Army 18. 1 Small Business Innovation Research (sbir) Proposal Submission Instructions

The application of spall suppression liner to minimize secondary fragmentation from ricocheting inside crew compartment and cause additional crew casualties. Fragments produced behind the armor by: residual penetrator pieces, the armor plug, and, the spall ring, when an armor hulled vehicle is impacted by kinetic energy, chemical energy, or explosively formed penetrator munitions. Fragments released behind the armor can kill or maim crew members, damage/destroy vehicle components, or cause inflammables to ignite. Damage caused by fragments can result in: mobility, firepower, or catastrophic system kills. In many cases, debris causes most of the lethality.

The intent is to develop one material that has energy absorption and spall material properties to absorb kinetic energy in a controllable and predictable manner, in such a way as to reduce the level of energy experienced by the vehicle and its occupants. Currently there is not a material that can be used as an interior trim energy absorption and spall liner material used in the interior of military vehicles.

Additionally, any materials which are used for military applications need to be validated for acoustical, thermal, and flame, smoke, and toxicity requirements. There is a variety of commercially available energy absorbing material or spall liner with both recoverable and non-recoverable characteristics; however the commercially available materials are not designed to comply with both requirements and with a high level of resistance to flame, smoke and toxicity, acoustical, and thermal.

The challenge to the military vehicle designer is to provide a material solution that can encompass one material solution for multiple purposes. The characteristics of the material are unique to military vehicle interior applications due to the vehicle’s exposure to blast events typically from IEDs. Unlike a commercial automobile, military vehicles are designed with heavy armor, heavy transparent armor and are significantly more enclosed. Upon the and underbody blast event, for which the armor is penetrated and the vehicle interior is exposed to high heat and/or flame, the materials inside the vehicle shall resist FST, to the extent the occupant has sufficient time to evacuate the vehicle.

PHASE I: Phase I of this effort shall consist of a feasibility study and concept development of one or more spall resistant energy absorption (EA) material(s). The feasibility study shall describe through an analytical approach the means for which the proposed material will be developed to achieve a pass performance to MIL-STD-662 and FMVSS 201U. The vehicle shall use a spall liner to reduce the lethality of behind-armor debris (BAD) to the occupants in normal fighting position from overmatching threats with performance requirements established in IAW ITOP 2-2-716 using both shaped-charge jet (SCJ) and explosively-formed penetrator (EFP) threats (specific threats to be defined by the Government at the start-of-work meeting). The energy absorption head impact criterion of HIC(d) < 1000 threshold and HIC(d) < 700 objective are the level of protection required. The concept development shall provide the expected performance of the proposed material’s protection capability and how this performance shall be achieved. The material concept may include multiple layers of materials. Design constraints shall be clearly defined. The material concept(s) shall provide confidence in support of performance to the following specifications, supported by sound engineering principles:

1. FMVSS 201U

Analytical tools such as Finite Element Analysis and modeling and simulation where appropriate, shall be used for this purpose. The outcome of Phase I shall include the scientific and technical feasibility as well as the commercial merit for the material concept solution provided. The concept(s) developed shall be supported by engineering principles. Supporting data along with material safety data sheets and material specifications shall also be included if available. The projected development and material cost and timing shall be included in the study. Phase I shall cover no more than a 6-month effort.

PHASE II: Phase II of this effort shall demonstrate the material concept(s) successfully perform to the criteria developed in Phase I.

The contractor shall also perform head impact testing on the material sample(s).The designed system (after being validated to the above criteria), shall be presented to TARDEC for validation testing. Ten (10) component level material samples sized 12”x12” samples shall be shipped to SANG for pre-verification of energy absorption head impact performance of less than 1000 HIC(d) 15ms at 15mph.

The contractor shall demonstrate through testing that the EA spall material reduces lethality of behind-armor debris (BAD). The contractor shall perform testing IAW ITOP 2-2-716 using both shaped-charge jet (SCJ) and explosively-formed penetrator (EFP) threats (specific threats to be defined by the Government at the start-of-work meeting). Three (3) tests shall be conducted with each threat against 24”L x 24”W x 0.5”Thk Rolled-Homogeneous Armor (RHA) per MIL-DTL-12560K, Class 1, in contact with both the EA spall material as well as MIL-STD-62474, Type 2, Class B material of equivalent areal density to the proposed EA spall material. The proposed EA spall material shall demonstrate an average reduction in the total number of fragmentation holes in the first plate, as well as average reductions in the 95th percentile cone half-angle in both the first and second plates.

The contractor shall demonstrate through testing that the EA spall liner does not ignite readily when exposed to a ballistic engagement, and shall not exhibit any form of melting or dripping when fully engaged in a fire event, and shall be self-extinguishing once a fire source is removed from the material. The contractor shall conduct testing of the EA spall liner material IAW ASTM E162 and demonstrate a flame spread index less than twenty-five (25). The contractor shall conduct testing of the EA spall liner material IAW ASTM E1354 (cone calorimetry) and demonstrate a 50kW/m2 flux with an average peak heat release rate less than eighty five (85). The contractor shall conduct testing of the EA spall liner material IAW ASTM E662 and demonstrate a smoke obscuration index less than two-hundred (200).

Once approved six samples of the system shall be provided for integration onto a vehicle for the purposes of blast, crash, roll over testing. The Contractor shall assist TARDEC in the installation of the parts to ensure proper fit and finish is achieved. The size of the sample shall be defined by the vehicle structure which will be made available by TARDEC to the contractor at the beginning of Phase II. In addition Phase II shall focus upon the validation and correlation of the modeling and simulation effort mentioned in Phase I, along with the fabrication and validation of the proposed material(s).

Additionally the study in Phase II shall provide test data, reports and all modeling and simulation models used to develop the system for concept validation. Any required modifications and retesting shall be conducted during phase II.

Note: the material shall also be durable and resist FST with minimal impact on the energy absorption performance of the material. The material shall demonstrate the ability to absorb energy and not fragment. The system shall also provide visual indication that it is damaged and not intended for additional impacts, example being crazing, evident deformation, color change or color with a distinct odor.

PHASE III DUAL USE APPLICATIONS: In the final Phase of the project the contractor shall prove out the effectiveness of the system on an Army Vehicle (or vehicle that is representative of a vehicle in the Army fleet) in both blast and crash scenarios. The contractor shall provide a material prototype for the roof and foot wells of the military vehicle (e.g. Bradley, MATV, Stryker, HMMWV, NGCV). If the material solution is also capable of being utilized for small component protection such as grab handles, then the contractor shall also provide a prototype component as such. The prototype material shall be validated by the contractor. This system has the potential to be utilized in any Military and Civilian truck and automotive applications, as well as potential naval applications, further study for naval applications may be required however. Additionally, the material will be applicable to commercial automotive industry.

REFERENCES:

1. FMVSS 201/201U, MIL-STD-2031 Fire and Toxicity Test, MIL-STD-1623 Fire Performance, ISO 12219-3 Interior Air of Road Vehicles, MIL-STD-810 Environment, MIL-STD-1472 Human Factors, MIL-HDBK-310 Global Climatic Data, ASTM G-21, ASTM E162 Surface Flammability of Materials, ASTM E1354 Heat and Smoke, ASTM E662 Smoke Occurrence, ASTM D6264/D6264M-12 Damage Resistance for Fiber reinforced Polymer Matrix Composite, ASTM D1242 Resistance to Abrasion, UL-94 Tests for Flammability of Plastic Materials

2. Pizhong Qiao,1 Mijia Yang,2 and Florin Bobaru, Impact Mechanics and High-Energy Absorbing Materials: Review, Journal of Aerospace Engineering, 21:4 (October 1, 2008), pp. 235-248; doi 10.1061.

3. Mertz, Harold, J, Irwin, Annette L., Prasad, Priya, Biomechanical and Scaling Bases for Frontal and Side Impact Injury Assessment Reference Values, Stapp Car Crash Journal, vol 43, (October 2003), pp. 155-188.

4. Qiao, Pizhong, Yan, Mijia, Bobaru, Florin, Impact Mechanics and High-Energy Absorbing Materials: Review, University of Nebraska-Lincoln, Digital Commons@University of Nebraska-Lincoln, (1October2008).

5. LaRue, Laura, Basily B., Elsayed, E.A., Cushioning Systems for Impact Energy Absorption, Department of Industrial and Systems Engineering, Rutgers University, elsayed@rci.rutgers.edu.

KEYWORDS: Spall liner, thermal, HIC (Head Injury Criterion), Occupant Protection, Energy Absorption, material, Flame, smoke and toxicity resistant, Head injury, Occupant Centric, interior trim, acoustical, fragment

A18-085

TITLE: Affordable Electric Unmanned Ground Vehicle Force Protection Sensor System

TECHNOLOGY AREA(S): Sensors

OBJECTIVE: Develop affordable Electric Unmanned Ground Vehicle Force Protection Sensor System that provides a multi-modal sensors to improve Army Force Protection capabilities.

DESCRIPTION: Army Force Protection requirements need to extend beyond perimeter sensor ranges. Previous Unmanned Ground Vehicle (UGV) Force Protection systems have been expensive and provided marginal unmanned sensor capabilities. Sophisticated yet inexpensive commercial sensors and driver-less automobile technology offer the opportunity to make significant advances in extending and lengthening base defense. Developing an affordable and effective Electric Unmanned Ground Vehicle Force Protection Sensor System that provides multi-modal sensors to improve Army Force Protection capabilities is achievable with today’s technology.

Unmanned Ground Vehicle (UGV) shall be 100% electric driven, capable of operating (sensors on) for 2 hours (Threshold) or 6 hours (Objective) on smooth surfaces (roads and fields) with a range of 10 Km (Threshold) or 30Km (Objective), be able to maneuver safely around obstacles and people based on either a pre-programmed route or directed by the Force Protection Command and Control (C2) system. The UGV shall provide steerable flood light and audio (transmit and receive). The UGV shall not cost more than $25,000 (Threshold) or $15,000 (Objective) and no replaceable component may be more than $5,000. Network connectivity (i.e. radios) will be provided by the Army and not part of these requirements.

Force Protection Sensor System shall consist of Electro Optics camera, Infrared (EO/IR) camera, Radar and/or LIDAR sensor(s), and Acoustic Sensors. Electro Optics camera shall provide High Definition (Threshold) or 4K Definition (Objective). Radar and/or LIDAR sensor(s) shall be capable of providing sensor data that can detection and track objects greater than 100 meters (Threshold) or 500 meters (Objective). Acoustic array sensors shall be capable of providing line of bearing within 5% (threshold) or 0.5% (Objective). All sensor data will be processed by the Force Protection C2 (i.e. minimal processing on-board). The Sensor suite shall not cost more than $25,000 (Threshold) or $15,000 (Objective) and with the exception of EO/IR sensors no replaceable component may be more than $5,000.

PHASE I: Carry out a feasibility study for an affordable Electric Unmanned Ground Vehicle Force Protection Sensor System capability. This assessment will validate Electric UGV Force Protection Sensor System with a limited UGV and sensor demonstration. Phase I will define factors for a Phase II electric UGV Force Protection Sensor System prototype demonstration.

PHASE II: Develop an affordable electric UGV Force Protection Sensor System prototype. Demonstrate electric UGV Force Protection Sensor System at an Army’s Research and Development location.

PHASE III DUAL USE APPLICATIONS: Develop prototypes and transition proven technology to appropriate potential DoD customers/transition partners. End state vision is a demonstrated capability to acquire a high capability unmanned ground vehicle equipped with a force protection / intelligence sensor package that meets affordability and performance criteria identified in Phase 1. Army uses to include: extending the range of force protection and incident investigation around a Fixed Operating Base via UGV patrol; enabling remote intelligence collection via cheap UGV asset. Transition is targeted towards Product Director Force Protection Systems as proof of concept for new capability demonstrating extended range operations for possible future acquisition. Commercial applications could include facility security, civil law enforcement applications, homeland security and search & rescue applications.

REFERENCES:

1. LOW-COST PLATFORM FOR AUTONOMOUS GROUND VEHICLE RESEARCH
AUTHORS: Nikhil Ollukaren, Dr. Kevin McFall, Southern Polytechnic State University, Marietta, Georgia, United States of America
DATE: 1 November 2014
JOURNAL: Proceedings of the Fourteenth Annual Early Career Technical Conference
The University of Alabama, Birmingham ECTC 2014
URL:http://scholar.google.com/scholar?start=70&q=affordable+unmanned+ground+vehicle+pdf&hl=en&as_sdt=0,47&as_vis=1

2. The University of Pennsylvania MAGIC 2010 multi-robot unmanned vehicle system

3. Improving the Control Behavior of Unmanned Ground Vehicle (UGV) using Virtual Windows

4. Real-Time Obstacle Avoidance and Waypoint Navigation of an Unmanned Ground Vehicle

5. Designing and control of autonomous Unmanned Ground Vehicle

6. Low-Cost Sensors for UGVs

TECHNOLOGY AREA(S): Electronics

The technology within this topic is restricted under the International Traffic in Arms Regulation (ITAR), which controls the export and import of defense-related material and services. Offerors must disclose any proposed use of foreign nationals, their country of origin, and what tasks each would accomplish in the statement of work in accordance with section 5.4.c.(8) of the Announcement.

OBJECTIVE: New analog radio-frequency (RF) signal processing and enhanced electromagnetic (EM) interference mitigation capabilities afforded by devices based on high-quality magnetic materials are desired for existing and future military communications, signal intelligence (SIGINT), electronic warfare (EW), and radar systems. This topic seeks the development of an industrial domestic manufacturing capability for high quality Yttrium Iron Garnet Films (YIG) films to use in the production of Frequency Selective Limiters (FSLs) that are tunable to different frequency ranges. Of particular interest is the Seed substrate on which the epitaxial magnetic film is grown.

DESCRIPTION: The number of systems relying on the use of the EM spectrum is increasing rapidly, in both military and commercial sectors. The rising spectral congestion is placing increasingly challenging requirements on the performance of components and modules that comprise the RF front-ends of communications, radar, and electronic warfare (EW) systems. Magnetic components, such as filters, phase shifters, delay lines, baluns, circulators, and isolators, among others, offer low insertion loss, high power handling capability, and low power consumption needed to improve the performance and reduce size, weight, power, and cost (SWaP-C) of these systems. In recent years, the use of single-crystal quality magnetic materials has resulted in significant performance improvements, as well as enabled new analog RF signal processing functionality, such as frequency-selective limiting (FSL) and signal-to-noise enhancement (SNE) devices.

PHASE I: Demonstrate the synthesis of single-crystal quality magnetic substrates in 2 inch diameter or 1.5 by 1.5 inch square form factor. The thickness of the magnetic layer has to be at least 10 micrometers. Demonstrate ferrimagnetic resonance linewidth, delta-H, of <1 Oersted and spinwave linewidth, delta-Hk, of <0.2 Oersted. The thickness of the magnetic layer has to be uniform to within 3% over the entire area of the substrate. The density of dislocations has to be below 1 per square centimeter over an area covering at least 80% of the surface.

PHASE II: Extend the single-crystal quality magnetic substrates synthesis technique to other magnetic material compositions to enable analog signal processing device applications 0.3 to 30 GHz. Demonstrate the synthesis of single-crystal quality magnetic substrates in 4 inch diameter or 3 by 3 inch square form factor. Demonstrate capability to produce magnetic layer thicknesses from 10 nm to 100 micrometers. Make a lot of 10 substrates available for verification testing to demonstrate quality, consistency and reproducibility.

PHASE III DUAL USE APPLICATIONS: Develop and characterize an industrial grade synthesis process with >90% yield and production rate of no more than 4 hours per substrate per process line. Develop a manufacturing plan and production cost reduction plan. Produce at least 100 substrates and gather and analyze statistics on defects, uniformity, and repeatability. Make a lot of 10 substrates and 10 devices available for verification testing to demonstrate quality, consistency and reproducibility.

REFERENCES:

1. J. D. Adam, "Mitigate the Interference: Nonlinear Frequency Selective Ferrite Devices," in IEEE Microwave Magazine, vol. 15, no. 6, pp. 45-56, Sept.-Oct. 2014.

2. H.L. Glass, “Growth of thick single-crystal layers of yttrium iron garnet by liquid phase epitaxy”, Journal of Crystal Growth, Volume 33, Issue 1, 1976, Pages 183-184, ISSN 0022-0248,

3. H.L. Glass, M.T. Elliot, “Attainment of the intrinsic FMR linewidth in yttrium iron garnet films grown by liquid phase epitaxy”, Journal of Crystal Growth, Volume 34, Issue 2, 1976, Pages 285-288

4. P.J. Besser, J.E. Mee, H.L. Glass, D.M. Heinz, S.B. Austerman, P.E. Elkins, T.N. Hamilton and E.C. Whitcomb, AIP Conf. Proc. No. 5 (1972) 125.

KEYWORDS: Magnetic substrate, spinwaves, radio-frequency, analog signal processing

TECHNOLOGY AREA(S): Electronics

OBJECTIVE: The objective of this effort is to develop an ultra-wideband ultra-Low Loss radome for very large antenna applications.

DESCRIPTION: The US Army has programs that requires an ultra-wideband ultra-low loss radome to protect large antenna structures in various harsh environments. This radome will be designed to survive in temperatures between -70 degrees F and 180 degrees F and winds in excess of 100 mph. It is to have an operational temperature range between -40 degrees F and 150 degrees F. The diameter of the dome is to be no less than 24 feet in diameter.

PHASE I: Develop ultra-wideband ultra-low loss radome design and develop proof-of-concept models to verify it can efficiently pass frequencies of interest (X-Ku Band), can withstand high peak powers (10 TW), a pulse length of 30 ns, and a pulse repetition frequency of 500 Hz.

The Phase II contract will be classified at the Secret level and a Form DD254 will be required. The successful bidders should anticipate the start of a facilities clearance process, if it does not yet possess one.

PHASE II: Based on the results of Phase I, build a proof of concept radome. Work with the systems developers to ensure that the antennas can meet the form factor requirements as well as other requirements for system integration. Baseline specification for new radome include: