America Makes Project Call Kickoff Webinar Maturation of Advanced - - PowerPoint PPT Presentation
Driven by Driven by Driven by America Makes Project Call Kickoff Webinar Maturation of Advanced Manufacturing for Low Cost Sustainment (MAMLS), Phase 3 December 1, 2017 John Wilczynski America Makes, NCDMM Technology Director
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December 1, 2017
John Wilczynski
America Makes, NCDMM Technology Director john.wilczynski@ncdmm.org
Erin O’Donnell
America Makes, NCDMM Program Coordinator erin.odonnell@ncdmm.org
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Project Call Summary
▪ Schedule ▪ Objective / Background ▪ Technical Topics / Funding
▪ Project Call Summary ▪ Project Call Process
▪ Step 1 : Project Concept ▪ Step 2 : Project Proposal Phase
▪ Evaluation Criteria ▪ Exhibits ▪ Nuances
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Event Date
11/27/2017
12/15/2017
12/19/2017
12/22/2017
01/03/2018
to Submit Full Proposals 01/17/2018
02/23/2018
03/21/2018
06/01/2018
Schedule
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Objective / Background - Detailed
Objective:
Phase 3 of the “Maturation of Advanced Manufacturing for Low-Cost Sustainment (MAMLS)” program is intended to address key challenges to insertion of AM technology for maintenance, sustainment, and logistics operations within the DoD that have been identified throughout Phases 1 and 2. Currently, these material, process, and post-process barriers are preventing greater penetration of AM technology for more challenging, safety critical applications or for the breadth
Background:
MAMLS Phase 1 successfully developed advanced manufacturing solutions to sustainment needs for USAF and DoD customers at Warner Robins ALC, Ogden ALC, Oklahoma City ALC, 910th Airlift Wing at Youngstown Air Reserve Station, and Navy FRC Cherry Point, primarily through successful transition of ground support equipment and process aids. MAMLS Phase 2 was launched in Spring 2017 and is focused on walking the path toward qualification for representative part families. Three parts were chosen for this task: bell crank family of parts to explore features of varying thicknesses on a flight critical component; oil-cooler family of parts to represent lightly loaded components with complex features and high functional requirements; and fairing family of parts to explore viability of material extrusion for core structure with composite sandwich panels.
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Objective - At a Glance
Objective:
▪ Develop and demonstrate advanced manufacturing technologies related to additive manufacturing that improve rapid part replacement/maintenance for legacy aircraft. ▪ Enable on-demand replacement of critically damaged or obsolete components that do not meet economic requirements of conventional supply chains. ▪ Develop and demonstrate rapid fabrication of shop tools such as assembly aids, jigs, and fixtures for sustainment center utilization. ▪ Identify technology gaps and transition issues that need to be solved prior to effective implementation. ▪ Reduction of the cost and lead time to fabricate replacement components for legacy aircraft as well as for rapid tooling, masks, fixtures, etc. ▪ Technology demonstrations and learning for future implementations both in industry and AF organic sustainment operations.
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Technical Topics / Funding Availability
Technical Topic Title Funding Topic 1: Feature Based Qualification using Directed Energy Deposition Not to exceed $2,500,000 in federal funding Topic 2: Understanding Manufacturing Realities of AM: Effects of Defects Not to exceed $1,000,000 in federal funding Topic 3: Emerging Process Technology for Low Criticality Part Families Not to exceed $600,000 in federal funding
NCDMM anticipates multiple awards, up to the available funding
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Technical Topics: Topic 1 – FBQ using DED
Feature Based Qualification using Directed Energy Deposition
The goal of this topic area is to apply FBQ approaches to the production of large scale, additively manufactured aerospace components utilizing DED techniques.
▪ Demonstrate the extent of utility of the FBQ approach ▪ Identify associated implementation challenges and risk reduction or alternative qualification strategies.
Analogy to Welding Procedure Specification
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Technical Topics: Topic 1 – DoD Roadmap Alignment
Feature Based Qualification using Directed Energy Deposition
Non-exclusive list of DoD AM Roadmap Elements which may be applicable: ▪ DoD.D.4 – Develop Design for Function Guidelines ▪ DoD.P.2 – Establish Stable and Robust AM Processes ▪ DoD.P.4 – Modify Existing or Develop New Process Capabilities ▪ DoD.V.2 – Develop Qualification and Certification Methods for Parts and Systems
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Technical Topics: Topic 2 – Effects of Defects
Understanding Manufacturing Realities of AM: Effects of Defects
The goal of this topic area is to quantify the effect of defects on the mechanical performance of additively manufactured material.
▪ Evaluation of material properties that are sensitive to statistical extremes is of particular interest, as well as the evaluation of real flaws rather than having to make assumptions about the relevance of intentionally induced flaws, such as CAD-embedded voids. ▪ Characterizing the extent to which specific post-processing approaches, such as Hot Isostatic Pressing, improve mechanical performance is also relevant to this topic area.
Lack of Fusion Defect
Gorelik M. Additive manufacturing in the context of structural integrity. Int J Fatigue (2016), http://dx.doi.org/10.1016/j.ijfatigue.2016.07.005
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Technical Topics: Topic 2 – DoD Roadmap Alignment
Understanding Manufacturing Realities of AM: Effects of Defects
Non-exclusive list of DoD AM Roadmap Elements which may be applicable: ▪ DoD.D.1 – Enable Robust, Integrated, and Intelligent Design Tools ▪ DoD.M.1 – Define Standard AM Materials Requirements ▪ DoD.P.1 – Develop NDE and Process Control ▪ DoD.P.2 – Establish Stable and Robust AM Processes ▪ DoD.V.2 – Develop Qualification and Certification Methods for Parts and Systems
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Technical Topics: Topic 3 – Emerging Processes
Emerging Process Technology for Low Criticality Part Families
The goal of this topic is to evaluate the ability of emerging AM processing and AM technologies to supply low criticality components that satisfactorily fulfill the required part function.
AFRL seeks to assess the degree to which the demonstrated solutions extend to part families of similar size, shape, criticality, and function.
The following processes as defined by ASTM F2792 will be considered for funding under this program area: ▪ Highly loaded material extrusion – e.g. fiber, metal, ceramic ▪ Vat photopolymerization ▪ Powder bed fusion with non-laser and non-electron beam energy sources ▪ Sheet Lamination
Some examples include, but are not limited to, unique electrical connectors, ducting, manifolds, instrumentation knobs, wiring harnesses, small brackets, and other non-critical end use items. Such parts may have identical function, but slightly different geometries or features that result in many variants of very similar parts.
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Technical Topics: Topic 3 – Emerging Processes
Emerging Process Technology for Low Criticality Part Families
Non-exclusive list of DoD AM Roadmap Elements which may be applicable: ▪ DoD.D.4 – Develop Design for Function Guidelines ▪ DoD.M.1 – Define Standard AM Materials Requirements ▪ DoD.V.1 – Build Cost Models and Decision Tools
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Project Call Summary
▪ $5,700,000 is being made available ▪ 24 months maximum period of performance
▪ 50% cost share required ▪ Funding Breakdown per Topic area
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Project Call Summary – Project Call Steps
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Project Call Summary – Evaluation Criteria
▪ Step 1 Evaluation Criteria
▪ Step 2 Evaluation Criteria
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Project Call Summary – Exhibits
▪ Exhibits Required in Submission
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Project Call Summary – Exhibit V
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Reporting and Eligibility Requirements
▪ Requirements
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Questions & Answers (Q&A)
▪ Frequently Asked Questions (FAQ) ▪ Email all questions about the Project Call to: projectcall@americamakes.us ▪ Dates for questions
▪ IMPORTANT NOTES:
page every Friday afternoon (https://www.americamakes.us/project-call-phase3-mamls/)
be answered
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