NCMS Final Reports

Project 140367, 8/06
Advanced digital fabrication rapid prototyping (ADF-RP) rapid tooling technologies offer an economical and time-saving solution to the legacy and obsolescent part supply and repair issues being faced today throughout the maintenance and supply systems. Comprehensive investigations of ADF-RP technologies and their applications included:  Benchmarking State-of-the-Art, Standards, Software/Data Capture, System Developments and Integration, Material Developments and Application, Advanced Digital Fabrication, and Technology Transfer.
NCMS Member – $100.00
Non-member – $150.00

Project 140407, 4/08
Assembly/disassembly planning and documentation remains a manual process that is often dependent on the skill and experience of the individual defining the process. This project utilized commercial software solutions integrated with technology developed. Initial trial of the system achieved reductions in assembly process planning cycle times from about 30 days without the automation developed in this project to 15 days with it.
NCMS Member – $100.00
Non-member – $150.00

Project 140433, 12/10
This project developed and deployed automated test equipment for night vision tubes which as the ability to replace the outdated manual test equipment presently used by government and industry. This capability will reduce cycle time for returned night vision devices and significantly reduce costs by increasing the reuse of image intensifier tubes.
NCMS Member – $100.00
Non-member – $150.00 Available 6/13

Project 140421, 10/12
The Commercial Technologies for Maintenance Activities (CTMA) Automated Process & Inspection Guide (AP&IG) Phase I project standardized both the inspection data and the inspections process for depot maintenance facilities. It utilized Aspire Solutions, Inc (ASI) commercial off-the-shelf (COTS) software application combined with COTS ultra-mobile PC technology to guide the user through the inspection process (improve accuracy) and standardize the defect data (enhance analysis capabilities).
NCMS Member – $100.00 Available 4/14
Non-member – $150.00 Available 4/15

Project 140375, 6/12
Since automatic test system test stations are employed throughout the DoD maintenance hierarchy, the transition from traditional instruments to synthetic instrumentation presented a significant opportunity to mitigate hardware obsolescence, reduce the equipment footprint, improve adaptation to emerging requirements and reduce the overall lifecycle cost of automatic test systems. Performance was benchmarked against the legacy U.S. Air Force F-15 Electronic Systems Test Set (ESTS).
NCMS Member – $100.00 Available 12/13
Non-member – $150.00 Available 12/14

Project 130171, 5/12
Work demonstrated the feasibility of manufacturing an automotive component in titanium, with such components integrated to critical areas of vehicle design for reducing mass and improve fuel efficiency.
NCMS Member - $100.00
Non-member - $150.00

Project 130171, 5/12
Validated high performance computing simulations enabled the detailed scrutiny of the multi-level, multi-variable design-space of machining titanium alloys from a profitability standpoint, which was otherwise not feasible to explore through cutting experiments alone.
NCMS Member - $100.00
Non-member - $150.00

Project 170609, 7/06
Painting operations release large quantities of solvent vapors into the atmosphere. Painting operations can constitute a facility’s single biggest environmental impact, with the greatest associated environmental compliance costs. This project developed a fundamentally new biological design, from initial concept to a pilot model tested on an operating paint line expected to operate at 25% of the cost of a thermal oxidizer.
NCMS Member – $100.00
Non-member – $150.00

Project 140390, 7/08
A prototype of an Intelligent Casting Cost Advisory system that reuses existing casting knowledge to provide users with real-time advice on “should costs” and selection of optimal casting process based on part-design criteria was developed. It is a key technological breakthrough that makes capture of practical production information in a knowledge-based system possible having a significant impact in all facets of the design, development, manufacture and support of current and future weapon systems.
NCMS Member – $100.00
Non-member – $150.00

Project 140420, 7/09
The Centralized Fleet Asset Management System (CFAMS) is a wireless fleet management hardware and software solution designed to optimize operations (both remanufacturing and supply), decrease maintenance costs, while improving equipment readiness, optimize fleet size, reduce vehicle and facility damage, and dramatically improve overall safety. Because CFAMS automatically captures motion hours, as well as movement with load data, the system enables changing to motion, or condition-based preventative maintenance.
NCMS Member – $100.00
Non-member – $150.00

Project 125247
This project provided a proof-of-concept to extend lifecycle maintenance and repair of fleet assets using existing test adapters, interfaces, and legacy software code. Innovative software translated and re-hosted five test program sets, written in obsolescent dialect, into modern test equipment.
NCMS Member – $100.00 Available 8/13
Non-member – $150.00 Available 8/14

Project 140324, 9/05
Traditionally maintenance has followed the philosophy of either run-to-failure or planned maintenance at regular intervals. Each of these approaches has been found to be more expensive and time-consuming when compared to condition-based methods, under which the condition of a machine is monitored and maintenance is only undertaken if conditions warrant it. This method equally applies to manufacturing processes where the settings of some machines or components may need to be altered based on the monitored condition of the process.
NCMS Member – $100.00
Non-member – $150.00

Project 140399, 2/09
Flight deck non-skid coatings must withstand extreme service conditions, including impact, abrasion and exposure to organic fuels and lubricants. Coatings were developed that met or substantially exceeded all MIL-PRF-24667B(SH) requirements for Type I (High-Durability) and Type V (Extended Durability) non-skid coatings.
NCMS Member – $100.00
Non-member – $150.00

Project 140167, 12/04
With defense electronic equipment lifetimes of 20 years or more, almost all such systems will, before the end of their useful life, encounter a situation where a component needed for repair is no longer available from routine stock. The current solution is for estimators to spend hours, even days, telephoning potential suppliers. This project sought to develop a web site to which estimators could post lists of parts sought, listed by project, and broadcast notifications of new posts to a list of potential suppliers. Suppliers could then scan the parts list and enter budgetary estimates of part prices for any parts they could supply. The estimator could then provide a much more accurate and timely estimate of the cost to repair a given system.
NCMS Member – $100.00
Non-member – $150.00

Project 140328, 8/06
The EWIS project provides improved commercially-available test systems to enhance the troubleshooting and testing capabilities of the maintainers and ultimately improving the overall integrity of electrical wiring systems. This technology is embodied in a handheld, easy-to-use, meter enabling the operator to rapidly connect, detect and locate hard faults in wiring assemblies. The unit performs a test in four seconds, displays the fault location in human readable characters and has computer-based training that requires only 45 minutes to complete. Personal computer-based SWR software utilities provide the ability to download from the meter, via serial bus, test waveforms for analysis.
NCMS Member – $100.00
Non-member – $150.00

Project 140430, 10/11
Quick identification of the faulty wire path and location of the fault assists greatly in providing increased mission readiness. EWIS I was centered on a reactive maintenance posture that was practiced at all maintenance levels. EWIS I effectively incorporated the use of the EWIS technology in the established reactive maintenance environment. EWIS II, also funded through the NCMS/CTMA Program, targeted implementation of new methods of electrical inspection to help foster a proactive posture. Multiple test protocols and other prognostic test approaches were implemented in EWIS II for feasibility in the DoD maintenance community. The equipment delivered under EWIS II is scalable and open architecture, which enables integration of future test capabilities and technology enhancements.
NCMS Member – $100.00 Available 4/13
Non-member – $150.00 Available 4/14

Project 125261, 7/12
This project sought to develop alternative environmentally friendly cutting methods and explore new methods of reducing emissions in order to comply with air operating and water discharge permit requirements at Puget Sound Naval Shipyard & Intermediate Maintenance Facility (PSNS & IMF). It included investigations of alternate oxyfuel gas cutting and equipment as well as alternate cutting processes, such as plasma arc cutting and laser cutting.
NCMS Member – $100.00 Available 1/14
Non-member – $150.00 Available 1/15

Project 140379, 7/11
This project is leading to a paradigm shift in the approach to the autoclave curing of composite parts. Improvements in computer power and sensors now enable higher quality composite manufacturing, and greatly reduced scrap as well. This project developed and tested tools to manage heat transfer for ovens and autoclaves used in the production and repair of composites.
NCMS Member – $100.00
Non-member – $150.00 Available 1/14

Project 160207, 1/04
This project resulted in the development of high-speed commercial metrology grade digital shape scanning system. The system does not require special lighting, or use of coatings in many applications, to enable inspection at the point of need without transporting parts to dedicated central inspection areas. Cycle time reductions gained resulted in the need for less pipeline inventory and greater availability. Accuracies of 0.002” were attained to improve quality and reliability. The system is applicable to many other depot and commercial applications.
NCMS Member – $100.00
Non-member – $150.00

Project 140396, 10/08
The purpose of this project was to develop the assembly process and to test the reliability of using the emerging higher-density surface-mount technology (SMT) devices and the chip-on-board (COB) die on the same printed circuit board with conventional SMT parts. Because of the much smaller and tighter traces and solder pads of this technology, development of the rework/repair processes is a significant capability need for industry and the DoD depot community. This report documents the results of designing, manufacturing, populating, assembly rework and reliability testing of printed circuit boards populated with the variety of high-density components using advanced SMT.
NCMS Member – $100.00
Non-member – $150.00

Project 150339,  8/04
In Phase III cutting processes were developed for components made of titanium, 5 axis feature recognition improved, and provision was made for embedding in automated NC output special functions such as torque controlled machining and probing cycles.3 Volume Set includes:

1. High Throughput Production Processing of Five (5) Axis Aluminum Components (HITHRU) Final Report.
2. High Throughput Production Processing of Five (5) Axis Titanium Components III (HITHRU III) Final Report.
3. High Throughput Production Processing (HITHRU) Aluminum Part Deployment Final Report.

NCMS Member – $100.00 Set-$200
Non-member – $150.00 Set-$300

Project 140368, 12/04
In the HITHRU Deployment phase the system was used for real production parts at WR-ALC.3 Volume Set includes:

1. High Throughput Production Processing of Five (5) Axis Aluminum Components (HITHRU) Final Report.
2. High Throughput Production Processing of Five (5) Axis Titanium Components III (HITHRU III) Final Report.
3. High Throughput Production Processing (HITHRU) Aluminum Part Deployment Final Report.

NCMS Member – $100.00 Set-$200
Non-member – $150.00 Set-$300

Project 140384, 1/06
Conventional chrome plating process is slow and expensive. Parts must first be masked so that only the desired areas are plated, a time-consuming task that must be performed by skilled artisans. Chrome in a standard plating setup is deposited slowly and unevenly, requiring extensive machining to bring parts back into tolerance. The extra labor contributes significantly to the overall turnaround time and cost of aircraft refurbishment. This project demonstrated the ability of a new development, “no-mask” tooling, to eliminate labor for masking, and to achieve much faster plating times and more uniform chromium deposits. The quality improvement and cost savings were so dramatic that no-mask tooling was adopted for standard production while the project was still underway.
NCMS Member – $100
Non-member – $150

Project 140403, 7/07

The no-mask concept is relatively new to chromium plating. It involves the design/fabrication of a rack and anode fixture, which are customized to particular parts. The main advantages of this approach are reduced labor for masking, faster plating times and more uniform chromium deposits. Hard chromium plating provides superior wear resistance for a wide variety of surface geometries. During Phase II, custom no-mask anodes were designed, fabricated and implemented for an additional six frequently plated aircraft parts (two during Phase I and six during Phase II), plus design changes were made to one of the Phase I anodes. Also during Phase II, generic tooling was developed for several less frequently plated parts.

NCMS Member - $100
Non-member - $150

Project 140403, 7/07
The no-mask concept is relatively new to chromium plating. It involves the design/fabrication of a rack and anode fixture, which are customized to particular parts. The main advantages of this approach are reduced labor for masking, faster plating times and more uniform chromium deposits. Hard chromium plating provides superior wear resistance for a wide variety of surface geometries. During Phase II, custom no-mask anodes were designed, fabricated and implemented for an additional six frequently plated aircraft parts (two during Phase I and six during Phase II), plus design changes were made to one of the Phase I anodes. Also during Phase II, generic tooling was developed for several less frequently plated parts.
NCMS Member - $100
Non-member - $150

Project 140404, 3/07
The objective of this project was to introduce new electrodeposited hard chrome plating equipment into Naval Air Systems Command (NAVAIR) Depot North Island maintenance activities, including advanced racks, fixtures, and anodes. New prototype tooling was designed, fabricated and tested and changes in production parameters, including costs and process steps were measured and documented. The results of this project will enable plating facilities to produce higher quality parts with substantially less time and effort than was possible with previous technology.
NCMS Member - $100
Non-member - $150

Project 140448, 7/12
The Total Life Cycle Systems Management Assessment Software Tool (TLCM-AT™) was used to run “what if” scenarios on maintenance, logistics, policies, removal of parts for repair; and spare consumption for return on investment in terms of readiness and costs for secondary repairable items.
NCMS Member - $100 Available 1/14
Non-member - $150 Available 1/15

Project 140432, 6/12
The primary objective for this project was to extend the use of High-Performance Cordage Deck Edge Netting (HPC DEN) in lieu of nylon strap netting by installing developmental square HPC DEN Spectra/polyester cordage aboard a U.S. Navy test vessel.
NCMS Member - $100 Available 12/13
Non-member - $150 Available 12/14

Project 140350, 7/12
Phase I of the project identified computer controlled advanced technologies including digitizing, shearography, ultrasonic photo imaging, microwave, mechanical impedance that can be integrated into an automated work cell to detect defects, moisture, and delaminating with the capture of historical data in digital form. While the IRPC project focused on the C-130 Radome, the work cell will be applicable to the repair of many different types and sizes of large composite structures such as helicopter side panels.
NCMS Member - $100
Non-member - $150

Project 140418, 4/11
The Electronic Performance Support System (EPSS) provides CH-53E helicopter maintenance technicians with a seamless prognostic, diagnostic, and repair suite that measurably increases the readiness and availability of the aircraft while reducing or eliminating associated maintenance expenditures. Phase II of the project further developed EPSS content pertaining to three additional CH-53E systems: Flight Controls, Propulsion, and Transmissions (TM series 140, 220, and 260 respectively).
NCMS Member - $100
Non-member - $150 Available 10/13

Project 140394, 7/11
The primary objectives in Phase II were to overcome scale-up and technical integration issues and to deliver an operational ARBSS for test, evaluation, and eventual production. This report summarizes the work conducted under the Phase II effort summarizing the design requirements and overall system design, then provides details of the laser workhead, the integrated robotic system, and the user interface
NCMS Member $100.00
Non-member $150.00 Available 1/14

Project 160216, 1/06
This project sought to develop a novel replacement for lead- (Pb) based solders. The focus of the material for development was a copper- (Cu) based ICA for use in the Electronics Industry, since there was a resolute market drive to eliminate lead-containing solders from all commercial electronics. During this ICA project, the team investigated two different methods to apply the ECORAP (electrically-conducting, oxidation-resistant adhesion promoter) coating without agglomerating the particles using scaleable processes. The successful demonstration of a scaleable vapor process was pursued with a fluidized bed reactor, while the solution coating process was demonstrated using a stirred-tank reactor.
NCMS Member - $100
Non-member - $150

Project 140435, 12/10

The Department of Defense (DoD) in 2003 mandated that all parts meeting specified criteria receive Item Unique Identifier (IUID) marks. The mandate can be relatively easily implemented for new acquisitions, but the non-recurring engineering (NRE) cost for updating the technical data for hundreds of thousands of legacy National Item Identification Numbers (NIINs) and physically marking millions of legacy parts in inventory is a daunting task. To address at least a significant portion of the total legacy part issue, an automated IUID Engineering Change Order (ECO) process was successfully developed under this IUID project.
NCMS Member - $100
Non-member - $150 Available 6/13

Project 140382, 6/07
Restoration of metallic surfaces plays a significant role in maintenance activities for both military and commercial applications. A variety of technologies are used in an effort to thwart corrosion. Kinetic spray technologies overcome a number of traditional spray “shortcomings.”  Kinetic spray deposition does not rely upon molten droplets that impact the surface and then solidify. Instead, the particules are accelerated, impact the surface, deform plastically, and cold fuse to the surface. This results in a better surface coating with less oxidation and higher density. Centerline’s Fusion Series 3800 system was successfully evaluated for this project. Additionally, the technology is amendable to portability, meaning the potential to use this technology in intermediate and field operations.
NCMS Member $100.00
Non-member $150.00

Project 140347, 7/05
The removal of paint from H53 and H60 main helicopter rotor blades is a labor intensive, expensive and environmentally sensitive operation. Determined to improve this process with advanced laser and vision systems, the Automated Robotic Blade Stripping System (ARBSS) team developed a proven automated robotic laser paint stripping technology that strips helicopter blades 75% faster than traditional methods, with practically zero error.
NCMS Member $100.00
Non-member $150.00

Project 140211, 12/06
As tanks, ships, submarines, and aircraft continue to operate beyond their intended life, part obsolescence management becomes an increasing challenge for asset sustainment, compromising military readiness. This project further developed the additive metal process, laser engineered net shaping, into a more robust system designed to repair a wider variety of parts vital to weapon systems readiness.
NCMS Member $100.00
Non-member $150.00

Project 140412, 5/10
To assist ballooning processes, the project team developed intelligent Optical Character Recognition (OCR) technology with a dictionary that includes General Dimensioning and Tolerancing (GD&T) symbols as well as both machine generated and handwritten alpha-numeric symbols. Artificial intelligence built into the OCR technology allows it to “learn” with use so that recognition accuracy improves over time. A key feature of the solution is that it divides the drawing into zones, separating drawing from title and notes blocks, which enables the use of specialized dictionaries for each zone, also improving recognition accuracy. To demonstrate a secure supplier collaboration environment, the project team leveraged learning from the Transatlantic Secure Collaboration Program (TSCP) which had already defined the requirements and architecture for a web-enabled system.
NCMS Member $100.00
Non-member $150.00

Project 140352, 5/05
Efficient logistical support and timely effective repairs, while critical to ensure that equipment is combat read, have become increasingly complex and difficult to manage. This project delivered advanced sensor and energy management technology installed on two Light Armored Vehicles (LAVs). An off-board diagnostic tool demonstrated the capability of performing a “health check” on the vehicle. Also demonstrated was on-LAV communication via an on-board capability to send “health check” data to the Depot Data Center for immediate action on the affected vehicle.
NCMS Member $100.00
Non-member $150.00

Project 140392, 7/07
The Phase II project objective was to develop, demonstrate and evaluate tools and techniques necessary to support Sense & Respond concepts in the LAV community. Asset health monitoring was refined and a support infrastructure was established to being to make use of the data collected. The results of the LAV II project have moved us markedly closer to the ultimate goals which are developing reliable prognostics, realizing true CBM, providing greater situational awareness at every level, and increasing operational availability across the fleet.
NCMS Member $100.00
Non-member $150.00

Project 140431, 5/10
LAV III was the third phase of the PM-LAV strategy to embrace Logistic Modernization and build on knowledge gained during the LAV Condition-Based Maintenance (CBM) Life Cycle Logistics Support Tool project. Asset health monitoring and the required support infrastructure were refined to enable scalable and web-based access to the end user. Sense & Respond saw the maturation of the Joint Asset Management Information Support System (JAMISS) as a tool designed to enable presentation of vehicle data in a coherent fashion in a scalable format for the end user. LAV III validated the “Best in Breed” selection of hardware, software and firmware designed to meet the PM’s requirements for a system designed around flexibility and reliability in the end-to-end Enterprise architecture environment.
NCMS Member $100.00
Non-member $150.00

Project 140438, 10/11
During this project the CTMA team worked to expand the concept of asset health monitoring; build an understanding of what data, and how much data is useful; explore means of translating data to knowledge; and disseminating that knowledge to those who need it, in a usable format. The project was unexpectedly stopped prior to completion “for the convenience of the government” causing inconclusive results and incomplete deliverables through no fault of the CTMA team. Although the project was truncated, significant progress was made in many of the technologies that will be necessary to enable CBM+ and Autonomic Logistics.
NCMS Member $100.00 Available 4/13
Non-member $150.00 Available 4/14

Project 130174, 1/12
This project exploited attributes of the dicyclopentadiene (DCPD) for liquid resin infusion process and demonstrated the feasibility starting with applied research (TRL 2) through technology development and lab testing of components/process (TRL 4). Results provide evidence that performance targets may be attainable based on projected or modeled systems.
NCMS Member $100.00
Non-member $150.00 Available 7/14

Project 140395, 7/05
The team developed, built, and tested for basic functionality a prototype Mobile-PMD™ system for repair and reclaiming damaged large thin wall engine or large curved surface components. This technology is geared towards larger area repair and portability. The initial tests of Phase I Mobile-PMD™ process prove the feasibility of the system of performing the intended repair/reinforcement operations on large components with suitable mechanical and metallurgical characteristics.
NCMS Member $100.00
Non-member $150.00

Project 140447, 7/12
The Total Life Cycle Systems Management Assessment Software Tool (TLCM-AT™) is a high-resolution, discrete event, stochastic simulation platform designed specifically for representing the full-system life cycle of vehicle fleets. It was utilized for this project to determine provisioning needs for a fleet of vehicles during specific operations and scenarios.
NCMS Member $100.00 – Available 1/14
Non-member $150.00 – Available 1/15

Project 140429, 6/09
The project scope concentrated on developing a methodology with limited capabilities for the ISMLT (Intelligent system for Modernizing of Legacy Tech-Data) prototype. The project led to development of unique software tools that showcased the capability of “stitching” together raster drawings and extracting shapes out of the raster images.
NCMS Member $100.00
Non-member $150.00

Project 140425, 5/10
The latest in a series of four projects involving implementation of revolutionary commercial electroplating methods that results in improved product quality and major cost savings at military depots. The initial three projects successfully applied approaches to hard chrome plating, while this project successfully extended the concept to nickel electroplating. During the project, innovative masking and nickel electroplating methods were designed and tested on aircraft parts requiring refurbishment.
NCMS Member $100.00
Non-member $150.00

Project 150501, 12/07
The project targeted the need to replace manual operations with automated dimensional measurement, and numerical control machining, for the repair of compressor airfoils. Machining studies were performed to develop tooling and machining approaches. A five-axis machining center was built and successfully tested. Long delays were experienced in attempting to resolve data transformation problems and the project was terminated.
NCMS Member $100.00
Non-member $150.00

Project 140331, 8/04
Whether it is a crucial broken part where no computer model or even drawings are available, or a maintenance technician in a tight airframe crawlspace needing information to diagnose a new problem just identified, the problem is timely access to technical data. The OptiCAM/I-POMX project focused on two seemingly disparate functions; 3D imaging for reverse engineering applications (OptiCAM) and the integration of a powerful tool for mobile access to an information system that can deliver work control documents and technical data to the point-of-maintenance (I-POMX).
NCMS Member $100.00
Non-member $150.00

Project 140331, 12/05
The OptiCAM portion of this project made significant advancements during Phase II. Scan accuracy was improved from 0.025 to 0.012 inches and the reverse engineering process itself was significantly improved. The I-POMX system was enhanced for the pilot by adding software that allowed a user to disconnect from the network, perform work using a local database as if he/she remained connected, and then automatically synchronizing both local and network databases on reconnection to the network.
NCMS Member $100.00
Non-member $150.00

Project 140409, 2/10
With weapons systems held in service well beyond their originally intended lifetime, parts fail or wear to the point of rendering the system mission incapable. Depots often find themselves needing to make replacements. All too often the technical data for a needed part is either missing or incomplete. For those cases, the depot must reverse engineer the part, constructing a Technical Data Package sufficient to manufacture the part. The project achieved three goals: Portable, rugged and low cost but accurate scanner; Easy transformation of “Cloud of Points” to 3D solid model; Development of a complete Reverse Engineering environment.
NCMS Member $100.00
Non-member $150.00

Project 140414, 6/09
A lack of immediate knowledge about oil quality leads to heavy costs when oil is changed either too soon or too late. Changing oil at the right time can only be done if the physicochemical properties can be determined accurately and precisely at the time the condition merits it. The objective of this project was to develop a commercialized product marketable to both DoD and the private sector. Successful development of a field-ready, commercialized, marketable portable/handheld oil assessment device suitable for real-time oil assessment by mechanics in the field was a project result.
NCMS Member $100.00
Non-member $150.00

Project 140397, 6/07
The project resulted in development of a commercial metrology guide scanning system that has been successfully installed for production applications. The commercial scanning system is based on the use of Accordion Fringe Interferometry (AFI). The chief advantage of AFI over conventional scanning approaches is that AFI allows simple, lightweight high-performance scanning systems to be produced that can be used to scan a broad range fo surfaces under a range of shop lighting conditions.
NCMS Member $100.00
Non-member $150.00

Project 140365, 2/05
Current life cycle data management processes dictate manual handoffs, delegations, and follow-through, which is a compromise in terms of productivity entitlement and lead to quality oversights. Industry is struggling to demonstrate a successful marriage of CAD engineering definition with the complete manufacturing process data in a PDM environment. The project piloted the integration of three technologies that together provide a means of automatically extracting all engineering requirements (GD& T plus specification and standards references) from UG-NX drawings and storing them under configuration management in the Teamcenter™ PLM system. The result can take management of characteristics (engineering requirements) from the 3 to the 6 Sigma level, virtually eliminating quality escapes.
NCMS Member $100.00
Non-member $150.00

Project 140368, 3/08
This project addressed major opportunities for improving the way in which product design data is linked to Quality Plan and Manufacturing Information throughout the Supply Chain and product lifecycle from initial design to depot maintenance. The work done during project execution to under the depot requirements sets the stage for broader deployment of the product lifecycle management (PLM) tools that were successfully demonstrated. Based on the pilot results, the total quality and productivity-related savings opportunity for an OEM is estimated to be between $11-13M per year.
NCMS Member $100.00
Non-member $150.00

Project 140367, 8/09
Additive technologies allow part design freedoms not possible with traditional fabrication methods. Complex-multiple part configurations can be constructed in a single build, thus allowing reduction in the numbers of component parts needing assembly. Forty parts were fabricated and 17 provided sufficient data on cost and readiness benefits resulting in $2.03M annual cost avoidance and up to 80% in time savings.
NCMS Member $100.00
Non-member $150.00

Project 140377, 5/06
For many years, researchers have sought chromium-free substitutes for hexavalent chromium processes, driven by toxicity concerns. However, there remain many applications for which no suitable substitute for hard chromium has yet been developed, and for which there is no immediate prospect of a replacement. These processes remain in use, despite well over a decade of attempts at replacement. Most process engineers are convinced that hard chromium plating is going to remain a necessity for some time to come. This project is based on the recent development of a new trivalent chromium electroplating process that will provide an alternative to the use of hexavalent chromium to achieve hard functional coatings. The project objective is to optimize the new process to meet military and industrial specifications and evaluate its performance.
NCMS Member $100.00
Non-member $150.00

Project 140327, 12/04
Direct part marking is in widespread use in commercial aerospace, automotive, electronics, semiconductor, and pharmaceutical industries. The Data Matrix (ISO 16022) is the dominant barcode symbolology used to place a permanent machine-readable code directly into material surfaces i.e., not using labels or tags. The challenge is to determine which marking method is acceptable for material types, so that the resulting symbology will survive (remain readable) after enduring harsh environments and therefore last the life of the part.
NCMS Member $100.00
Non-member $150.00

Project 140446, 7/12
Developed performance specifications for an enhanced version of the Automated Rotor Blade Stripping System and a concept of operations for fully stripping a V-22 fuselage using laser/robotic technologies.
NCMS Member $100.00 – Available 1/14
Non-member $150.00 – Available 1/15

Project 140323, 4/07
Chemical agent resistant coatings (CARC) camouflage application to military land-vehicles is currently a labor-intensive process that requires the applied of a single-color base coat, followed by manually drawing the camouflage pattern in chalk to allow the application of the final two colors. The project approach involved combining vision and robot technologies to advance the state-of-the-art using an interface between the vision system and the robot. The project was designed to first assess the feasibility of the approach and to demonstrate the concept, prior to launching into a full-scale robotic painting implementation.
NCMS Member $100.00
Non-member $150.00

Project 140385, 1/06
Cincinnati Lamb, LLC developed a Field Reliability Evaluation Electronic Log (FREEDOM E-LOG) system to monitor equipment health and process effectiveness of its machine tool installations. It captures data automatically (without human intervention), stores it, processes it, and in some installations automatically sends data to Cincinnati Lamb for archival. It can be tailored to accommodate virtually any factory equipment and/or manufacturing process. The project team piloted the technology in a variety of industrial and depot maintenance applications.
NCMS Member $100.00
Non-member $150.00

Project 140389, 10/12
The problem addressed in this project was online access to real-time and historical process status and equipment health information. Phase II provided previously unavailable visibility into the status and health of shop floor equipment. Phase III deployed condition monitoring in a production environment on equipment assets making status available over the site enterprise network.
NCMS Member $100.00Available 4/14
Non-member $150.00Available 4/15

Project 140388, 8/08
The objective of this project was to determine the feasibility of developing a Static Event Detector (SED) Health Monitoring System. This system would alert inspectors or equipment operators to an electrostatic discharge (ESD) event that may have inflicted latent or catastrophic damage to critical electronic components resulting in a weapons system’s degraded performance. A SED is a device that detects the passage of an electrostatic discharge event. It can be as simple as a fuse or a metal-oxide semiconductor (MOS) device, both are single use devices. A magneto-optic static event detector (MOSED) is a subset of SEDs. It is resettable and thus reusable and is the type of SED developed during this project.
NCMS Member $100.00
Non-member $150.00

Project 130175, 12/12
The purpose of the project was to develop a software tool capable of predicting the distortion, residual stress state and microstructural phases for heat treated aluminum alloys. The feasibility of using a predictive software for 7075 aluminum part heat treatment design was successfully demonstrated.
NCMS Member $100.00
Non-member $150.00

Project 140376, 7/09
The Test Program Set (TPS) Migration System project was undertaken to provide lower migration costs, for depot Automated Test Systems (ATSs) and their support lifecycles, when equipment modernization is required. ATSs are employed to facilitate diagnosis and repair of failed and suspect weapon system components. These ATSs are being upgraded with modern supportable commercially equivalent test platforms that are developed to take the Air Force repair capability forward for another extensive period. Initially the project evaluated emerging technologies for migrating test applications when ATS are modernized or upgraded. This capability analysis led to a more pragmatic focus on existing commercially available environments that held promise in resolving the cost issues with porting legacy applications to the new generation systems.
NCMS Member $100.00
Non-member $150.00

Project 140311, 9/04
The Commercial Technologies Maintenance Activities (CTMA) Thermal Spray booth Equivalency project was launched to address a critical need in the plasma spray coatings industry—variances from booth-to-booth or cell-to-cell for parameters which affect the plasma plume, and hence, the resultant coatings. This project developed a portable booth monitoring system that allowed the user to optimize spray booth conditions and translate these conditions easily to other booths.
NCMS Member $100.00
Non-member $150.00

Project 130176, 10/12
The purpose of the R&D effort was to develop strategies for sandwich composite construction technologies for significant weight reduction for automotive applications and to develop computationally efficient models to predict the behavior of sandwich composites using model-based brokerage portals. Identified glass fiber composite/balsa core sandwich composites and their processing methods for automotive applications in stiffness critical applications.
NCMS Member $100.00
Non-member $150.00

Project 140415, 6/09
The project focus was to specifically demonstrate the feasibility of electric current augmented ultrasonic consolidation of titanium for the repair of structural components made of titanium alloy (Ti-6-4). The development of a satisfactory tool steel sonotrode became a major hurdle in the accomplishment of the project goals. The specific repair-oriented application explored were: Feature Restoration (Damage Repair) of Metal Airframe Features; Damage Repair of (Forged) Aircraft Structural Components; Pumps, Tubing, Heat Exchangers, Reaction Vessels; and Armor.
NCMS Member $100.00
Non-member $150.00

Project 140427, 8/11
Traditional chromium plating releases a mist of highly corrosive droplets that pose a risk to process operators. Hexavalent chromium has been implicated in long-term health effects, including cancer. In Phase II, an extensive series of tests was performed on samples produced using Faraday’s trivalent chrome process. The samples were able to successfully pass several key tests and performed comparably to hexavalent chrome. In Phase IIA encouraging results were achieved by modifying process plating parameters and select tank additives, a potential increase in platable current density range.
NCMS Member $100.00
Non-member $150.00 Available 2/14

Project 140423, 9/10
VALMT pioneered an innovative process in volumetric error compensation for large machine tools. VALMT will save ship and aircraft manufacturers millions of dollars. Machine tool calibrations used to take an entire week. VALMT allows the same process to be performed in a day. The benefits of this technology aren’t just time savings; it will allow for more accurate parts, reducing or eliminating expensive re-work during assembly.
NCMS Member $100.00  Available 3/12
Non-member $150.00 Available 3/13

Project 160214, 9/03
The scope of the AEPT Program focused on developing the materials, design, and processing technology for embedding passive devices into circuit board substrates.Current passive device technology supports a signal of 1 GHz. This program targeted frequencies of 1–10 GHz by using embedded passives to maintain signal integrity, enabling significant improvement in data transmission rates. Key innovations include new materials that better fit the application domain along with the process and design accommodations needed to use these materials. The 329-page final report presents the newly developed materials, design, and processing technology for embedding passive devices into circuit board substrates. The document includes many charts, tables, and photographs, many in color.
NCMS Member $50.00
Non-member $75.00

Project 170403, 10/95
A detailed summary of testing on 29 chromium-free alternatives for conversion coating of aluminum alloys. Salt spray, conductivity, and paint adhesion tests were performed on coated samples of five aluminum alloys. Report includes an environmental impact assessment of the alternatives, compared to a standard chromate coating.
NCMS Member $50.00
Non-member $75.00

Project 150306, 6/01
This technology report is the first public release of data from a four-year development effort by an NCMS-led project team that designed and built three advanced spindle pro¬totypes, and tested and evaluated the spindles’ cutting performance. The report details how the prototypes were designed and manufactured, and how the test results fared against performance expectations. In resolving discrepancies between results and expectations, the project development team discovered the root cause of a previously unexplained motor stator heating source. The team considers its discovery and subse¬quent control solution to be major contributions to the design and manufacturing of high-speed, high-productivity spindles. (216 pp; 40+ tables; 90+ graphics (nearly 30 in color).
NCMS Member $50.00
Non-member $75.00

Project 170605, 12/01
Pollution control equipment for paint lines can be a manufacturing facility’s costliest environmental item and coating facility operators are always interested in better and cheaper ways to achieve environmental compliance. As new manufacturing lines are built, and as old lines are upgraded, the technology must be periodically reviewed to be sure a facility is making the most sensible decision in selecting its pollution control equipment. This project worked with the Barstow Marine depot to identify pollution control technology for their current paint booth as well as a larger facility to be constructed. The results can be applied to a wide variety of military and commercial facilities.
NCMS Member $50.00
Non-member $75.00

Project 170408, 6/00
This 152-page document is a picture, a guidebook, and a roadmap. It is: a snapshot of the environmental state of the metal finishing industry, based on an extensive survey of metal finishing operations throughout the United States; a detailed, process-by-process collection of best practices—a guidebook for saving money and reducing waste in all common metal finishing operations; and a roadmap for future progress.
NCMS Member $50.00
Non-member $75.00

Project 140163, 5/00
The objective of this project was to provide a standardized methodology to enable DoD depot and field repair facilities to determine suitable substitute materials for weapon system repair and re-manufacture. The project deliverable included assessment of OEM specifications for material substitution issues, draft tests, and procedures to enable organic implementation of science based material substitutions, and a software tool to aid in the implementation of the substitution methodology.
NCMS Member $50.00
Non-member $75.00

Project 150320, 4/03
This report summarizes the first of a two-phases of The Development and Evaluation of Near-Dry Machine Tools for the Production of Aluminum Components (Near-Dry) project to determine if the near-dry machining (NDM) process offers enough technical and economic benefits to replace the conventional high-pressure through-the-tool coolant process—the WET process. NDM, which uses small quantities of biodegradable lubricant, circumvents most of the health and safety issues associated with conventional metal-cutting coolants and it is less expensive to own and operate than the WET process.
NCMS Member $50.00
Non-member $75.00

Project 150320, 12/03
This report summarizes the second of the two-phase project whose objective was to evaluate the achievable benefits from an advanced near-dry production machining process. Machining Enterprises, Inc. (MEI), a parts manufacturer for the automotive industry, piloted the first phase of the program by machining 30,000 GM engine brackets. Data from this pilot project established the technical and economic feasibility for using near-dry technology in a U.S. factory. In comparison to a conventional process incorporating high-pressure coolant delivered through the spindle, the near-dry process was determined to be 8.5% less expensive – even without taking into account the costs of eliminating a central coolant treatment facility as well as the costs of dealing with coolant-related health issues.
NCMS Member $50.00
Non-member $75.00

Project 140168, 12/02
Many forging, extrusion, heading and other metal forming processes use graphite-based lubricants, phosphate coatings, and other potentially hazardous or harmful substances to improve the tribology of the metal forming process. A focus on environmentally conscious manufacturing is consistent with the objectives of metal forming companies, metal forming equipment manufactures and the material and coating suppliers. A holistic approach to replacement of phoscoatings was developed by the NCMS team and a description of the tests and results are presented in this report.
NCMS Member $50.00
Non-member $75.00

Project 160213, 12/00
This collaborative effort advanced the use of embedded capacitance technology for power supply decoupling. The deliverables consisted of materials development and characterization, and board fabrication process development. This 132-page report pre¬sents the results of the tests to evaluate newly developed planar capacitance materials and fabrication processes. More than 135 charts, tables, photographs—many in color.
NCMS Member $50.00
Non-member $75.00

Project 160301, 4/97
Findings of the Environmental Stress Screening (ESS) 2000 Project, which had the goal of identifying and evaluating both cost of performing particular ESS processes and their effectiveness. Four technologies/processes were evaluated: military environmental stress screening; highly accelerated life test/ highly accelerated stress screen, electro¬dynamic highly accelerated life test/ highly accelerated stress screen; and liquid ESS.
NCMS Member $50.00
Non-member $75.00

Project 140168, 12/02
The mission of the project was to provide to designers a web-based advisor that provides the detailed forging process knowledge now only available from highly experienced forging process engineers. The advisor system uses an innovative reasoning scheme that is based a (user definable) weighted table. The scheme proved to work well and is much more easily understandable by manufacturing engineers that a more traditional backwards-chaining rule set.
NCMS Member $50.00
Non-member $75.00

Project 150337, 9/02
Three final reports are available for this project, which spanned a total of four phases over several years.In Phase I an older software system automatically recognized turning and 3 axis milling machined features and automatically created NC code was updated. Feature recognition for 5 axis features typically found in aerospace structural components was developed. Dynamic characteristics of the Cincinnati Machine Lancer V5 vertical 5 axis machining center were measured and cut tests performed to map safe operating zones that maximized the use of spindle power while avoiding chatter zones. Based on those results an algorithm was devised to calculate axial and radial depth of cut plus spindle rpm for high productivity machining. Feature recognition and cutting processes were validated by using the software on actual aerospace parts. In Phase II the formerly Unix only system was ported to MS Windows and a new user interface developed that allows users to modify feature recognition and method generation rules. A single report covers Phases I and II.3 Volume Set includes:

• High Throughput Production Processing of Five (5) Axis Aluminum Components (HITHRU) Final Report.
• High Throughput Production Processing of Five (5) Axis Titanium Components III (HITHRU III) Final Report.
• High Throughput Production Processing (HITHRU) Aluminum Part Deployment Final Report

NCMS Member - $50.00 Set-$200
Non-member - $75.00 Set-$300

Project 140208, 9/02
Visual simulation technology has been available in the market for several years, and has been used selectively in high-end graphical applications. Use of the technology for practical applications has typically been limited in deployment due to the traditionally high costs of these types of systems, as well as previously awkward methods (special viewing glasses or lenses or sometimes in sacrifice of quality of the image) of being able to easily “view” the results. The Interactive Visualization project achieved the goal of understanding where and how to apply the enhanced visualization technology for benefit in targeted applications areas, while also identifying areas of improvement or modifications of the technology that would better enhance the objectives of the individual projects.
NCMS Member - $50.00
Non-member - $75.00

Project 140209, 12/02
This project pursued the merits and feasibility of a material deposition repair technology called Laser Engineered Net Shaping (LENS™). The collaborative project participants produced a commercialized version of the LENS™ equipment and proceeded to determine both technical and economic feasibility on commercial and military applications.
NCMS Member - $50.00
Non-member - $75.00

Project 140158, 11/03
A variety of landing gear components are failing without having reached their desired service lives. The failures are due primarily to stress corrosion cracking (SCC) and fatigue. The objective of this project was to improve the fatigue life and SCC resistance through the application of laser peening technology to selected components.
NCMS Member - $50.00
Non-member - $75.00

Project 170503, 8/01
A four-year collaborative, multi-partner effort developed and evaluated lead-free solder alloys that would meet the harsh-environment requirements for electronic assemblies used in automobile, avionics, oil drilling, and military applications. After evaluation against toxicity, manufacturability, cost, reliability, and availability criteria, 241 solder alloys were down-selected to 7 lead-free alloys that exhibit performance superior to both tin-lead and tin-silver eutectic solders at –55 to +160°C. Results are presented in the 110-page final report, which is delivered on a compact disk.
NCMS Member - $50.00
Non-member - $75.00

Project 170502, 8/97
A detailed evaluation of 79 lead free alloys, down selected to 7 promising candidate replacements. Includes a manufacturing evaluation of compatible surface finishes and extensive reliability evaluations. The 108-page report contains 25 tables and more than 35 figures (photos, diagrams, and graphs), some of which are in color.
NCMS Member - $50.00
Non-member - $75.00

Project 170502, 6/99
This database is the most comprehensive collection of information on lead-free solder¬ing technology in existence today. The data is the result of an effort by a consortium of 11 industrial companies, academic institutions, and national laboratories working on a 4 year-program to identify and evaluate alternatives to eutectic tin/lead solders. Contains more than 40 published reports and presentations from the collaborative team, and all the technical data created during the project. Visit http://lead-free.ncms.org. To implement networked access, contact Melissa Sullivan (734)995-3158 or msullivan@ncms.org.
NCMS Member - $50.00
Non-member - $75.00

Project 173003, 4/02
The project identified and evaluated a number of advanced technologies at national laboratories and universities in an effort to find a viable solution for leak testing in today’s manufacturing environment. Four technologies were selected for research and development. Three primary objectives drove the project: cycle-time reduction, sensitivity, and simultaneous leak location. Secondary objectives were: robustness, cost effectiveness, and ease of use. The metrics used by the industrial participants to evaluate these new technologies were: long-term facilities cost savings, headcount savings, quality, and overall efficiency of the leak test operation.
NCMS Member - $50.00
Non-member - $75.00

Project 140315, 3/01
In a project recently supported by the National Center for Manufacturing Sciences (NCMS), the enabling technology for weld flaw avoidance was successfully developed and transitioned into a commercial product. The cost-sharing Commercial Technologies for Maintenance Activities (CTMA) program has brought new and needed welding control technology to the Albany depot. Control leads to reduced costs and process cycle times by reducing flaws and rework. The technology has been adapted for uses in the Albany weld shop to not only reduce costs, but also to train welders and provide a source of documentation required by the depot to meet ISO-9000 audit requirements.
NCMS Member - $50.00
Non-member - $75.00

Project 170301, 7/97
This guide can help the manufacturer select the right metalworking fluid for the job and the facility. Fluids are complex blends, which must perform a number of tasks simultane¬ously under a wide range of conditions. A wide variety of tests have been devised to indicate how well a particular fluid is likely to perform; this guide reviews over 150 test methods. The intent is to help sort out the tests, choose the right tests to perform, and interpret the results. Test methods are evaluated according to specific areas of concern: health and safety, environment, compatibility, performance, and maintenance.
NCMS Member - $50.00
Non-member - $75.00

Project 160206, 9/99
This report describes the steps taken and the progress made in developing the enabling technologies to build low-cost, flexible, automated equipment to assemble optoelectronic devices. Among the technologies developed for high-precision assembly are a virtually frictionless, magnetically supported positioning lead screw; low-cost, sensor-based as¬sembly platforms; micro stages; active vibration control; and high-precision 3D machine vision for automated assembly. Examples describe how these flexible technologies can be combined to address a variety of assembly requirements.
NCMS Member - $50.00
Non-member - $75.00

Project 160700, 11/96
The project report consists of three separate PWB team reports:

1. Imaging Team Final Report – The research effort focused on large-panel (18 in. x 24 in.) manufacturing to: develop a method to quantitatively assess conductor formation; char¬acterize existing imaging technology capability; extend the capability of existing technol¬ogy to produce high-yield, 6-mil pitch conductor circuitry; and to identify one more breakthrough technology with the potential to produce high yield 4-mil pitch circuitry.
2. Materials Component Team Final Report - The research effort characterized and advanced PWB interconnection technology to meet customer component attachment needs and requirements. This effort was responsible for improving present-day materi¬als and developing next-generation materials and processes used in PWB fabrications.
3. Surfaces Finishes Team Final Report – The research effort covered work in the following thrust areas: solderability assessments; solderable finish stress evaluations; baselining and benchmarking of PWB surface finishes; surface finish technology improvements; and evaluations of surface finishes for new attachment technologies.

NCMS Member - $50.00 each Set – $125
Non-member - $75.00 each Set – $200

Project 130120, 1/00
Results of the project include how to make substantial improvements, not just incremental improvements, in product development lead times by studying the methodologies of world class companies that had distinguished themselves by being fast to market with the highest quality products.
NCMS Member - $50.00
Non-member - $75.00

Project 140318, 9/03
The Process Substitution Methodology project for composite materials provided immediate benefit to the Department of Defense (DoD) war fighting capability during missions in Afghanistan, Kosovo and Iraq. The primary goal of this project was to develop and install the basic tools required to support material state management approach upon which the substitution methodology is based. The rapid revision of the processes that allowed for expansion of the Predator mission is just one example of how this technology can be applied. The material state management approach provides production personnel and support engineers with visibility on the effects of changes in process on the cure rate and cures state of the composite.
NCMS Member - $50.00
Non-member - $75.00

Project 140207, 12/01
The objective of this program is to demonstrate and install a computer-automated alternative to the conventional plate-and-etch technology for producing printed wiring boards. The process is based on newly developed metallo-organic decomposition chemistry for direct, additive metallization of holes and printing of circuit traces. The new technology, named Parmod®, has been used to prepare demonstration circuits with pure copper conductors on laminate substrates which are believed to be the equivalent of conventional plate-and-etch circuits.
NCMS Member - $50.00
Non-member - $75.00

Project 170604, 4/02
This study extends and updates an earlier NCMS study completed in 1995. This new study compares the performance of 18 conversion coatings, including 17 chromate-free alternatives and 1 chromate-based control, from seven suppliers, on six aluminum alloys. Data from side-by-side testing is provided for three typical tests: salt spray corrosion resistance, contact electrical resistance, and paint adhesion.
NCMS Member - $50.00
Non-member - $75.00

Project 150600, 7/99
The 1st ed. was published to convey the fundamentals of reliability and maintainability practices for machinery and equipment users and suppliers in the transportation indus¬tries. The 2nd ed. provides an updated framework enabling machinery and equipment user and supplier personnel at all operating levels to more clearly understand the impact and importance of R&M activities throughout the machinery and equipment life cycle. It was revised with consideration given to the Tooling and Equipment (TE) Supplement to QS-9000, and SAE FMEA publication J1739, among other R&M standards.
NCMS Member - $50.00
Non-member - $75.00

Project 140201, 6/98
This document is a detailed industry roadmap generated out of the Rapid Prototyping Technology Advancement NCMS collaborative project. The roadmap thoroughly posi¬tions rapid prototyping technologies in their current state and in stages over the next 15 years. The roadmap also begins to address the inter-relations between rapid prototyping and other relevant technologies such as virtual reality and high-speed machining.
NCMS Member - $50.00
Non-member - $75.00

Project 160201, 9/98
The project objective was to significantly improve assembly process yields, with an ulti¬mate goal of developing a methodology to achieve a six sigma quality level. The effort focused on the solder paste deposition, component lead quality, and component place¬ment process aspects of SMT. Team members used a continuous improvement meth¬odology to establish baseline performance, conduct benchmark evaluation, refine exist¬ing process capabilities, and identify or develop low-cost process monitoring equipment or specifications. 174 pages, 87 figures (more than a third in color), 24 tables.
NCMS Member - $50.00
Non-member - $75.00

Project 120605, 6/03
The Automated Work Process Planning project was formed between industry and the Tobyhanna Army Depot (TYAD) to address industry and depot needs to shorten cycle times, reduce out of stock rates while lowering pipeline inventory requirements, provide improved visibility of in process orders and enhance resource planning capabilities. The specific goal was to develop, and demonstrate, a cost effective, automated workflow planning system through development of a business process-driven Information Technology (IT) architecture with the capability to continuously respond to change as tasks are performed. This required the integration of legacy Workflow, PDM and Project Management systems.
NCMS Member - $50.00
Non-member - $75.00