLabs

•NAVMAR

•Navy Metalworking Center

•Northrop Grumman

•Spatial Integrated Systems

•Sikorsky

•Stratasys

•TRI

•Maven Group

•Connecticut Center for Advanced Technology

•Craven Community College

•Georgia Institute of Technology

•Institute for Maintenance Science & Technology , NC State Univ.

•North Carolina State University

•Penn State University

•Purdue University

•University of Virginia

Engaged discussion with 97 technical experts

Plenary Synopsis(Technology Needs)

•Diagnostics and Testing–Advanced NDI and automated testing

• Environmentally Sage Designs / Processes–Replacement for cadmium and chromium

plating processes –Alternate primer coatings eliminating

hexavalent chrome.• Reverse Engineering

–Ability to establish technical data package and replacement part in the absence of technical data

–Convert legacy 2D data to 3D data for computer-aided manufacturing.

• Predictive Maintenance–Real-time infrastructure and technology to

support knowledge-based maintenance decisions.

• Advanced Coatings–Resist corrosion & erosion degradation.

• Knowledge-based parts location capability–Ability to actively locate any asset at any time

• Distance Support–High-Speed Voice Over Internet Protocol and

high-resolution video.

• Lightweight materials• Mobile forward-based maintenance• Aircraft Battle Damage Repair (ABDR) – Key

Enabler–Develop portable, battle damage repair and

rapid manufacturing technologies.–The ability to repair battle damage with minimal

external support–ABDR manuals

• Readiness Modeling–Tools for reliability, sparing, and total ownership

cost–Cost Wise Readiness Integrated Improvement

Program (CWRIIP)–Evaluating Advanced Total Life-Cycle Assessment

Software Tool (ATLCAST)

Plenary Synopsis(Technology Needs)

•Composite Technologies–Improved characterization in dynamic

environment–Enhance producibility and reduce

variability–Critically examine composite qualification

requirements for cost-reduction opportunities.

–Articulate ROI based upon mission performance enhancements (due to weight reductions).

•Rapid Prototyping–Blade Repair

•Repair Technologies–Corrosion Repair–HVOF WCCo–Composite Repair

• Corrosion– Design in corrosion resistance– Corrosion smart designs

• Manufacturing– High Speed Machining of titanium– Gears– Design with repair in mind.

• Common Themes– Microstructural processing & modeling– Modeling & Simulation– Computational methods

• Improved Structural fatigue analysis techniques

• Maintenance repair data (Material Condition Assessment)

• Depot Maintenance (Schedule and Cost)

Green Manufacturing

Goal: Effect a 30% reduction in cost and 30% increase in through put, by accelerating the insertion of extant and emerging Environmentally Friendly Manufacturing Technologies

Objectives:

1. Increase the paint application rate 50% over the current baseline and reduce the Personal Protection Equipment (PPE) costs 30% or more.

2. Increase the rate of paint removal 25% over the existing baseline rate. Lower the solid waste (blast media) and industrial waste (chemical stripper rinse water) costs associated with Navy aircraft de-painting 50%

3. Reduce the defects 95% for metal finishing applications (e.g., hard chrome plating etc.) and reduce the Personal Protection Equipment (PPE) costs 30% or more.

Green Manufacturing

• Non-Chrome Primer (5-10 yrs)– Hexavalent chrome is toxic and carcinogenic– Non-chrome primers have not demonstrated acceptable corrosion results

• Environmentally Friendly Chemical Stripper (5-10 yrs)– Existing environmentally friendly stripper systems (benzyl alcohol based) work

too slowly.– Other strippers cause corrosion.

• Rapid cure polyurethane (5-10 yrs)– Top coats can require up to 7 days to cure. – Pot life is too short.

• Powder Coating & De-coating Process (1-5 yrs)– Coatings must be applied at high temperatures (350-400F) which can cause

damage to the substrate.– Coatings are tenacious and are not easily removable with chemical stripper

alone.

• Chrome Plating Alternatives (1-5yrs)– HVOF

Green Manufacturing Needs(Less than 5 years)

• Can be done immediately – Training – Video depicting proper painting methods– Implementation of Non Cr Conversion Coating – Recycle Waste Water

• Could be implemented in less that 5 Years– Painting technology

• Plural Component Paint System• Facility Needs: Reduce Make-up Air from 100% to 20%

– De-painting Technologies• Bio Blast, Barrier Coating, Powder Coat De-painting, Zirconium Blast

– Chrome Plating Technology and Alternatives• Conforming Anodes• Process Controller• Insulate and Cover All Plating Rinse Tanks • Separate Dry On-Off Air Controls for Each Tank

Modeling and Simulation

Goal: Effect a 30% reduction in cost and 30% increase in through put, by accelerating the insertion of extant and emerging Modeling and Simulation Technologies

Objectives:

1. Reduce the time and cost associated with developing work content/profile estimates for manufacturing and repair processes by 75% while increasing the accuracy of initial estimates by 25%

2. Reduce production line work in process (WIP) by 50% and increase throughput by 25% over the baseline process.

3. Reduce the time required to plan and implement proposed changes for manufacturing, repair, overhaul, or warehousing by 50%, with increased confidence.

Modeling and Simulation

• Generation of 3D models and associated meta-data from paper & raster legacy designs. (10 yrs)

• Automatic generation of simulation models from standard data formats (5-10 yrs.) is needed to ensure models maintain currency with changing product configurations – No standard input format is available for discrete event simulation

models. Such formats are needed to create and update models. – Develop discrete event modeling tools that can take this standard input

and automatically generate functional, accurate models form the data.

• Develop methods to assess the impact of platform condition & history on repair work content. (5-10 yrs.)– The work content required for a component, system, or end item is

highly dependent upon its condition upon induction. The challenge is to develop tools to better capture the operating history of an item.

Modeling and Simulation

• Repair and Overhaul engineering information must be consistent and adequate in level of detail. – As process capabilities change, semi-automatically regenerate repair

instructions (5-10 yrs) – Create an interactive, collaborative environment between

engineering and manufacturing / planning (5yrs)

• Affordable, easy to use, maintainable tools for developing on-demand, richer work instruction content. (5 yrs)

• Tools to analyze existing & historical usage data and lead time data and use results to improve part availability. (5 yrs)

• Develop data mining & statistical analysis tools for creation of process models.(5 yrs)

Rapid Prototyping Technology

Goal: Effect a 30% reduction in cost and 30% increase in through put, by accelerating the insertion of extant and emerging Rapid Prototyping

Objectives:

1. Cut procurement time (from need to part in inventory) by 50% with no sacrifice in geometry accuracy or properties for fatigue and non-fatigue. (Produce parts with least process steps and human intervention from "art to part." Fully integrate and automate RP processes).

2. Identify 5 components for repair using material additive processing that will reduce replacement cost by 60%

3. Provide for the production of aerospace components using Rapid Prototyping processes through the development of standard/general qualification procedures for all aerospace structural and propulsion components that are candidates for manufacture by RP processes.

Rapid Prototyping TechnologyDirect Digital Manufacturing (DDM) • Identified as the most promising technology to achieve cost and time savings.• There are a variety of DDM processes including Selected Laser Sintering (SLS), Laser Engineered

Net Shapes (LENS), Solid Freeform Fabrication (SFF), and Electron Beam Melting (EBM). • Permits components to be fabricated directly from digital media, e.g., CAD/CAM files.

Two DDM focus areas were identified• Direct Digital Manufacturing (DDM) process of Non-metallic Component Manufacture

– Low quantity non-metallic components that are non-stock, non inventory parts such as seals and gaskets or special purpose parts made of plastics or elastomers

• Direct Digital Manufacturing (DDM) process of Metallic Components– Applications include low volume, high value parts; components that are no longer

manufactured, repaired and refurbished; and new design prototypes.

Systemic Technology Needs• DDM modeling and simulation to relate processing to microstructure to properties. • Non-destructive Evaluation methods and tools, e.g., microporosity• A DDM Qualification and Certification Methodology which eliminates the need for component

by component certification.• Improved equipment reliability and reproducibility

Rapid Prototyping Technology Needs

• DDM of Metallic Materials– Gear “teeth” refurbishment (5-10 yrs)– Single crystal blade repair (5-10 yrs)– Blade and vane length recovery (0-5 yrs) – Housing repair. (0-5 yrs)

• DDM of Non-metallic components– Gaskets and Polymeric seals (0-5 yrs) – Carbon fiber reinforced (0-5 yrs)

• Standard Engineering Process Specification and Joint Qualification Standards (5-10 yrs)

• Equipment Reliability and Repeatability (0-5 yrs) • NDE (0-5 yrs)

– micro-porosity, acceptance criteria

Repair Technology

Goal: Effect a 30% reduction in cost and 30% increase in throughput, by accelerating the insertion of extant and emerging Repair Technologies

Objectives:

1. Implement structural repair technologies that will increase throughput by 100%

2. Implement technology to improve / achieve material state awareness at an annual cost savings of 50%

3. Implement corrosion control technologies that will double the time between required maintenance intervals and reduce maintenance cost by 50%

Repair Technology

• Additive Material Restoration (10 yrs)

– Use of DDM and other techniques to repair and restore structural components

• Damage assessment (10 yrs)

– Smart coatings for corrosion and fatigue damage (10 yrs)

– NDI technologies for inspection through coatings and/or multiple structural layers (5-10 yrs)

• State of health determination (10 yrs)

– Modeling and data interpretation / damage assessment

– Condition based maintenance (CBM) technologies

– Wide area sensing for structural health determination.

• Alternative Coating Systems (5-10 yrs)

– HVOF, Cold Spray, Cladding Alternatives.

Transition Hurdles

Goal: Effect a 30% reduction in cost and a 30% increase in throughput by significant decreases in the non-technical hurdles to technology insertion

Objectives:

1. Improve processes that could increase technology insertion by 50%.

2. Assure that 100% of the efforts needed to insert technologies are properly resourced

3. Reduce the time associated with the qualification, certification and insertion of new technologies by 80%.

Transition Hurdles

• There is a lack of visibility into the current processes, policies, and funding mechanisms being used to develop, qualify, and implement new cost saving maintenance technologies.– Establish an NAE policy and integrated NAE process for

technology insertion into the maintenance environment.– Establish and properly resource a technology transition

program manager.

• The process of qualifying and certifying new technologies is unclear, cumbersome, and costly. – A clearly defined processes are needed in which

certification requirements are fully developed up-front.

Transition Hurdles(Individual Working Groups Input)

Green Manufacturing 1. Lack of funding and funding gaps

related to a) funding cycle, b) color of funding and c) CIP threshold

2. Engineering Approval Process3. Technical Manual Changes4. Environmental and Safety Laws

and Regulations5. Public Affairs (public perception)6. Facility Logistics (infrastructure

availability)/Equipment Readiness7. Training (knowledge, skills and

abilities)

Modeling and Simulation1. Lack of training, time, and

funding2. Lack of engineering talent with

industrial and manufacturing experience. Engineer are too removed from the realities of depot and manufacturing environment.

3. Lack of cost-based data and metrics supporting M&S implementation

4. Long development times and extended acquisition cycle

5. DMS obsolescence

Transition Hurdles(Individual Working Groups Input)

Rapid Prototyping 1. The lack of an effective rapid

prototyping qualification process. 2. The price and availability for

single part replacements related to the economics of material quantities, tooling, set up, and production scheduling.

3. The cost and time associated with multiple sourced contracting for scanning, modeling, and manufacture.

4. Availability of OEM data and the need to protect proprietary data

5. Vendor certification6. Technical data exchange

Repair Technologies1. Resources for equipment and

equipment installation and facility modifications

2. Training (Fleet & Depot personnel)

3. Technical Instruction Changes4. Intransient internal culture

(We’ve been doing this for years…)

5. Logistics of implementation (Configuration Control of affected parts/systems)

6. OEM resistance and impediments7. Performance based logistics

contracts8. Information Technology not

allowing

Actions and Recommendations

• Initiate two AirSpeed Projects based on issues identified in the Non-technical Transition Hurdles Working Group– Technology insertion project should be jointly sponsored by the CTO and FRC.

– The Qualification & Certification project should be sponsored by the CTO with full participation by 4.3 and 4.4.

• Focus Command resources on the high payoff technologies identified in the working groups, for example– Direct Digital Manufacturing

– Condition Based Maintenance (CBM) and damage assessment technologies

– Non-Chrome primers, environmentally friendly strippers, and rapid cure polyurethane paints.

– 3D model generation from legacy data; methods to assess work content based upon platform condition and history

– Gear tooth repair; single crystal blade repair; transmission housing repair; blade and vein repair.

Path Forward

• Continue post workshop analysis

• Brief Stakeholders

• Write and disseminate report

• Advocate AirSpeed Projects for Non-technical Transition Hurdles

• Pursue sponsorship for high payoff technologies.