The following CTMA projects were recently approved:

Corrosion Resistant Solid State Thin-Walled Component Joining for Maintenance and Repair Applications

This project is specifically targeting one of the more challenging classes of weld repair and fabrication – thin-walled components.  Thin-walled components often require the use of the highest skilled welding artisans within the depot infrastructure due to the intricate nature of avoiding burn through and component thermal warping.  To avoid this, thin-walled components (common in nearly every military platform) are often over-engineered or buttressed with thicker metal reinforcements.  These countermeasures add significant unwanted weight to the platform and also increase the corrosion prone weld filler regions that results from conventional welding.  This project seeks to develop and test a new solid state joining method that does not melt the materials to be joined thus increasing dimensional accuracy, corrosion resistance, and weld cycle time.

The new state-of-the-art technology to be explored in this project stems from the use of a novel manufacturing method called Deformation Resistance Welding (DRW), which can be utilized to join a wide variety of thin-walled components common to virtually every DoD platform.  Further, the DRW technology can be readily retrofitted into any depot facility for rapid utilization as the fundamental technology is based upon the well-known principles of resistance spot welding yet applied to large components of many shapes and sizes.

Improved Stealth and Lower Cost Operations for U.S. Naval Ships using High-Performance Cordage Deck Edge Netting

The U.S. Navy uses two styles of deck edge netting:  metallic cord netting that is durable but very heavy and difficult to repair shipboard as well as add to a ship’s radar cross section.  The other netting that is used is nylon netting that is lightweight and has no radar signature but need to replaced every 18 to 24 months due to UV degradation, shrinkage and abrasion.  This project will evaluate a new cordage net that is lightweight, has no radar signature and has a Navy tested life of five years. This netting is machine-made and promises reduced lifecycle cost. 

Aerospace Engineering & Manufacturing Magazine has a great article highlighting the success of the award-winning NCMS-CTMA Volumetric Accuracy for Large Machine Tools (VALMT) project.

...One of the most vexing catch-22s in large-part machining appears to have finally been caught. Rapid volumetric compensation for high accuracy in large-scale five-axis machining is now within the grasp of the manufacturing community.

Why is this significant? Large components are often painstakingly crafted from numerous smaller components because the best machining technologies are not accurate enough to achieve the tight tolerances on large monolithic parts that could reduce part count and assembly time

...A joint project of the National Center for Manufacturing Sciences called Volumetric Accuracy for Large Machine Tools (VALMT)—involving Mag Industrial Automation Systems, Automated PrecisionInc. (API), Boeing, and Siemens—recently completed development of a rapid, and hence game-changing, approach to volumetric error compensation. Created especially for large and multi-axis machines, the system achieves the goals set by the design consortium: to reduce the downtime needed to determine necessary volumetric compensations from weeks to a day or less via a simple automated process that improves a machine tool’s volumetric performance by 50% or more.

Full Article

VALMT Podcast

Photos from the 2010 Commercial Technologies for Maintenance Activities Symposium.

 Register Now!

Early Bird Discount ends 2 MAR, Room Block ends 3 MAR

Ever wonder how technology requirements are identified
 in DoD maintenance facilities?

Do you think you have a solution to one of their key sustainment needs?

The 2010 CTMA Working Symposium highlights sustainment requirements, ongoing DoD projects addressing some of these needs, and interacting with the leaders in the DoD and industry responsible for improving weapon system sustainment.

This event offers the unique opportunity to network with technology providers while displaying technology to Department of Defense (DoD) personnel.

Speaker Spotlight

MG Nickolas G. Justice, U.S. Army Research and Engineering Command, (RDECOM).  As the commanding general of RDECOM, MG Justice leads a worldwide organization of more than 17,000 scientists, engineers and other professionals who keep the Army on the cutting edge of technology through the operation of subordinate research and development centers and laboratories

Agenda Highlights

• Insertion Requirements Workshop- What IS and What IS NOT a requirement? This workshop will identify what the process is for generating and budgeting for a
  requirement.

• Project Tracks- Coatings/Corrosion Control, Inspection/Test, Environmental, Workload/Workforce/Material Management, Metal Working, Manufacturing, Composites.

• Project Briefs- DoD sponsored programs highlighting new technologies focusing of sustainment of legacy platforms.

• Evening Reception- Networking including tabletop technology displays.

Early Discount Registration   Draft Agenda

 

Special thanks to our sponsors!

For more information please contact:

Debbie Lilu, debral@ncms.org, 734-995-7038.

Location: The Clubs at Quantico, Marine Corps Base, Quantico, Virginia.

Expect to learn about the services technological needs, discuss the new technology roadmap now under development, and to review current CTMA project efforts in addition to tabletop displays and extensive networking opportunities. Stay tuned for more information.

For more information please contact:

NCMS Program Manager Debbie Lilu at (734) 995-7038 or debral@ncms.org

The NCMS-CTMA project, Laser Coating Removal of Composite Helicopter Blades, has successfully installed the paint stripping unit at Cherry Point, which is certified for production use. We welcome people interested in seeing this unit work in production as we celebrate with a ribbon-cutting ceremony at Cherry Point, North Carolina.

The ribbon-cutting will include remarks by RDML Tim Matthews (COMFRC/AIR), Col.Scott Loch (Commander FRC East), CAPT Stephen E. Iwanowicz (Commander, NUWC Division Keyport) as well as testimonies from the artisans from the paint stripping shop. Following the ceremony, attendees are invited on a tour of the FRC East facilities in the afternoon.

For more information please contact:

NCMS Program Manager Debbie Lilu at (734) 995-7038 or debral@ncms.org.

Current decontamination methods used by maintenance personnel result in exposure to dangerous chemicals and pose disposal problems.

We propose to develop and prototype a state-of-the-art automated cleaning system for weapons components, with applicability to aviation, transportation and other industry applications.  Using surface chemistry modeling methods and analysis of existing component substrates, and considering specific contaminants of each component, HPC computer modeling will pre-determine the chemical agents required to affect optimum cleaning with minimal waste generation.  The prototype cleaning system will be capable of mixing the precisely determined chemical solutions designed to break down the specific hazardous substances on contaminated, reusable components.  What we call the “C5” Unit (Chemical Composition Cleaner for Contaminated Components) will employ techniques such as high voltage ionization, phased plasma and/or ultrasonic principles, coupled with applicators, attachments, or enclosures designed specific to user needs. 

A prototype portable, on-site hazardous waste treatment system will be developed; utilizing the onboard chemical elements and/or heat, this unit will completely neutralize or effectively reduce known byproducts generated by the cleaning phase.  (The vehicle may vary dependent on specific industry/component requirements). This will further reduce personnel exposure (for example, in the case of torpedo cleaning, by eliminating the requirement for worker-staffed deep sinks and manual hazmat-grit removal) and waste generation. 

We will test the prototype and analyze by-product levels to meet EPA safe levels.

This project currently seeks commercial and Department of Defense participants with an interest in aerospace; heavy equipment/auto repair; military aircraft/ship/mechanized overhaul and weapon turn-around facilities.

For additional information contact:

NCMS Program Manager, Jeff Walker, jeffw@ncms.org (360) 782-1370, or Heidi Hottinger, heidi@ncms.org (360) 782-1370

The safe disposal of retired naval vessels poses a huge environmental challenge.

This project will provide alternative green metal cutting methods for use during vessel disposal to reduce metal fume emissions in full compliance with Washington State and Puget Sound Clean Air Agency opacity requirements, Federal Clean Water Act, and to reduce costs during the cut-up phases of aircraft carrier disposals.

Several technologies will be evaluated as potential replacements for oxy-fuel cutting. Abrasive Water-jet cutting, inert gas, laser, mechanical cutting, and machining are potential replacement methods.  Process improvement methods will also be evaluated in an effort to control emissions from both oxy-fuel and other traditional cutting methods. Each possible replacement or improvement comes with its own unique set of problems and challenges to overcome. These challenges include efficiency, hazardous waste by-products, and other safety and environmental issues.

This project currently seeks commercial and Department of Defense participants with an interest in the disposal of naval vessels.

For additional information contact:

NCMS Program Manager, Dana Ellis, danae@ncms.org (360) 782-1370

Congressman Pete Hoekstra (R-MI) talks with NCMS President & CEO Rick Jarman and Koops, Inc. founder Wesley Koops