Defense Manufacturing in 2010 and Beyond Meeting the Changing Needs of National Defense (1999) / Chapter Skim
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2 Defense Manufacturing Capabilities Required for 2010
2 Defense Manufacturing Capabilities Required for 2010
Pages 19-46
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From page 19... ...
This requires improved design methods and 19
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From page 20... ...
DEFENSE NEEDS FOR 2010 The committee reviewed DOD documents to determine the technology areas that will be important for future defense manufacturing, including a DOD technology forecast regularly generated in an effort to plan for future needs. This forecast, known as the Defense Technology Area Plan (DTAP)
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From page 21... ...
A key manufacturing capability is the design and processing of high strength-to-weight materials, particularly composites, for which new design concepts and processing methods are needed to reduce costs. Electronic systems must also be designed and packaged to withstand the high g forces and vibrations in this severe environment.
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Defense-unique needs for subsurface sea combat vessels (submarines) include: reducing acoustic signatures and increasing shock resistance while reducing costs.
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Requirements include: smaller crews, automated drivers, training, smaller radar signatures, reduced mobility component weight and volume, and increased power. Integrated product and process development and virtual prototyping are two of the manufacturing capabilities that will be critical to meeting these challenges (DTAP, 1997~.
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From page 24... ...
; and smaller ramjet components. These technical challenges in manufacturing requirements are aimed at miniaturization, low-cost production processes, and advanced composite materials and processes and should be addressed in an integrated manner.
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Several major manufacturing and design challenges are associated with these weapons, including: packaging constraints for electrothermal chemical technologies; the development of high-efficiency plasma igniters; the development of high-energy-density propellants; the development of an advanced medium-caliber composite barrel with high-efficiency rail design; weight minimization; and smaller component sizes for electromagnetic and directed energy weapons. Cross-cutting Technologies Several technology areas for defense products, which are broadly applicable to defense systems, are discussed below.
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From page 26... ...
Both tracked and wheeled tactical vehicles will have built-in low observability features. For example, the future scout and cavalry system will be designed to avoid detection; the Marines' advanced amphibious assault vehicle will have reduced radar, acoustic, and infrared signatures; even self-propelled artillery and tanks, arguably the least stealthy systems, will have reduced visual, acoustic, infrared, and muzzle blast signatures.
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From page 27... ...
According to DTAP, controlling vortex flow and flow separation in low observable configurations is a major technical challenge for air platform technology (DTAP, 1997~. DTAP also lists technical challenges for the acoustic signatures of submarines in complex hydrodynamic flows, including improved understanding of hydrodynamic forcing mechanisms and the resulting response and acoustic radiation of structural components, and improved prediction of highly complex hydrodynamic flows to reduce the need for experimental evaluations and to enable the development of propulsors and maneuvering concepts.
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Radar Sensors. The radar used in military combat systems, such as fighters, bombers, and tanks, is different in purpose and technical requirements from the radar used in commercial aircraft and by law enforcement agencies.
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Infrared windows can be made from various materials, all of which are costly. For sensors in high-performance, stealth aircraft like the F-22, both the materials and manufacturing processes are expensive.
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DTAP lists several major technical challenges in the area of warnings against radar threats, including the development of a high-accuracy direction-finding capability; the development of functional elements using monolithic microwave integrated circuits (MMICs) ; and pulse-level specific emitter identification extraction, processing, and automation (DTAP, 1997~.
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From page 31... ...
. improve packaging to increase structural reliability and reduce connector problems · improve built-in test diagnostics to reduce "retest OKs" and reduce the amount spent on automated external test equipment · use modular/throwaway components to facilitate maintenance by eliminating the need to return the components to a depot and repair them · develop prognostic capabilities, or intelligent system health monitors, to facilitate maintenance and reduce life-cycle costs replace military specification cards with COTS hardware to lower costs substantially and improve reliability (provided that the hardware can withstand the required environmental stresses or can be mounted on shock mountings or otherwise protected)
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From page 32... ...
Widespread commercial applications of this technology for single-chip packaging, multichip packaging, and direct attachment to printed wiring boards are expected by 2010. For advanced military applications, reliability measures will include thermal shock resistance, thermal cycling fatigue, temperature or humidity bias, and mechanical shock and vibration resistance.
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From page 33... ...
Some of the specific capabilities are listed below: · systems architectures that permit the secure use of COTS computers, software, and networks . · interoperability of defense logistics systems and the diverse systems used by suppliers network management and control protocols for data security in distributed design and manufacturing operations to prevent interruption, jamming, sabotage, and interception · models for defense products with multiple levels of resolution to enable simulation-based design · databases of weapons system life-cycle costs that can be integrated into design systems to enable life-cycle cost trade-offs simultaneously with design evolution · production process capabilities and cost databases that can be integrated into design systems to provide simultaneous assessments of design alternatives and production costs, manufacturing risks, and manufacturing systems designs product data models and storage and retrieval architecture capable of seamlessly handling all data modalities product structure directories to meet unique structural requirements for defense products that also have open architecture and meet commercial standards
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Manufacturing capabilities that will be critical to minimizing unit production cost at low production rates include: flexible production lines, procurement of materials in bulk, modeling of production during the design process. and adaptive process control to achieve 100 percent first time yields.
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The application of advanced computer-aided visualization techniques can provide a thorough understanding of dimensional changes throughout the construction process and help determine specific process changes to improve dimensional quality. The key term in dimensional control is "as-built," which assumes postoperation (e.g., after the part has been machined)
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From page 36... ...
Automated manufacturing processes and inspection and measurement systems should provide highly accurate and automated dimensional quality control in making, cutting, forming, assembling, and welding parts using tools and processes, such as lasers, water jets, electron beams, and high-speed machining. Automated, highly accurate systems are needed for verifying the accuracy of assembly tools and component locations.
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From page 37... ...
Overall Process Optimization above the Plant Floor Optimal effectiveness and efficiency of manufacturing systems will require improvements "above the plant floor," as well as improvements on the floor. The establishment of a nonrecurring manufacturing process control requires simultaneous product and process views, single view management, a single numbering system (e.g., for work orders, work breakdown structure, shop orders, drawing numbers, part/assembly numbers)
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From page 38... ...
to operate reliably in harsh military environments open-system architectures (including modular designs) to facilitate upgrading systems and accommodate unexpected changes in the availability of parts · intelligent health monitoring systems for electronic mechanical subsystems with predictive capabilities to facilitate maintenance · dimensional control in large structures · adaptive process controls to improve first-time yields · life-cycle cost analyses concurrent with design .
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From page 39... ...
DEFENSE MANUFACTURING CAPABILITIES REQUIRED FOR 2010 TABLE 2-1 Required Defense Manufacturing Capabilites Based on the Defense Technology Area Plan 39 Technology Area Manufacturing Capability Weapons System Platform Technologies Aircraft weapons systems Surface and subsurface sea combat vessels Land combat vehicles Weapons Technologies Expendable munitions Repair techniques for aging systems Nonintrusive, real-time monitoring techniques for flight loads and damage Design techniques and processing methods for high strength-to-weight materials, particularly composites Design concepts and processing methods that reduce the costs of composite structures Electronic systems able to withstand high g loads and severe vibrational environments Affordable processing methods for launch equipment with reduced drag and signature Weapons systems capable of launching weapons at high speeds and under high g loadings Design concepts that minimize weight and volume of vessel systems and reduce life-cycle costs Automated, intelligent monitoring and control systems System-level design approaches to reduce acoustic signatures and cost, and increase shock resistance Design simulations to enable accurate performance versus cost trade-offs Maintenance and upgrade technologies for aging systems Integrated product and process development Virtual prototyping High-yield, robust fuze production process Methods for precise filling of explosives in munitions Automated filling of explosives in munitions to increase safety, improve process yield, and ensure performance continued
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40 TABLE 2-1 continued DEFENSE MANUFACTURING IN 2010 AND BEYOND Technology Area Manufacturing Capability Missiles and torpedoes Guns Mobile weapons systems Cross-cutting Technologies Low observability technology Sensors Methods for miniaturizing system components Low-cost production processes Composite materials for advanced propulsion systems Methods to reduce cycle time and nonrecurring costs in production processes Overall system designs based on common subsystems Methods to reduce cycle time and nonrecurring costs Methods for packaging electrothermal chemical technology Designs for high-efficiency plasma igniters and highenergy-density propellants Designs for high-efficiency rails Designs to minimize weight and size of components Precise, automated methods for applying low observability coatings Process control sensors that can operate in hostile processing environments Affordable manufacturing techniques, processes, and tools that can form complex shapes with high stealth and aerodynamic/hydrodynamic performance Process models based on finite-element analysis of materials characteristics during forming Conformal mold line technology Methods for design trade-offs to minimize signatures created by gaps and edges Radar-absorptive materials and structures that are strong, lightweight, able to withstand extreme heat, formable into complex shapes, and affordable Designs for lightweight, effective infrared shielding Designs for high-performance radomes and infrared windows that are affordable and easy to manufacture Designs for electro-optical systems that are affordable, easy to install, and that have minimal drag and signatures High-density packaging for functional elements using monolithic microwave integrated circuits
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From page 41... ...
DEFENSE MANUFACTURING CAPABILITIES REQUIRED FOR 2010 TABLE 2-1 continued 41 Technology Area Manufacturing Capability Electronics Automated validation tools to replace flight testing Commercial software systems to replace proprietary systems Methods to bridge existing networks using field programmable gate arrays, new wiring, and commercial protocols Avionics packaging with increased structural reliability and reduced connector problems for aging systems Built-in test diagnostics for aging systems Modular components to facilitate maintenance of aging systems Intelligent health monitors for aging systems Commercial hardware to replace military specification cards and improve reliability Commercial programmable network protocols to replace existing buses and networks and reduce costs Software engineering tools to facilitate upgrades and cope with rapid obsolescence of electronic technology Lightweight chip-on-board platforms that feature electronic miniaturization Platforms with reliability in terms of thermal shock resistance, thermal cycling fatigue, temperature and humidity tolerance, and mechanical shock and vibration resistance. Materials, components, and processes that can be used in harsh military environments High-precision, high-reliability connectors, back planes, and traces Interruption-free connector systems Optical interconnections for ultra-high data rates Manufacturing processes for multilayer boards Conformal coating techniques and capacities to prevent dendritic growth Glass manufacturing technology for liquid crystal displays continued
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42 TABLE 2-1 continued DEFENSE MANUFACTURING IN 2010 AND BEYOND Technology Area Manufacturing Capability Information systems Manufacturing Processes and Technologies Production rate transparency Composite repairs Systems architecture that permits secure use of commercial-off-the-shelf computers, software, and networks Defense logistics systems that are interoperable with the diverse systems used by suppliers Network management and control protocols to ensure data security in distributed design and manufacturing operations Product models with multiple levels of resolution for simulation-based design Databases containing weapons system life-cycle costs for integration into design systems Production process capabilities and cost databases for integration into design systems Product data models and storage and retrieval architectures capable of handling data seamlessly Product structure directories that are open and meet commercial standards Intelligent agents for locating and retrieving information Automated reverse-engineering systems based on scanning of the actual part Parametric modeling to enable design trade-offs Flexible production line Procurement of materials in bulk Methods for modeling production processes during design Adaptive process controls to enable 100 percent first time yields Automated composite repairs On-system, on-site repair technologies and processes that are affordable and efficient
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DEFENSE MANUFACTURING CAPABILITIES REQUIRED FOR 2010 TABLE 2-1 continued 43 Technology Area Manufacturing Capability Dimensional control Titanium processes Overall process optimization above the plant floor Manufacturing processes and assembly sequences that determine dimensional tolerance stack-ups for modular construction Design methods that incorporate tolerance stack-ups at interfaces between modules or assembled parts Measurement systems that provide highly accurate electronic information on as-built parts Computer-aided visualization techniques Noncontact inspection during manufacturing operations Process data systems that integrate product analysis and design, manufacturing process analysis and design, tool analysis and design, and inspection/ control system analysis and design Computer-aided design systems that integrate design, production processes, measurement processes, and compare ideal and as-built products Automated, highly accurate dimensional control systems using advanced photographic or laser technology Nondestructive inspection technology for titanium castings Method for coating structural titanium investment castings that produces limited reaction with molten titanium and where inclusions are detectable Process for producing titanium honeycomb from alloy 15-3 Nonrecurring manufacturing process control with single view management, single numbering system, visual statusing system
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From page 44... ...
44 DEFENSE MANUFACTURING IN 2010 AND BEYOND TABLE 2-2 Broad Categories of Required Defense Manufacturing Capabilities Category Manufacturing Capability Composites processing and repair Electronics processes Information technology systems Design methods and processes for low-cost structural composites Design methods for low-cost composite materials Composite materials for advanced propulsion systems Low-cost composite surfaces for tactical missiles Automated composite repairs On-system, on-site composite repair technologies that are affordable and efficient Intelligent health monitoring systems Electronic systems able to withstand high g loads and severe vibrational environments High-density packaging for functional elements using monolithic microwave integrated circuits Electronics packaging with increased structural reliability Built-in test diagnostics Commercial programmable network protocols to replace existing buses and networks Software engineering tools to facilitate upgrades Lightweight chip-on-board technology for miniaturization High-precision, high-reliability connectors, back planes, and traces Interruption-free connector systems Optical interconnections for ultra-high data rates Designs to prevent dendritic growth in high-density electronics Manufacturing technology for liquid crystal displays Commercial software systems to replace proprietary systems Systems architecture that permits secure use of commercial off-the-shelf computers, software, and networks Defense logistics systems that are interoperable with the diverse systems used by suppliers Network management and control protocols to ensure data security in distributed design and manufacturing operations Databases containing weapons systems life-cycle costs for integration into design systems Production process capabilities and cost databases for integration into design systems
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From page 45... ...
DEFENSE MANUFACTURING CAPABILITIES REQUIRED FOR 2010 TABLE 2-2 continued 45 Category Manufacturing Capability Information technology systems continued Sustainment Design, modeling, and simulation Product data models and storage and retrieval architectures capable of handling data seamlessly Product structure directories that are open and meet commercial standards Intelligent agents for locating and retrieving information Automated reverse-engineering systems based on scanning of the actual part Nonrecurring manufacturing process control with single view management, single numbering system, and visual statusing system Repair techniques for aging systems Nonintrusive, real-time monitoring techniques for flight loads and damage Maintenance and upgrade technologies for aging systems Automated validation tools to replace flight testing Avionics packaging with increased structural reliability and reduced connector problems for aging systems Built-in-test diagnostics for aging systems Modular components to facilitate maintenance of aging systems Software engineering tools to facilitate upgrades Product models that enable accurate life-cycle performance versus cost trade-offs Integrated product and process development Virtual prototyping System designs based on common subsystems Process simulations based on finite-element analysis of materials characteristics during forming Product models that enable stealth versus other performance characteristics trade-offs Designs for affordable, high-performance radomes and infrared windows Designs for affordable, easy-to-install electro-optical systems with minimum drag and signature Product models with multiple levels of resolution to enable simulation-based designs Parametric modeling to enable design trade-offs continued
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From page 46... ...
46 TABLE 2-2 continued DEFENSE MANUFACTURING IN 2010 AND BEYOND Category Manufacturing Capability Integrated product, tool, and manufacturing process designs Design methods that incorporate tolerance stack-ups Computer-aided design systems that integrate design, production processes, measurement processes Production processes Affordable processing methods for launch equipment with reduced drag and signature High-yield, robust fuze production process Methods for precise filling of explosives in munitions Automated filling of explosives in munitions to increase safety, improve process yield, and ensure performance Methods to reduce cycle time and nonrecurring costs in production processes Precise, automated methods for applying low observability coatings Affordable manufacturing techniques, processes, and tools that can form complex shapes Conformal mold line technology Manufacturing processes for multilayer boards Conformal coating techniques to prevent dendritic growth Glass manufacturing technology for liquid crystal displays Flexible production lines Adaptive process controls to enable 100 percent first time yields Manufacturing processes and assembly sequences that determine tolerance stack-ups for modular construction Measurement systems that provide highly accurate electronic information on as-built parts Computer-aided visualization techniques Noncontact inspection during manufacturing operations Automated system for accurate location of assembly tools and components Nondestructive inspection for inclusions in titanium castings Process for producing titanium 15-3 honeycomb
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