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
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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
• 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%
– 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
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