Joint Technology Exchange Group CMTC Brief

Joint Technology Exchange GroupCMTC Brief November 05, 2003 Gary W. Schuerfeld Chairman, The Composites Consortium This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.

Scheduled Topics • Overview of Composites Manufacturing Technology Center (CMTC) • Overview of Ongoing Projects at the CMTC • Overview of Future Composites Applications and Vision for the US Navy This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.

Composites Manufacturing Technology CenterOverview This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.

Composites Manufacturing Technology Center • One of Nine US Navy MANTECH Centers • Managed by SCRA’s Applied Research and Development Institute (ARDI) • Technical Work Performed by The Composite Consortium (TCC) • Wide Scope of Activities Possible: • Science and Technology MANTECH This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.

Composites Manufacturing Technology Center • Sponsor: • Award Date: • Contract Period: • Contract Amount: • Contract Type: ONR MANTECH Program October 2000 5 Years Contract Ceiling : $120M ONR Core Funding : $ 60M Cooperative Agreement This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.

US Navy Centers of Excellence (COE) Institute for Manufacturing and Sustainment Technologies (IMAST) Penn State, PA National Center for Excellence in Metalworking Technology (NCEMT) Johnstown, PA Electro-Optics Center (EOC) Kittanning, PA Electronics Manufacturing Productivity Facility (EMPF) Philadelphia, PA Best Manufacturing Practices Center of Excellence (BMP) College Park, MD Navy Joining Center (NJC) Columbus, OH Energetics Manufacturing Technology Center (EMTC) Indian Head, MD Center for Naval Shipbuilding Technology (CNST) Charleston, SC Seneca, SC This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.

Composites Manufacturing Technology Center SCRA Corporate Offices This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.

Composites Manufacturing Technology Center • Personnel • Henry E. Watson - ARDI and CMTC: Executive Director • Jim Sabo - CMTC: Technical Director • Skip Wharton - ARDI: Director of Finance and Procurement • Jada Gates - ARDI: Senior Contracts Manager • Rhett Cheatham - ARDI: Projects Administrator • Ivan Snell - CMTC: Director, Special Programs • Gary Schuerfeld - CMTC: Chairman, The Composites Consortium • Lillian Rumsey - ARDI: Coordinator • Lesley Morrison - ARDI: Administrative Assistant • Dr. Art West - ARDI: Technical Director • Headquarters • 934-D Old Clemson Highway • Eagles Landing Professional Park • Seneca, South Carolina 29672 • Phone: 864-653-7590 • Fax: 864-653-7434 This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.

CMTC/TCC Structure Through a cooperative agreement with the Office of Naval Research (ONR), the Applied Research and Development Institute (ARDI), an operating unit of the South Carolina Research Authority (SCRA), manages the Composites Manufacturing Technology Center (CMTC) located in Seneca, South Carolina. The CMTC chairs The Composites Consortium (TCC), an organization of industry-focused, balanced team of prime contractors, composites industry suppliers, universities, and institutes. Through the Navy’s Manufacturing Technology Program (MANTECH), as well as other directed DoD funding, TCC members are able to perform on a wide range of Government projects across all service branches. This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.

Technical Advisory Board (TAB) Executive Steering Committee (ESC) CMTC/TCC Structure This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.

TCC Technical Advisory Board (TAB) • What is the Technical Advisory Board? • The Technical Advisory Board (TAB) is an assemblage of key composites technical experts from within The Composites Consortium (TCC). Each TCC member organization appoints one technical representative to the board. • What does the Technical Advisory Board do? • The TAB assists in the development of a Composites Manufacturing Technology Center technical strategic plan, advises and assists the Center’s Technical Director with the process of MANTECH project development, attends reviews of projects within their area of expertise, consults on technical issues within a specific area of expertise, and by identifyingcomposites manufacturing technologyneeds and priorities. In addition, the TAB may assist the CMTC in the selection of proposals if multiple proposals are received for a given project. This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.

TCC Technical Advisory Board (TAB) This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.

Executive Steering Committee (ESC) - What is the Executive Steering Committee? • The Executive Steering Committee (ESC) is a group of senior level managers from within the Composites Consortium (TCC). The 8-member ESC is composed of two TCC representatives from each of the following four groups: • Members who are primarily aerospace contractors, • Members who are primarily shipbuilding or ocean structures contractors, • Members who are research universities/institutes/laboratories, and • Members who are primarily supplier contractors or technology suppliers. • ESC members are nominated and elected by member companies of The Composites Consortium (TCC). - What does the Executive Steering Committee Do? • The ESC provides overall coordination for technical reviews and technology transfer. In addition, the ESC (1) Reviews all CMTC issues to be submitted to the Navy MANTECH database, (2) Assists in the development of the technical strategic plan for TCC, and (3) Assists the Executive Director of the CMTC in maintaining and coordinating support for TCC, identifying additional sources of funding, marketing TCC to potential customers, This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.

Executive Steering Committee (ESC) This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.

Current TCC Status • The Composites Consortium • 25 Current Members • Research Universities • Weapons Platform Primes • Specialty Fabricators • University Affiliated Research Centers (UARC) • Training & Education Organizations • Supports All Weapon Platforms • Aerospace (Including Unmanned Vehicles) • Surface Ships and Vehicles • Undersea • Land Vehicles • Space Structures This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.

Current TCC Members • Alliant Aerospace Company • Atlantic Research Corporation • ARC Technologies, Inc. • Bell Helicopter – TEXTRON, Inc. • The Boeing Company • Clemson University • Composite Solutions, Inc. • General Dynamics Corporation (Bath Iron Works, Electric Boat, Land Systems) • Goodrich Corporation • Lockheed Martin Corporation • Mississippi State University • Northrop Grumman Newport News • Northrop Grumman Integrated Systems • Northrop Grumman Ship Systems • Pennsylvania State University - Applied Research Laboratory • Raytheon Company • Robert C. Byrd Institute (RCBI) • Sikorsky Aircraft Corporation • SPARTA Composites, Inc. • Specialty Materials, Inc • Structural Composites, Inc. • Touchstone Research Laboratory • Virginia Polytechnic Institute and State University • Wake Forest University • York Technical College • New Members This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.

TCC Member Locations Alliant Aerospace GD-Bath Iron Works ARC Technologies Specialty Materials Boeing Sikorsky GD-Land Systems Boeing ARL/PSU NGIS RCBI Goodrich GD-Electric Boat TRL NGNN Virginia Tech Atlantic Research Wake Forest York Tech NGIS Composite Solutions SPARTA Clemson Univ. Goodrich Raytheon SCI Bell Helicopter NGSS Mississippi State This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.

CMTC Website http://cmtc.scra.org TCC Info Page This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.

Composites Manufacturing Technology CenterOngoing Projects Distribution Statement D: Distribution authorized to U.S. DOD and U.S. DOD Contractors only, for administrative and operational use. WARNING - This document contains technical data whose export is restricted by the Arms Export Control Act (Title 22, U.S.C. SEC 2751 et seq.) or the Export Administration Act of 1979, as amended, Title 50, U.S.C., App 2401, et seq. Violations of these export laws are subject to severe criminal penalties. Disseminate in accordance with the provisions of DOD Directive 5230.25 and OPNAVINST 5510.161.

The Marine Composites Technology Center • West Melbourne, Florida Spence Center for Composites Technology Columbia, South Carolina TECHNOLOGY TRANSFER CENTERS TTC THRUST Transfer innovative, defense-critical composites manufacturing technology skills from development programs to widespread applications, and to assist in ensuring the affordability of composites for Navy use York Technical College York, South Carolina

Technology Transfer Centers • Accomplishments • York Technical College • Developing a New Navy Training Course “Introduction to Composites” Aimed at Maintenance/Repair Personnel • Performed a Survey of Existing Navy Composites Training and Certification Programs at Three Main Aviation Maintenance Depot Locations • Conducted DACUM’s (Develop A CUrriculuM) for Composite Repair Training and Certification Programs at Cherry Point, North Island and Oceana Naval Air Stations. This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.

Technology Transfer Centers • Accomplishments • Spence Center for Composite Technology • Sponsored a Conference Entitled “Navy-Commercial Partnerships for World Class Manufacturing.” • Developed a Training Manual for the Safe Handling, Use, and Disposal of Composites Materials • Developed Manufacturing Processes for the Production of Radomes using Flouroalaphatic Cyanate Resin and Astroquartz Fiber This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.

Technology Transfer Centers • Accomplishments • Marine Composite Technology Center • Conducted A Resin Infusion Demonstration at the Composite Fabricators Association (CFA) International Symposium on Vacuum Infusion Processing and Resin Transfer Molding • Developed Booklet: “Alternative Approaches to Closed Molding”, a Primer of VARTM-type Infusion Processing Methods • Developed Booklet: “Potential Composite Applications for Oliver Hazard Perry Class Frigates”, detailing Composites Solutions for Fleet Corrosion Issues. This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.

PROJECT OBJECTIVE Develop, demonstrate and document improvements to the wet filament winding process as applied to pressure vessel fabrication AIM-9X COMPOSITE PRESSURE VESSEL FABRICATION PROJECT TEAM Atlantic Research Corporation ROI = 24:1

Composite PressureVessel Fabrication • Project Number:A0937 • Performing Activity: Atlantic Research Corporation • Start/End Dates: 04/99 – 12/03 • Primary Benefit: Provides manufacturing technologies that will substantially reduce the costs of high-performance composite pressure vessels to a level where they will be competitive with metal pressure vessel alternatives. • Objective: Develop, demonstrate and document improvements to the wet filament winding technology as applied to pressure vessel fabrication. • MANTECH Cost: $1,789K Cost Share: $267K • Implementation Cost: None • Systems Impacted: AIM-9 SIDEWINDER, RAM, SM, HELLFIRE • Implementation: ARC to provide improved WFW technology prior to AIM-9X EMD • Technical Achievements: • The Fiber Damage Assessment task, a precursor to fiber wet-out, was completed. • The fiber tensioner, spreader, and resin bath systems integrated system was delivered and mounted onto an ARC filament winder and is functional. • NDC Corp. traveled to ARC for installation and calibration of a gamma gage system. • Benefit Analysis/ROI • Investment • ManTech Program: $1.79M • Unit Cost Analysis • GFE MK-36 Steel Motors: $8000 • Upgrade to AIM-9X: $6823 • Motor Unit Cost: $14,823 • Projected Procurement of 6680 AIM-9X and 1500 RAM (USN & FMS) • Total Cost Avoidance: $37.5M • Warfighting Return • IM Compliance • Lives Saved • $2.5B Past Carrier Damage • Composite Case Required to Meet Missile Performance Goals Expected Unit Cost ROI = 24:1 40 30 Millions Saved 20 • Status: • CECMT issued stop work order February 2001 • Project restarted under CMTC January 2002. • The extended interruption in the contract is requiring some duplication of effort to relearn programming of the new control software and to restart the project. 10 MANTECH cost = $1.79M FY1 FY2 FY3 FY4 FY5 Fiscal Year

Composite Pressure Vessel • Composite Pressure Vessel Fabrication • 4” JANNAF Tubes • Testing of Tubes from the Baseline Winder Completed. • Three Tubes from the ManTech Winder Tested. Additional Tubes Being Fabricated for Test • Statistical Analysis After All Tubes Tested • 6” Hydroburst Bottles • Two ManTech Winder Bottles Wound/Prepared for Hydroburst • Additional Bottles Being Fabricated • Problems With ManTech Winder Delayed Project Approximately 2 Months This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.

Gantry Trolley Composite Gantry/Trolley Type Structures • At the NSWC/CSS Station in Panama City, FL • Composite Barge Was Being Considered for Test Pond • Customer Determined Composite Barge to be High Technical, Cost & Schedule Risk • Customer Specified Steel Barge • Barge/Building Installation Completed: Dedication Ceremony 09 September 2003 This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.

Gantry Trolley Aerial View of Acoustic Test Facility Old Barge 26’x38’ This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.

Gantry Trolley New Barge (30’ x 60’) w/Building This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.

PROJECT OBJECTIVE Automate the Z-fiber installation process eliminating the concerns of manual insertion and provide additional cost savings to the F/A-18E/F. AUTOMATED INSERTION OF Z-FIBER FOR COMPLEX SHAPES PROJECT TEAM Northrop Grumman Aztex, Inc. ROI = 1.4 w/o Partial Depth

Automated Insertion of Z-Fiber for Complex Shapes • Project Number: A1007 • Performing Activity: Northrop Grumman Corp., El Segundo, CA; Aztex • Start/End Dates: 10/01 – 01/04 • Primary Benefit: Significant improvements in composites affordability and increased system performance for advanced composite structures. • Objective: To automate the Z-fiber insertion process on F/A-18 E/F eliminating production and quality assurance concerns related to the manual insertion variability and fatigue. • MANTECH Cost: $2.68M Cost Share: $721K • Implementation Cost: TBD • Systems Impacted: F/A - 18 E/F and derivatives, other vehicles with joined composite parts • Implementation: Initially a/c FF- 108 (5 parts), fully a/c FE-120 (all 37 parts) Prototype Automated Insertion Head (End-Effector) Current Manual Insertion Head • Benefit Analysis/ROI • Benefit Analysis Assumptions • Makes a/c effectivity • All identified parts captured • 400 total aircraft purchased • Increase in aircraft build from 36/yr. to 48/yr. for FY 05. • Benefit Analysis Results • Initially $12K saved per a/c ultimately $30K saved per a/c • ROI calculation • Significant savings over projected a/c program lifetime with partial depth insertion implemented. • Technical Achievements: • Prototype end-effector head designed, fabricated and delivered for concept proofing and troubleshooting. • Prototype end-effector head demonstrated on flat panel hat-stiffened composite parts. • Initial coupon testing displays promising results for a maturing technology. Expected ROI = 4.5:1 8 6 $Millions 4 • Status: • Machine systems/customer requirements document finalized. • Automated machine builder procurement specification contract currently in bidding process. MANTECH cost = $2.68M 2 FY04 FY05 FY06 FY07 FY08 Fiscal Year

Demonstrated Benefits • Reduced Touch Labor • Reduced Weight • Reduced Part Count • Reduced Defect Count • Increased Interlaminar Capability • Improved Damage Tolerance Z-FIBER AUTOMATED INSERTION Mechanical Fastener Attachment Advanced Attachment with “Z-Pins” • Requires: • Pre-Curing of Multiple Details • Drilling/Countersinking of Fastener Holes • Application of Liquid Shim • Wet Installation of Fasteners • Requires: • Integration of Composite Lay-ups • Installation of Z-Pins Prior to Cure • Backside OML Sealing Pre-Cured Composite Radius Block Co-Cured Composite Hat Stiffener Pre-Cured Composite Skin Co-Cured Composite Skin .011” Dia. GR/BMI Z-Pins (420 pins/in2) This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.

Z-FIBER AUTOMATED INSERTION Complex Curvature Components This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.

Z-FIBER AUTOMATED INSERTION 6-Axis Gantry Automated Insertion Equipment This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.

F- 414 Engine PROJECT OBJECTIVE Improve the affordability of SiC-C composite engine exhaust components by streamlining and optimizing the manufacturing production process. SiC-C COMPOSITE FLAPS AND SEALS PROJECT TEAM Goodrich Corporation ROI = 6.58

Manufacturing Technology for SiC-C Composite Flaps and Seals • Project Number: A1013 • Performing Activity: Goodrich Corporation • Start/End Dates: 09/02 – 08/04 • Primary Benefit: Reduced Cost for F414 Engine Exhaust and Seal Components • Objective: Identify, and Validate for Production, a Lower Cost SiC Fiber/Prepreg Resin System and Develop Process Modifications That Will Reduce the Cost and Cycle Time of the Carbon Vapor Deposition (CVD) Process. • MANTECH Cost: $856K • Implementation Cost:TBD • Systems Impacted: F/A-18 Hornet • Implementation: Process Changes Will Be Submitted to GEAE Engineering for Review.GE Will Fund Engine Testing Under Their F414 Development Engine Testing Program. Commitment has been obtained from NAVAIR F414 IPT to Support Engine Qualification Tests • Status: • Anticipated Project start September 2002 • Benefit Analysis/ROI • Benefit Analysis Assumptions • Based on 520 Engine Sets • Estimated Cost Savings of $9.8K Per Engine • Spare Parts Are Not Included in Analysis • Benefit Analysis Results • Cost Savings of $5,078K Over 520 Engines • ROI = ($9,768 X 520) / $856,000 = 5.93 • Project Tasks: • Task 1: Reduce CVD Cycle Time • Combine Pyrolysis and Carbonization Steps • Measure The Effect Upon Composite Densities And Mechanical Properties • Task 2: Substitute Low Cost Fiber and Alternate Resin/Filler System • Task 3: Validate Process Improvements • Manufacture Engine Hardware Panels • Generate Mechanical Properties • Task 4: Manufacture a Set of Engine Hardware • Task 5: Engine Test Hardware (GEAE Funded)

PROJECT OBJECTIVE Develop an improved composite protection layer for ship main propulsion shafts that will afford corrosion protection over a twelve-year docking cycle. PROPULSION SHAFT COMPOSITE SURFACE TREATMENT PROJECT TEAM Newport News Shipbuilding NSWC Carderock Division Norfolk Naval Shipyard Portsmouth Naval Shipyard Puget Sound Naval Shipyard ROI = >10:1 Over 5 Year Cycle

Propulsion Shaft Composite Surface Treatment • Project Number: S1012 • Performing Activity: Northrop Grumman Newport News; NSWCCD; Puget Sound, Portsmouth and Norfolk Naval Shipyards • Start/End Dates: 09/02 – 05/05 • Primary Benefit: An Improved Shaft Coating System Will Help the Navy Achieve a 12-year Docking Cycle while Reducing Shaft Life Cycle Costs. • Objective: Develop an Improved Composite Protection Layer for Ship Main Propulsion Shafts That Will Afford Corrosion Protection for Twelve Years. • MANTECH Cost: $1,441,700 • Implementation Cost: $16,460 - $49,500 Fabrication Cost Increase Per Shaft • Systems Impacted: CVN 68 Class Nuclear Aircraft Carrier; CVN77 & CVNX Next Generation Nuclear Aircraft Carriers; DDG-51 • Implementation: Approvals Secured From SEA 05Z12, SEA 05Z2, NSWCCD SSESDET / Code 9323, SEA 05M1, PMS 312D, CNAP N43 for the CVN-70 RCOH availability. Tech Transfer/Training to Navy Shipyards • Status: • Anticipated Project start September 2002 • Benefit Analysis/ROI • Benefit Analysis Assumptions • Repair Cost Extrapolated From Shipyard Repair Cost Estimates for Current Shaft Covering Practices (Does Not Include Submarines). • 383 Shafts on Surface Ships Replaced or Repaired Every 7 Years (on Average). • $64,000 - $192,450 Repair Cost (Relative to the Shaft Size) Per Shaft Every 7 Years ($33,966,825 Total Estimated Repair Cost Savings Every 7 Years) • $16,460 - $49,500 Fabrication Cost Increase Per Shaft ($519,730 Total Fabrication Cost Increase Every 7 Years) • Benefit Analysis Results • $34 Million Cost Avoidance Over 7 Years • 5-Year ROI = 5/7 x ($33,966,825 – $519,730)/$1,395,000 = 16 • Project Tasks: • Task 1 - Manufacturing Process Development • Task 2 - Peel Testing/Environmental Conditioning • Task 3 – Manufacturing Trials & Scale Test Shaft Fabrication • Task 4 - NSWCCD Testing of Scale Shafts • Task 5 – Planning for RCOH 70 and CVN 77 • Task 6 – Repair Procedure Development • Task 7 – Technology Transfer to Navy Shipyards

PROPULSION SHAFT SURFACE TREATMENT Polysulfide Coating Application Polysulfide Coating Application Application of GRP Overwrap Application of GRP Overwrap This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.

PROPULSION SHAFT SURFACE TREATMENT • Carderock Development of Scale Shaft Evaluation Progress Continues on the “Four Square” Test Apparatus and Test Facility This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.

PROJECT OBJECTIVE Develop a manufacturing process to incorporate composite structural armor into the EFV troop ramp door reducing the weight by 20% and eliminating the costly appliqué armor system EXPEDITIONARY FIGHTING VEHICLE TROOP DOOR PROJECT TEAM General Dynamics Land Systems ARL Penn State ROI = 14.3 : 1

EXPEDITIONARY FIGHTING VEHICLE TROOP DOOR • Project Number: C1011 • Performing Activity: General Dynamics Land Systems; ARL Penn State • Start/End Dates: 08/02 – 06/04 • Primary Benefit: Reduced Cost and Reduced Weight for the EFV Rear Door Assembly. • Objective: Develop a Manufacturing Process to Incorporate Composite Structural Armor Into the EFV Troop Ramp Door Reducing the Weight by 20% and Eliminating the Costly Appliqué Armor System • MANTECH Cost: $ 920K Cost Share: $ 325K • Implementation Cost: The Manufacturing Technology Developed Is Not Expected to Require New Facilities. • Systems Impacted: Expeditionary Fighting Vehicle (EFV) • Implementation: A commitment has been obtained from the EFV Hull Mechanical Systems IPT Lead (Mr. Michael Lange) to support the installation and testing of the prototype assemblies on EMD vehicles E2, 3 and 5. • Status: • Anticipated Project start August 2002 • Benefit Analysis/ROI • Benefit Analysis Assumptions • Number of Vehicles = 1013 • Cost Savings of $5K per Door • Value of Weight Savings = $100 per Pound x 80 lbs/door = $8,000 • Assembly, Logistics and Other Potential Cost Savings Not Included • Benefit Analysis Results: Total Cost Savings of $13,169K • ROI = (1013 vehicles x $13,000 per vehicle)/ $919,500 = 14.3 • Project Tasks: • Task 1 – Redesign & Analysis (Cost Share Task) • Task 2 – Manufacturing Process Development • Task 3 – Machining, Assembly, and Quality Assurance/Inspection • Task 4 – Ballistic Testing (Cost Share Task) • Task 5 – Fabrication of Prototype #1 • Task 6 – Process Optimization • Task 7-9 – EMD Vehicle E2, E3 and E5 Hardware Fabrication

PROJECT OBJECTIVE Develop affordable and reliable manufacturing process that address the specific embedment fabrication issues while concurrently assessing the process impact on structural and electrical performance. AFFORDABLE INTEGRATED STRUCTURAL APERTURES PROJECT TEAM Northrop Grumman AEW/EW Northrop Grumman Ship Systems ROI = 7.53:1

Affordable Integrated Structural Apertures • Project Number: A1042 • Performing Activity: Northrop Grumman Integrated Systems • Start/End Dates: May 2003 – January 2006 • Primary Benefit: Reduced Cost and Reduced Weight for the Satellite Communications Antenna System for the E-2C Aircraft • Objective: Develop Affordable And Reliable Low-pressure Autoclave And Vacuum Bag Cure Hand Lay-up Manufacturing Processes That Address Specific Embedment Fabrication Issues While Concurrently Assessing The Process Impact On Structural And Electrical Performance. • MANTECH Cost: $ 1,980K Cost Share: $ 600K • Implementation Cost: Est. $5M E-2C Program Production Non-recurring Cost • Systems Impacted: E-2C Hawkeye • Implementation: This Project Is Part Of The E-2C (PMA231) Technology Insertion Plan To Enhance The Overall Airborne Early Warning Capability For Advanced Hawkeye Program. • Status: • Project Started 20 May 2003; Kickoff Meeting 04 June 2003 • Benefit Analysis/ROI • Benefit Analysis Assumptions • Number of Vehicles = 223 (Includes Spares & Retrofits) • Acquisition Cost Savings of $50K per Aircraft • Value of Weight Savings = $300 per Pound x 20 lbs/Unit = $6K • Recurring Cost Savings of $20K per Year (Maintenance Labor Savings and Reduced Fuel Consumption) • 10 Year Service Life • $5,000K E-2C Program Non-Recurring Cost • Benefit Analysis Results: Total Cost Savings of $57,100K • ROI =$57,100K/($2,580K + $5,000K) = 7.53 • Project Tasks: • Task 1: Embedded Antenna Type Downselect • Task 2: Manufacturing Development • Task 3: Subcomponent Fabrication • Task 4: Demonstrate Repairability, Electrical Performance • Task 5: Fabricate 2 Full-Scale Articles • Task 6: Validate Cost/Weight Benefits

Affordable Integrated Structural Apertures Embedded Antenna Secondary Embodiment: Advanced Hawkeye Embedded IFF Elements This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.

Affordable Integrated Structural Apertures 1/5 Scale Advanced Hawkeye Rotodome Mockup Radar Elements Graphite/Epoxy Skin Fiberglas Skin This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.

PROJECT OBJECTIVE Address the need for a more affordable, carrier-capable airframe leading to an alternate, low risk, more affordable J-UCAS airframe product. J-UCAS CONCEPT EXPLORATION REQUIREMENT Current airframe designs and manufacturing capabilities must be improved in order to meet J-UCAS affordability goals. • PROJECT PERFORMERS • Boeing Company • Northrop Grumman

Joint Technology Exchange Group CMTC Brief