Results from the 2003 NCMS/CTMA Working Symposium on Sustainment.

The New Project Ideas below resulted from the workshop discussions at the 2003 Symposium held April 1,2 in Salt Lake City.  If you are interested in collaboration in any of these projects, please contact the NCMS staff indicated for each track.  The project ideas are presented in two forms.  The more detailed ideas under each track list interested participants from the Symposium.  At the end of each track is a listing of other project ideas that were identified in the workshop, but seen as lower priority by the Symposium participants. The project teams for each project will then work together to define the effort for possible submission to the CTMA program.  For any general questions, please contact Chuck Ryan, chuckr@ncms.org, 734-995-4905.

I. New Project Ideas: Metals NCMS Contact: Steve Hale, steveh@ncms.org, 734-995-2195

1. Laser Repair In-Situ Plating Alternatives and In-Situ Quality Monitoring

Interested Participants:  H&R Technologies, NUWC Keyport, Penn State (ARL), POM, Boeing (Titanium Alloys), Toolmen/SMU, Barstow MC3, Albany MC3

2. Sheet Metal Fabrication PMO – Rapid Manufacturing Repairs, Prototype

Interested Participants:  Industrial Origami, Anniston Army Depot, Sikorsky, Caterpillar, Boeing, H&R Technologies, Solidworks, Metalsoft, U of M, NASA, OC-ALC, Pearl Harbor NSY, China Lake NAVAIR, Cherry Point NADEP, Barstow MC3 and Albany MC3

3. Serialized Tracking (follow-on to Parts ID) including Avionics and Electronics (Predictive Analysis Tools is a step beyond)

Interested Participants: AES Total Quality Systems, Telesis, Boeing, Cherry Point NADEP, USMC, OC-ALC, Puget Sound NSY

4. Coating Removal and Surface Prep

Interested Participants: Boeing, Penn State (ARL), Lasertronics, Sikorsky, Lockheed Martin, Pearl Harbor NSY, USMC, Anniston Army Depot

5. 3D Technical Data (STEP) (Reverse Engineering)

Interested Participants: Anniston Army Depot, Cincinnati Machine, Boeing, Maxim-IT, Sikorsky, U of M, USMC, OC-ALC

6. FSW – Friction Stir Welding

Interested Participants: Cincinnati Machine, Boeing, USMC

7. Trivalent Chrome Replacement for Hexavalent Chrome

Interested Participants: Sikorsky, Boeing, Faraday Technology, Cherry Point NADEP, OC-ALC, USMC

8. Residual Stress Management in Machined Parts (NCMS contact: Tony Haynes)

Interested Participants: Sikorsky, Boeing, Cincinnati Machine, Warner-Robins ALC, Oklahoma City ALC, Cherry Point NADEP

Additional Project Ideas (track 1 - metals):

9. NDE Techniques/Skills                                                     

10. Maintenance Mentoring                                                    

11. Corrosion Issues/Methods Matrix of Solutions                  

12. Halon Replacement                                                           

13. Welding Fume Evacuation                                                 

14. High Speed Machining Centers                                         

15. In-situ Laser Repair Capability                                          

16. NDI Internal Weld Spatter                                                

17. Low Temperature/Multi-Color Powder Coating                  

18. Robotic Painting

19. Automated IC Engine Piston Carbon Removal                  

20. Laser Shot Peening                                                           

21. Air Frames – Doors/Floor Panel Fabrication                     

22. Serialized Tracking and Predictive Analysis Tools              

23. Modeling/Simulation Fatigue Cracking                               

24. Corrosion Modeling                                                          

25. NDE                                                                                                                             

26. Coating Removal                                                              

27. Coatings/Primerless Topcoats

28. Cadmium Replacement                                                  

29. Turbine Blade Coatings (Russian Proprietary Coatings)     

30. Elimination of VOC’s in Coatings                                      

31. Biodegradable A/C Deicing Materials                               

32. Leaky Fuel Tanks – Sealants

II. New Project Ideas: Composites and Lightweight Structures NCMS Contacts: Connie Philips, conniep@ncms.org, 734-995-7051, Manish Mehta, manishm@ncms.org, 734-995-4938

1. Sealants/Coating (Parts:  Bladder/fuel tank/access panels)

• Leak Detection

  • Helium

  • Photo acoustics/UT

  • Gas imaging

• Rejuvenation

  • Chemical catalyst/activator

  • Laser

• Removal/Restoration

  • Laser

  • Waterjet/Drop blast

  • Chemical

Interested Participants:  Boeing, OC-ALC, WR-ALC, Elixair, Helitech, Lasertronics, OO-ALC

2. Thick Composite Structural Repair (>2 inches thick)

(Future combat systems and DDX—future naval combatants) 

• Multiple Functionality Structural Composites

• Multiple Bond Lines

• Real Time Cure Knowledge

• Innovative Processes/Tooling (VARTM/liquid molding)

• Preform Processing/Handling

Interested Participants:  United Defense, General Dynamics Land Systems, Boeing (FCS System Integrator with SAIC), Northrop/Grumman, Bath Iron Works, Army/Navy Mantech, AvPro, Siemans Composites, Anniston Army Depot, University of Delaware- Center for Composite Materials (CCM), SCRA – Navy Mantech

3. Overhaul and Repair Using Composites

• Material Substitution

• Low Temperature Cure

• Low Cost Tooling

• Real Time Process Control

•  Integrate NDE Technologies into Process Controls

• Repair Design Analysis (process)

• Inspection (NDI)

• Modification Process

• Paint Removal

• Certification

Interested Participants: Advance Processing Technology, Boeing, Sikorsky, Lastertronics, Cherry Point NADEP, OO-ALC, CCAD, GE Engines

Additional Project Ideas (track 2 - Composites and Lightweight Structures):

1. Weight Reduction (Recapitalization)
2. Composite Armor and Aircraft Repair Tech. (e.g., FCS, Boeing and Aircraft Repair) - Multiple Bond Line Repair
3. Non Destructive Evaluation and Inspection Criteria
4. Composite Degradation: New Processes and Materials studies to Repair
5. Joining of Composites (Similar and Dissimilar)

6. Parts Tracking for Composites

7. Low Observables (LO) Capabilities at Depots
8. Repair, Paint, Test/Verify
9. Predictive Analysis and Maintenance Capabilities
10. Repair Methods for Joint Strike Fighter (Unique Issues)

11. Cosmetic/Touch-up Training in Composites Technology/Kits

12. Composite Superstructures
13. Fire Retardant Technology
14. Corrosion and Substitution Materials
15. Lower Temperature Cure Film Adhesives
16. Real Time Composite Cure Monitoring
17. Reconfigurable Tooling (e.g. 2Phase project) and RM/RT
18. Effort and Handling Reduction via Automation in Depots

III. New Project Ideas: Electronics  NCMS Contact: Lee Patch, leep@ncms.org, 734-995-4972 

1. Automated Test Equipment Software Analysis and Test Program Set Translation Tool

• Minimize recurring cost when migrating test program set (TPS) to new automated test equipment (ATE) platform(s)

• Develop automated methods for extracting test requirements from legacy ATE/TPS

• Develop “Middleware” to generate new TPS on modern system(s)

• Enable data collection for trend analysis and Knowledge Base

Interested Participants: Warner Robins ALC, Ogden ALC, Oklahoma City ALC, Tobyhanna Army Depot, NUWC Keyport, Teradyne, Honeywell, Agilent

2. Synthetic Instrumentation Insertion for Automated Test Equipment (ATE)

• Address Instrumentation Obsolescence

• Develop multi-use, software-configurable, test instrument technology

• Provide a path for common test platform

• Include Boundary Scan capability

• Minimize upgrade costs

Interested Participants: Warner Robins ALC, Oklahoma City ALC, Ogden ALC, Tobyhanna Army Depot, NUWC Keyport, Teradyne, Honeywell, Agilent, Huntron

Additional Project Ideas (track 3 - Electronics):

3. Automated conformal coating removal (NCMS to review Tobyhanna project)

4. Predictive Maintenance Tools (can we integrate CALCE POF tools with preventative maintenance tools - AF ManTech interest)

5. Modeling and simulation for Test & Evaluation

6. Automated contact cleaning (pin & finger)

7. Infra Red (IR) imaging of phased array antenna emissions

8. Wireless monitoring of harness/cable status on shipyard cranes

IV. New Project Ideas: Advanced Manufacturing and Best Business Practices  NCMS Contacts: Mike Gnam, mikeg@ncms.org, 734-995-4971, Tony Haynes, tonyh@ncms.org, 734-995-4930 

1. Serialized Tracking Systems

Interested Participants: Oklahoma Air Logistics Center

2. Remote Inspection of Confined Spaces

Interested Participants: PSNS, PHNSY, PNS, NNS, Penn State ARL, Ford, GM, Ethereal, Ogden ALC, AES  Total Quality Systems

3. Predictive Analysis

Interested Participants: OC-ALC, OO-ALC, NUWC Keyport, RLW, Cincinnati Machine

4.  Obsolescence Tracking

Interested Participants: NUWC Keyport, DLA, OC-ALC, OO-ALC, NSWC Crane

5.  Non-skid coatings

Interested Participants: Penn State (ARL),Puget Sound NSY, Norfolk NSY, H&R Technologies, POM

6.  Reverse Engineering

Interested Participants: Boeing, NUWC Keyport, USMC

7.  Rapid Manufacturing & Repair

Interested Participants: NUWC Keyport, USMC, PHNSY, PSNS, Extrude Hone, POM

8.  Automated Test Equipment (self-diagnosis, mobile, and reconfigurable)

Interested Participants: Ogden ALC, NUWC Keyport, TYAD, Teradyne, Honeywell

9.  High Performance Motion Control Devices

Interested Participants: IQL, Warner Robins ALC, Caterpillar, Boeing, Honeywell, Cincinnati Machine 

Additional Project Ideas (track 4 - Advanced Manufacturing):

10. HAZMAT Reduction

11. Fuel System Prob reduction

12. Performance-based Acquisition

13. Parts Tracking

14. Predictive Analysis Tools

15. Flow Day Reductions

16. Roadmapping

17. Coatings

18. Fuel Cells

19. Maintenance Mentoring Systems

20. Process Flow modeling

21. Configuration Management

22. Knowledge Management

23. Transition to Lean

24. Microchip Tracking

25. Loft foil to CAD conversion

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