Air force 17. 1 Small Business Innovation Research (sbir) Phase I proposal Submission Instructions

OBJECTIVE: Evaluate performance, reliability, and safety of more complicated circuits repair (e.g., repair of hybrids and modules using extracted die). Develop new techniques to perform assessment as needed.

DESCRIPTION: Die Extraction and Reassembly (DER) has been successfully demonstrated for monolithic military integrated circuits (see AF161-142). Hybrid integrated circuits and multichip modules (that are out of production and without sources of supply) are being repaired by replacement of internal semiconductor die. The die needed for repair are often obsolete. Die extraction offers a low-cost, quick reaction solutions for repairing critical parts from many legacy aircraft and space systems.

Background on DER:

If the needed IC is available but not in the required package, recently another option has emerged. The process is called DER. Typically the same die is supplied in many different packages. The DER process takes a die equivalent to the obsolete die from an undesirable package and reassembles that die into the needed package, hybrid or module. The oil drilling industry’s need for high-reliability, high-temperature electronics drove early development of the DER process. The goal was to take parts in low-cost stress-sensitive plastic packages, developed for systems with benign operating conditions and re-package them for use in extreme, high stress environments. The DoD has similar requirements but the DER techniques have not been certified so as to ensure DER part meet mil grad requirements. Furthermore, the tools, techniques, and knowledge needed to certify DER parts for military use are still in development. Innovations are sought to develop tools and techniques that will eventually lead to a certification process similar to those in place for MIL-STD-883 compliant parts. Also innovators are sought to develop the necessary physics based analytical and testing techniques to determine the operating and environmental limits of digital and analog die of different technology families, complexities, functions/performance, from different vendors and die foundries following die extraction and repacking processing.

Care must be taken to ensure ICs match the CAD model parametric for best circuit operation. Military detail specifications often have fewer specified parameters and looser parametric limits than those found in commercial data sheets, though both commercial and mil versions were assembled using the same die. Military equipment designers use part level CAD models that match the parametric content of that part vendor's commercial specification.

PHASE I: Define and document a manufacturing process for DER ICs.

Document an expected return on investment (ROI) with a goal of 3:1.

PHASE II: Document an expected ROI.

PHASE III DUAL USE APPLICATIONS: Use Phase II processes to develop/test DER ICs for use on two aircraft (as different as possible) to resolve reliability and/or diminishing manufacturing sources (DMS) issues.

REFERENCES:

1. Environmental Requirementshttp://www.dla.mil.
- Military Standard (MIL-STD) 883J - Test Method Standard, Microcircuits
- MIL-STD 750 - Test Methods for Semiconductor Devices
- MIL-PRF-38510 - General Specification for Microcircuits
- MIL-PRF-19500 - General Specification for Semiconductor Devices
- MIL-PRF-38534 - General Specification for Hybrid Microcircuits
- MIL-PRF-38535 - General Specification for Microcircuits

2. Defense Logistics Agency (DLA) Approved Test Facilities

3. Statement of Work for Die Extraction/Reassembly Process, AFRL Validation Effort, 21 Aug 2015, F-16 Program Office, Wright Patterson AFB OH.

4. Patented DPEM Process for Die Removal, DPA Components International (Simi Valley, CA)http://www.dpaci.com/patented-dpem-process-for-die-removal.html.

5. Die Extraction Strategy Solves DMSMS Challenges, Global Circuit Innovations (Colorado Springs, CO)http://www.cotsjournalonline.com/articles/view/102446.

KEYWORDS: integrated circuit, IC, microcircuit, Die Extraction and Reassembly, manufacturing, obsolescence, diminishing manufacturing sources, reliability

AF171-122

TITLE: V/W-band Accelerated Life Test System

TECHNOLOGY AREA(S): Space Platforms

The technology within this topic is restricted under the International Traffic in Arms Regulation (ITAR), 22 CFR Parts 120-130, which controls the export and import of defense-related material and services, including export of sensitive technical data, or the Export Administration Regulation (EAR), 15 CFR Parts 730-774, which controls dual use items. Offerors must disclose any proposed use of foreign nationals (FNs), their country(ies) of origin, the type of visa or work permit possessed, and the statement of work (SOW) tasks intended for accomplishment by the FN(s) in accordance with section 5.4.c.(8) of the solicitation and within the AF Component-specific instructions. Offerors are advised foreign nationals proposed to perform on this topic may be restricted due to the technical data under US Export Control Laws. Please direct questions to the AF SBIR/STTR Contracting Officer, Ms. Gail Nyikon, gail.nyikon@us.af.mil.

OBJECTIVE: Develop a V/W-band accelerated-temperature radio frequency (RF) life test system for multi-channel testing of solid-state power amplifier device technologies.

DESCRIPTION: Future V-band and W-band high data-rate satellite communications concepts and related space electronics developments require the lifetime assessment of advanced millimeter-wave solid-state technologies. Assessment results from life test systems provide an indication of advanced millimeter-wave transistor processes’ viability for long-term space application. However, integrated RF accelerated life test (ALT) systems are currently not commercially available for these frequencies. Required is the innovative development of multi-channel RF ALT systems that include low-insertion-loss test fixtures to address V-band (71-76 GHz) and W-band (81-86 GHz) frequencies. The integrated test system should include the RF drive and driver amplifiers required for future life testing of representative Standard Evaluation Circuits (SECs) in the developed system’s V- and W-band WR-12 (60-90 GHz) test fixtures. RF drive considerations should consider the possibility of single-stage SECs, including millimeter-wave single-stage gallium nitride monolithic integrated circuits. The integrated system should further include software monitoring/control of the hardware’s dc and RF inputs and outputs, as well as temperature control and monitoring of baseplate temperatures of the devices-under-test. Independent control and monitoring of each channel’s device-under-test should be addressed with the integrated multi-channel RF ALT system.

PHASE I: Concept design of a multi-channel accelerated-temperature life test system for V/W-band life testing of power amplifier technologies and related standard evaluation circuits (SECs). The design concept should include low-insertion-loss test fixtures to support the RF drive required for 71-76 GHz and 81-86 GHz testing over the life test system’s baseplate temperature limits.

PHASE II: Assembly, test and development of the prototype multi-channel, accelerated-temperature V/W-band life test system designed in Phase I, as well as the demonstration of the prototype low-insertion-loss test fixtures designed in Phase I.

PHASE III DUAL USE APPLICATIONS: The life test systems would support the assessment of advanced RF power transistor processes for military space, airborne, and ground applications and further support the assessment of advanced RF power transistor processes for commercial space, airborne, and ground applications.

REFERENCES:

1. P. Vassiliou, Understanding Accelerated Life-Testing Analysis, 2003 Annual Reliability and Maintainability Symposium, 2003.

2. B. Barr, High Temperature, High Power RF Life Testing of GaN on SiC RF Power Transistors, MA-COM Technology Solution White Paper.

KEYWORDS: RF lifetesting, accelerated temperature, space electronics

TECHNOLOGY AREA(S): Space Platforms

The technology within this topic is restricted under the International Traffic in Arms Regulation (ITAR), 22 CFR Parts 120-130, which controls the export and import of defense-related material and services, including export of sensitive technical data, or the Export Administration Regulation (EAR), 15 CFR Parts 730-774, which controls dual use items. Offerors must disclose any proposed use of foreign nationals (FNs), their country(ies) of origin, the type of visa or work permit possessed, and the statement of work (SOW) tasks intended for accomplishment by the FN(s) in accordance with section 5.4.c.(8) of the solicitation and within the AF Component-specific instructions. Offerors are advised foreign nationals proposed to perform on this topic may be restricted due to the technical data under US Export Control Laws. Please direct questions to the AF SBIR/STTR Contracting Officer, Ms. Gail Nyikon, gail.nyikon@us.af.mil.

OBJECTIVE: Develop dual Ka-band and Q-band low noise amplifiers for satellite communications (SATCOM), point-to-point digital radios, and wideband receiver applications.

DESCRIPTION: Signal noise poses a significant challenge to long-distance satellite communications, impacting bit error rates, the level of transmitter radiated power required to close the link, and, indirectly, the payload size, weight and power. The purpose of this topic is to develop dual Ka/Q-band, innovative, state-of-the-art low-noise amplifiers (LNAs) using advanced low-noise Monolithic Microwave Integrated Circuit (MMIC) processes to demonstrate compact, producible, dual-band Ka-band and Q-band LNAs for space and terrestrial applications. This topic is intended to support research exploring the best approach and process for achieving low noise and high gain over both Ka and Q-band with optimum linearity (measured by the output third-order intercept point, or OIP3, across the frequency of operation). The goal is to demonstrate the ~2 dB noise figure level-of-performance that can currently be achieved in separate Ka-band and Q-band low-noise amplifiers for satellite application, but instead accomplish this noise figure performance in a single dual-band LNA. Overall performance goals include simultaneous operation at Ka-Band (27.5 to 31.0 GHz) and Q-Band (43.5-47 GHz), with noise figure at room temperature <2.0 dB, small signal gain >20 dB, input and output return loss better than -10 dB, power consumption <500 mW, IIP3 >5 dBm, OIP3 >25 dBm, and RF input survivability of 1W. An operating temperature range -40 to +85 degrees C is anticipated. The total dose radiation tolerance goal is 300 krad (Si).

PHASE I: Design a dual Ka-band and Q-Band MMIC LNA meeting the objectives identified above. Validate the LNA design through modeling and simulation.

PHASE II: Fabricate the LNA MMIC design(s) for dual Ka-band and Q-band. Characterize for amplifier noise, gain, linearity, and power consumption under typical operating conditions.

PHASE III DUAL USE APPLICATIONS: Military low noise amplifiers for these frequency bands will support WGS and AEHF follow-on satellites and point-to-point digital radios. Commercial LNAs operating at these frequencies will support commercial millimeter-wave wireless and wideband receiver applications.

REFERENCES:

1. Armengaud, V., Laporte, C., Jarry, B., Babak, L., “27–31 GHz MMIC low noise amplifier with filtering functions for space communication system,” 19th International Crimean Conference, 14-18 Sept. 2009.

2. Qiangji Wang, Yunchuan Guo, “Ka-band self-biased monolithic gaas pHEMT low noise amplifier,” Microwave Technology & Computational Electromagnetics (ICMTCE), 2011.

3. Qian Ma, Leenaerts, D., Mahmoudi, R., “A 30GHz 2dB NF low noise amplifier for Ka-band applications,” Radio Frequency Integrated Circuits Symposium (RFIC), 2012.

4. Yu-Lung Tang, Wadefalk, N., Morgan, M.A., Weinreb, S., “Full Ka-band High Performance InP MMIC LNA Module,” IEEE MTT-S International Microwave Symposium, 2006.

5. Moyer, H.P., Kurdoghlian, A., Micovic, M., Lee, T., “Q-Band GaN MMIC LNA Using a 0.15µm T-Gate Process,” Compound Semiconductor Integrated Circuits Symposium, 2008.

6. Schwantuschke et al; “Q- and E-band Amplifier MMICs for Satellite Communication,” IMS 2014, June 2014.

KEYWORDS: Ka-band, Q-band, LNA, MMIC

TECHNOLOGY AREA(S): Air Platform

The technology within this topic is restricted under the International Traffic in Arms Regulation (ITAR), 22 CFR Parts 120-130, which controls the export and import of defense-related material and services, including export of sensitive technical data, or the Export Administration Regulation (EAR), 15 CFR Parts 730-774, which controls dual use items. Offerors must disclose any proposed use of foreign nationals (FNs), their country(ies) of origin, the type of visa or work permit possessed, and the statement of work (SOW) tasks intended for accomplishment by the FN(s) in accordance with section 5.4.c.(8) of the solicitation and within the AF Component-specific instructions. Offerors are advised foreign nationals proposed to perform on this topic may be restricted due to the technical data under US Export Control Laws. Please direct questions to the AF SBIR/STTR Contracting Officer, Ms. Gail Nyikon, gail.nyikon@us.af.mil.

OBJECTIVE: Produce a low cost, ultra-long endurance (>7 day) Unmanned Air Vehicle (UAV) suitable for intelligence, surveillance and reconnaissance (ISR) missions.

DESCRIPTION: Unmanned air vehicles play an important role in today’s military operations. They are invaluable in locating time critical targets, reporting enemy positions and movements to battlefield commanders, and destroying tactical targets. One important aspect of these operations is the ability to provide persistence in monitoring an area of interest. Most of the current UAV’s are designed to remain in flight for time periods of 20-40 hours, primarily limited by fuel capacity. This creates a deployment and logistics challenge for battlefield commanders to maintain eyes on target for extended periods of time, which is usually achieved by deploying multiple waves of UAVs.

The objective of this topic is to develop a low cost UAV with very long endurance, of at least seven days, that would enable the ISR mission to be accomplished with reduced manpower and system resources (esp. number of vehicles) to maintain near continuous coverage. Operating footprint should minimize personnel and hardware as compared to other UAV systems. Notionally the UAV will transit from its launch point to the area of interest nominally several hundred miles away, and loiter in that region for the mission duration, although the ability to move quickly between nearby areas of interest is also desired. The UAV should provide the capability to fly at 10,000-15,000 feet AGL, with a payload of 250lbs and 2000W power requirement. The system must be able to operate in 50 knot winds aloft, with minimal degradation in range and endurance or deviation from the area of interest. The system must also demonstrate minimal acoustic and visual signature to be virtually undetectable by ground personnel. The system must also be able to transit light to moderate icing conditions associated with climbing and descending through stratus cloud layers containing known icing conditions. The system does not need to loiter for prolonged periods in icing conditions. Typical take-off profiles are constant slope and minimum altitude changes are required once on profile.

A number of possible technologies can be considered to meet this requirement, but it is anticipated that the most likely candidates include hybrid power systems, solar power, and possibly power harvesting. Other technologies such as conventional airships (may not meet winds aloft requirement), laser power transmission (difficult to provide laser transmission to remote areas of interest), and tethered aircraft (no flexibility to move to remote areas) may not be suitable unless innovative approaches can be developed to overcome their limitations for the envisioned missions.

Some key desired capabilities of the system are:

PHASE I: The contractor shall provide trade studies and engineering design necessary to define the operational system & associated technologies. The contractor shall show evidence that key enabling technologies are adequately mature (e.g., Technology Readiness Level >=6). Key enabling technologies shall include propulsion system, electrical power generation, flight control adequate to control necessary endurance parameters, energy storage, & anti-icing systems if required.

PHASE II: The contractor shall develop and test a UAV that provides the capability to loiter over an area of interest for >7 days.  The test program shall culminate in a demonstration, on a government test range, of >7 days endurance at representative altitudes, carrying payload and mass simulators totaling 250 lbs.

PHASE III DUAL USE APPLICATIONS: The various technologies developed in Phase II are applicable to military and government applications. There are potential commercial applications in a wide range of diverse fields that include airborne communication nodes for cellular communications, crop monitoring, and site security.

REFERENCES:

1.  “Effect of power system technology and mission requirements on high altitude long endurance aircraft”, Colozza, Anthony J. NASA Report Number NASA-CR-194455, 1994.

2. “Low Reynolds number, long endurance aircraft design”, Foch, R. & Ailinger, K. AIAA, Aerospace Design Conference, Irvine, CA, 3-6 February 1992.

3. “High Altitude Long Endurance Air Vehicle Analysis of Alternatives and Technology Requirements Development” Craig L. Nickol and Mark D. Guynn and Lisa L. Kohout, Thomas A. Ozoroski, 45th AIAA Aerospace Sciences Meeting, Reno, NV, 8-11 Jan. 2007.

KEYWORDS: long endurance air vehicle, unmanned aerial system, UAV, airborne surveillance, persistent intelligence surveillance and reconnaissance

AF171-125

TITLE: Aerial Refueling of UAVs

TECHNOLOGY AREA(S): Air Platform

The technology within this topic is restricted under the International Traffic in Arms Regulation (ITAR), 22 CFR Parts 120-130, which controls the export and import of defense-related material and services, including export of sensitive technical data, or the Export Administration Regulation (EAR), 15 CFR Parts 730-774, which controls dual use items. Offerors must disclose any proposed use of foreign nationals (FNs), their country(ies) of origin, the type of visa or work permit possessed, and the statement of work (SOW) tasks intended for accomplishment by the FN(s) in accordance with section 5.4.c.(8) of the solicitation and within the AF Component-specific instructions. Offerors are advised foreign nationals proposed to perform on this topic may be restricted due to the technical data under US Export Control Laws. Please direct questions to the AF SBIR/STTR Contracting Officer, Ms. Gail Nyikon, gail.nyikon@us.af.mil.

OBJECTIVE: Radically increase mission length and on-station availability of Unmanned Air Vehicles (UAVs) by developing capability to conduct air-to-air refueling (AAR) of Groups 4 and 5 UAVs with calibrated airspeeds of 130 KCAS or less.

DESCRIPTION: Unmanned air vehicles play an important military role for locating time critical targets, reporting enemy positions and movements to battlefield commanders, and destroying strategic targets or lethal ground systems. Additionally, these unmanned systems are being designed to remain in flight for time periods of multiple days or more. Unfortunately, returning to base of operations to obtain additional fuel creates a deployment and logistics challenge.

Boom-and-receptacle and probe-and-drogue are the two hardware configurations and methods commonly used for AAR. In the former, a refueling boom on the rear of the tanker aircraft is steered into the refueling port on the receiver aircraft. In this method, the job of the receiver aircraft is to maintain proper position with respect to the tanker. With the probe-and-drogue method, the tanker aircraft trails a hose with an aerodynamically stabilized flexible “basket” or drogue. The receiver aircraft has a probe that must be placed or docked into the drogue. This is the preferred method for small, agile aircraft because the equipment is small and lightweight, and a human operator is not required on the tanker aircraft.

One of the challenges faced in AAR is minimum airspeed. For this effort the focus will be Groups 4 and 5 UAVs with maximum airspeeds of 130 KCAS. In order to maximize potential on-station capability, it is desirable to minimize the distance the UAV must travel in order to reach the refueling orbit. Since many military UAVs operate inside hostile territory, bringing a large manned tanker into this arena is problematic. Because of this, an unmanned, automated tanker could a potential solution.