Achievement Award Winners
2008 Award Recipients
LASCOR Panel Evaluation and Implementation Phase II
The Navy Metalworking Center (NMC) led the effort to transition LASer-welded corrugated-CORe (LASCOR) metallic sandwich panels to future Navy applications. LASCOR is a stiff, lightweight and modular steel structure that offers corrosion resistance, reduced weight and less distortion.
Because of the superior technical performance and the competitive cost of this technology, LASCOR is currently being used to develop DDG 1000 Deck Edge Safety Berms and Personnel Safety Barriers for General Dynamics Bath Iron Works and Northrop Grumman Shipbuilding–Gulf Coast.
LASCOR technology is estimated to have significantly reduced the Navy’s overall acquisition procurement cost based on increased competition and a low-cost solution.
The NMC project was recognized for optimizing the LASCOR design for materials, manufacturability, joining, structural and protection performance and cost, as well as successfully manufacturing large (78 x 240-inch) LASCOR panels of CRES 2003, a lean duplex stainless steel from Allegheny Ludlum.
Testing has shown that these panels provide enhanced strength, protection and corrosion resistance. Other potential LASCOR applications being investigated for implementation include decks, bulkheads, covers, doors, ramps and other structural applications.
LASCOR project team members included the Office of Naval Research, Concurrent Technologies Corporation, Bath Iron Works, Applied Thermal Sciences, Northrop Grumman Shipbuilding, Naval Surface Warfare Center Carderock Division, Naval Sea Systems Command and the Institute for Manufacturing and Sustainment Technologies.
Government / Industry Team Members:
- Jessica Stainback McDonald, Naval Surface Warfare Center, Carderock Division
- Gregory Woods, Office of Naval Research Manufacturing Technology Program
- Robert Spangler, Navy Metalworking Center/Concurrent Technologies Corporation
- Kevin Stefanick, Navy Metalworking Center/Concurrent Technologies Corporation
- Michael Lichtenfels, Navy Metalworking Center/Concurrent Technologies Corporation
- Applied Thermal Sciences
- David Roberts, General Dynamics Bath Iron Works
- David Bergstrom, Allegheny Ludlum
- Michael Bjornson, Naval Sea Systems Command
Advanced Low Observable Coatings Program
High performance coatings require concise thickness control at the nanometer/micron thickness . Current batch processes for these coatings are prohibitive in cost and throughput to support transition. Unfortunately, no manufacturing process previously existed to prepare these films based on metals, ceramics and polymers on a continuous industrial scale.
The fundamental element of the Advanced Low Observable Coatings (ALOC) facility is its ability to deposit nanolayer films using either vapor deposition or reactive sputtering on a roll 72” wide and up to 5,000 ft long. This is complemented by a 72” wide liquid roll coater capable of depositing polymer films as thin as .2 micron (200 nanometer). For the lightweight paints these thin films are removed from a carrier film and broken up in a thin film recovery station. The resulting thin film particles are further processed by drying, grinding, sizing, color blending, and final quality assurance.
These pigment particles are then loaded into the base polyurethane paint and sprayed using standard spray equipment. The resultant paints weigh up to 35 percent less than the baseline polyurethane formulations. The 35 percent weight savings over conventional paints is expected to result in billions of dollars in life cycle cost savings due to this weight reduction.
During the ALOC program, investments were made to enhance the capabilities in several major areas related to production of advanced thin film coatings. ManTech made capability enhancements that included: increased web speeds, increased product quantity without increased deposition time for roll width, greater throughput and higher capacity for the thin film recovery equipment, greater cross web thickness control, and UV cured polymers for the liquid roll coating process.
Government / Industry Team Members:
- Kenneth M. Johnson, Air Force Research Laboratory
- Joseph P. Costantino, Air Force Research Laboratory
- Timothy J. Wisecup, Air Force Research Laboratory
- James N. Satteson, Air Force Research Laboratory
- Ronald Hubbard, General Atomics, Advanced Technologies Group
- Kirk Norton General Atomics, Advanced Technologies Group
- Sean McGarry, General Atomics, Advanced Technologies Group
- PPS Technician Staff, General Atomics, Advanced Technologies Group
2008 Defense Manufacturing Technology Achievement Award Nominees
The manufacturing technology project nominees that were considered for the tenth annual award were completed and/or demonstrated in FY08 or FY09. The nominees were:
- Advanced Low Observables Coatings (ALOC) Facility
- Aerial Multi-Axis Platform (AMP)
- LASCOR Panel Evaluation and Implementation Phase II
- Digital Heads-Up Displays (DHUD) Reflective Microdisplay Device Manufacturing
- Laser Image Projection
- HSLA-115 Evaluation and Implementation for CVN 78
- Development of Friction Stir Welding for Expeditionary Fighting Vehicle (EFV) Hull Components
- Current Generation Active Electronically Scanned Array (AESA) Improvements
- Composite Submarine Sail Cusp