Department of the navy (don) 17. 1 Small Business Innovation Research (sbir) Proposal Submission Instructions introduction

Due to the evolving nature of this topic, the development of Probability of Detection (POD) curves will be limited to the variables within the manufacturing process adopted, the microstructural variation, types and size of defects, and the parameters of the NDE technology used to evaluate the parts with number of specimens being one of the POD parameters.

The ability to inspect AM parts will enable usage of metallic AM parts to reduce long lead times on replacement parts, mitigate issues with part obsolescence, and result in new component designs for increased performance. Through this SBIR, the company will develop and demonstrate the performance of the NDE technology to accurately account for microstructural variability in its ability to locate and size embedded defects.

PHASE I: The company will develop an NDE concept that is capable of imaging the interior features of micro structurally and geometrically complex AM parts. The company will demonstrate the feasibility of the concept in meeting Navy needs and will establish that the concept can be developed into a useful product for the Navy. Testing and analytical modeling will establish feasibility. The company should include specifics on the type AM process that will be used, the types of defects (volumetric, cracking/delamination, surface roughness) that will be observed, and identify the proposed complexity of the metallic AM part. The Phase I Option, if awarded, will include the initial design specifications and capabilities description to build a prototype in Phase II.

PHASE II: Based on the results of Phase I and the Phase II Statement of Work (SOW), the company will develop and deliver a prototype NDE system for evaluation. The prototype will be evaluated to determine its capability in meeting the performance goals defined in the Phase II SOW and the Navy requirements for the NDE methodology. The system performance will be demonstrated through prototype evaluation and testing to occur through monitoring of the AM part during the buildup process and/or inspecting the final product and validation of the results through destructive testing and metallographic analysis. Testing will demonstrate the performance of the NDE technology to accurately account for microstructural variability in its ability to locate and size embedded defects. Probability of detection (POD) curves will be developed within the scope of the work carried out under Phase II and will be required. Evaluation results will be used to refine the prototype into an final design that will meet Navy requirements. The company will prepare a Phase III development plan to transition the technology to Navy and potential commercial use.

PHASE III DUAL USE APPLICATIONS: The company will be expected to support the Navy in transitioning the technology for Navy use under the Systems Engineering/Technical Authority (SE/TA) Operations & Maintenance, Navy (O&MN). The company will further refine an AM methodology according to the Phase II development plan for evaluation to determine its effectiveness in operationally relevant environment. The company will support the Navy for test and validation to certify and qualify the system for Navy use. Private Sector Commercial Potential: This technology has potential applications in a wide number of sectors including medical, aerospace, automotive and other commercial industries. The ability to provide NDE tools to qualify and certify AM parts will enable transitioning of AM technology for critical applications.

REFERENCES:

1. NAVSEA Tech Publication, T9074-AS-GIB-010/271; http://ntpdb.ddlomni.com/TechPubs/271/TP%20271%20Rev%201.pdf

2. Waller, Jess M., Regor L Saulsberry, Bradford H Parker, Kenneth L Hodges, Eric R Burke and Karen M Taminger, Summary of NDE of additive manufacturing efforts in NASA. AIP Conf. Proc. 1650, 51 (2015); http://dx.doi.org/10.1063/1.4914594

3. Christopher Brown, Joshua Lubell and Robert Lipman, National Institute of Standards and Technology (NIST), Additive Manufacturing Technical Workshop Summary Report, Technical Note (NIST TN) – 1823, December 04 2013.

4. ASTM-I F2792: Standard Terminology for Additive Manufacturing Technologies; http://www.astm.org/FULL_TEXT/F2792/HTML/F2792.htm

5. Waller, Jess M., Regor L Saulsberry, Bradford H Parker, Kenneth L Hodges, Eric R Burke and Karen M Taminger, Nondestructive Evaluation of Additive Manufacturing: State-of-the-Discipline Report. NASA/TM-2014-218560; http://ntrs.nasa.gov/search.jsp?R=20140016447-

KEYWORDS: Non-destructive evaluation; non-destructive testing; additive manufacturing; 3D printing; rapid prototyping; microstructural impact

Questions may also be submitted through DoD SBIR/STTR SITIS website.

N171-071

TITLE: Plug-and-play Analytical Framework for Distributed Structured and Unstructured Data Sets for Condition Based Maintenance Plus (CBM+)

TECHNOLOGY AREA(S): Information Systems

ACQUISITION PROGRAM: Program Executive Office Integrated Warfare Systems (PEO IWS) 1.0 – AEGIS Combat System

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 Announcement. Offerors are advised foreign nationals proposed to perform on this topic may be restricted due to the technical data under US Export Control Laws.

OBJECTIVE: Create an agnostic algorithmic software framework, which consumes disparate sources of structured and unstructured data to increase the accuracy and fidelity of Prognostic Health Management (PHM) results.

DESCRIPTION: Condition Based Maintenance Plus (CBM+) is maintenance performed based on evidence of need and integrating Reliability Center Maintenance analysis with those enabling processes, technologies, and capabilities that enhance the readiness and maintenance effectiveness of DoD systems and components (reference 1). The analytical component of CBM+, Prognostic Health Management (PHM), relies upon mathematical algorithms fed by equipment condition data, both historical and current. A significant barrier to using this data for informed maintenance and subsequent operational decision-making is that the data often resides in disconnected systems, which do not have the flexibility to include new approaches, combine results, or be accessible as a single source. Additionally, the analysis environments often exclude data sources that are not primary or they deal with known data inputs and include preset factors to take the place of the unknown data sets. Current approaches to data analysis and/or mining lock data within disparate organizations have no ability to provide a comprehensive and integrated picture. The Navy seeks a “plug-and-play” Analytical Framework that can deploy on board naval platforms in order to increase the scope, validity, veracity, and speed of PHM results. The framework should be flexible enough to accept both structured/unstructured data sources and multiple/changing analytical packages, and respond with a single comprehensive model of health. The framework must increase the flexibility of the analysis and be data-agnostic with inputs in order to take the analysis of equipment condition to a higher fidelity. The increased fidelity is required to help the AEGIS community accurately assess failure trends, improve system design, lead to more accurate maintenance and mission planning, and increase logistics response (reference 2).

The primary function of the plug-and-play framework for equipment health management developed will be to link disparate unstructured and structured data sources. This includes data from the Operational Readiness Test System (ORTS) as well as unstructured data from 2-kilos and/or ships’ logs. The framework must also accept a wide variety of micro diagnostic capabilities in order to create a comprehensive PHM solution. It is expected that the software framework solution will ultimately link individual analysis capabilities (or advanced algorithms) which address specific and targeted areas of maintenance need. These algorithms will likely be supplied by a wide variety of experts from Government and industry, wherein domain experts will develop targeted analytics capabilities focused on determining the best path for the detection and understanding of equipment health based on the elements, components, and systems involved. As can be imagined, the number of individual elements and components within an integrated system of systems can grow to be very large. As such, the framework should be created with an extensible architecture in order to take advantage of future technological developments and new algorithms. Both the quality of the data to be analyzed and the ability to analyze it will thereby improve and provide future expansion of capabilities that do not require a new software platform.

The final system requirement will be the ability to handle large amounts of data such as those found in Big Data ingestion and streaming applications. Novel techniques for handling large data ingestion and streaming should still enable the solution to be configurable to integrate from many different sources, even as these sources change. Proposed approaches should ensure that the results of analysis could be made available to credible subscribers.

Once operational, the solution must be able to assemble disparate data and information into actionable knowledge to increase Operational Availability without overwhelming the Sailor and provide insight to shore-based activities.

PHASE I: The company will develop an initial concept approach and design for a plug-and-play analytical framework that includes disparate data that may be structured and/or unstructured. The company will also advance a method for developing a software platform capable of integrating multiple data sources and producing actionable results from the framework. The company will explore the feasibility of the proposed technology/approaches to meet the intent of expanded CBM+ and electronic prognostics in support of shipboard maintenance. Feasibility will be determined through testing at a land-based test site that allows for the use of existing CBM-related data sets. Government test capabilities are available for use at Naval Surface Warfare Center (NSWC)-Port Hueneme (CA) and NSWC-Dahlgren (VA) or the company could utilize structured and unstructured data provided by the Government at a test site of their choosing. The company will also define a plan of action for technology development, testing, and integration into a Combat Systems cross-domain environment.

PHASE II: Based on the approach explored in Phase I and the Phase II Statement of Work (SOW), a prototype software solution with the ability to launch multiple analytical packages will be demonstrated in a simulated combat system environment. The prototype must be delivered and be capable of demonstrating a method for aggregating and utilizing disparate sources of data in the analysis and prognostication of maintenance decision paths. The offeror will provide a detailed test plan to demonstrate the deliverable meets the intent of advanced CBM+ and electronic prognostic efforts. A Phase III qualification and transition plan will also be provided at the end of Phase II.

PHASE III DUAL USE APPLICATIONS: During Phase III, the company will further refine the prototype software solution developed in Phase II and support the Navy in the system integration and qualification testing for the software technology framework. This will be accomplished through land-based and ship integration and test events managed by PEO IWS to transition the technology into the CBM+ efforts for AEGIS platforms. Private Sector Commercial Potential: Many private sector organizations are working to implement CBM+ as a means for reducing operating costs and increasing uptime. Markets such as manufacturing and transportation will be able to exploit the results of this topic.

REFERENCES:

1. Office of the Assistant Secretary of Defense for Logistics & Materiel Readiness. “Condition Based Maintenance Plus (CBM+). "April 2016. www.acq.osd.mil/log/mpp/cbm+.html.

2. Collum, P. H. “OPNAVINST 4790.16B Condition Based Maintenance and Condition Based Maintenance+ Policy.” 01 Oct 2015. URL last visited on 19 April 2016. https://doni.documentservices.dla.mil/Directives/04000%20Logistical%20Support%20and%20Services/04-700%20General%20Maintenance%20and%20Construction%20Support/4790.16B.pdf.-

KEYWORDS: CBM+; Prognostics Health Management; Structured Data Analytics; Analytical Agnostic Framework; Plug-n-play; Unstructured Data Compilation

Questions may also be submitted through DoD SBIR/STTR SITIS website.

N171-072

TITLE: Removable and Maintainable Future Hull Arrays

TECHNOLOGY AREA(S): Materials/Processes

ACQUISITION PROGRAM: VIRGINIA Class Program Office (PMS 450), Program Office (PMS 401), and OHIO Replacement Program Office (PMS 397); Large SONAR Hull Array

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 Announcement. Offerors are advised foreign nationals proposed to perform on this topic may be restricted due to the technical data under US Export Control Laws.

OBJECTIVE: Develop an innovative hull array technology that allows removal and replacement of failed sections of a hull array and that will significantly reduce life cycle costs.

DESCRIPTION: The Navy has identified the need to improve hull array acoustic performance of submarines to decrease vulnerability against threats. Currently, the Navy is developing technologies for building and installing large SONAR arrays external to the hull of a submarine. These technologies allow for a lightweight, scalable array, which provides many options for installation. In order to minimize life cycle costs for these large hull arrays, technology to improve repair and maintainability of the hull array is crucial. It is anticipated that life cycle cost savings of up to $500K per platform are realizable using removable and maintainable hull array technology.

The current approach to attaching arrays to the hull of a submarine uses viscoelastic-bonding materials. The current design and manufacturing approach of bonding the arrays to the submarine hull severely limits the ability to repair the array sensors or cables during an Extended Dry-dock Selected Refit Availability (EDSRA). Additionally, inspection of the current submarine hull welds is difficult to perform in the regions where the hull array covers the welds. Therefore, the Navy is seeking innovative design and manufacturing techniques for attaching acoustic array panels to the submarine hull to improve platform production, operation, and maintenance costs. Minimization of the Mean Time to Repair (MTTR) failed hull array sections is a key metric of any proposed innovative solution.

Current array design and manufacturing processes build the array in half-stave sections, each containing the requisite cabling, acoustic sensors, and connectors to assemble the entire array into an installation fixture that is brought up to the submarine for its final attachment and bonding to the hull.

The innovative technology shall focus on other final array attachment designs to the hull that significantly improve the ability to repair failed sections of the array or to remove and replace the same in order to conduct Unrestricted Operations (URO) inspections. Attachment and removal concepts must not be detrimental to array acoustic performance and must be robust enough to survive the operational, physical, and environmental challenges encountered in a shipboard submarine environment. The company shall design and fabricate test panels that demonstrate this innovative technology for evaluation by the Government. This technology will include concepts such as investigations into design principles, materials, and construction techniques, as well as creating a benchmark “trade space” of innovations against array performance, weight, neutral buoyancy, reliability, maintainability, and the following critical array design parameters:

• Operation during hydrostatic pressure extremes 0 – 1000 psi

The Phase II effort will likely require secure access, and NAVSEA will process the DD254 to support the contractor for personnel and facility certification for secure access. The Phase I effort will not require access to classified information. If need be, data of the same level of complexity as secured data will be provided to support Phase I work.

PHASE I: The small business will define and develop concepts for an innovative hull array technology to implement a reliable means of attaching and removing the array that can survive the operational, physical, and environmental requirements of a shipboard submarine environment discussed in the Description section. The small business will investigate approaches to readily remove and replace sections of the hull array without the use of bonding agents. The small business shall determine technical feasibility through modeling or analysis and provide characteristics of the proposed approach to array attachment to demonstrate it meets acoustic and environmental requirements. The Phase I Option, if awarded, should address technical risk reduction and provide performance goals and key technical milestones.

PHASE II: Based on the results of Phase I, the small business will develop prototype innovative hull array technology panels for evaluation by the government. The removable and repairable prototype panels will be attached to a representative submarine hull section to determine their capability in meeting the performance goals as defined by the Navy. The validity of the prototype will be shown by a demonstration conducted by the Navy on Government land or water-based test facilities or vehicles during Phase II. The company will prepare a Phase III development plan to transition the technology for Navy production and potential commercial use. Secure access to classified data will be required in Phase II.

PHASE III DUAL USE APPLICATIONS: The company will further refine the prototype and support the Navy in transitioning the innovative hull array technology for production use. The company will demonstrate manufacturing technique(s) to attach a production representative panel to a submarine hull in accordance with the Phase III development plan. The demonstration will be conducted on a U.S. Navy submarine in an operationally relevant environment. Private Sector Commercial Potential: Industries, such as Electric Boat, Newport News, and Navy Shipyards that employ large sonar structures subjected to at-sea environments and require removable, repairable, and periodic inspections, will benefit from this technology. The commercialization of this technology will help reduce the overall life-cycle cost of other industry sonar systems.

REFERENCES:

1. Freitag, Lee. “Acoustic Communication with Small UUVs Using a Hull-Mounted Conformal Array.” http://www.matsysinc.com/products/sonar_transducers/docs/acoustic_communications_small_uuvs.pdf

2. “NSSN Virginia Class Attack Submarine, United States of America.” naval-technology.com. http://www.naval-technology.com/projects/nssn-

KEYWORDS: Removable and maintainable Hull Arrays; future hull arrays; viscoelastic bonding; Extended Selected Dry-dock Refit; Unrestricted Operations; Mean Time to Repair (MTTR)

Questions may also be submitted through DoD SBIR/STTR SITIS website.

TECHNOLOGY AREA(S): Battlespace, Electronics, Sensors

ACQUISITION PROGRAM: VIRGINIA Class Program Office (PMS 450)/ OHIO Replacement Program Office (PMS 397)

OBJECTIVE: Develop a power unbalance conditioning system for submarine electrical systems enabling correction of 3-phase current unbalance.

DESCRIPTION: The primary objective of this research and development effort is to improve on the currently available large-scale solutions to current unbalance, and smaller scale correction devices focused on correcting supply side instead of demand side unbalance. Current power unbalance correction technology like the Eaton Electronic Voltage Regulator (EVR) (ref 1) are focused on providing clean balanced power to a load, not to regulate for the benefit of the source. The technology has too large of a footprint, being over 40 inches high and 700 lbs. at the 30 kW level. A more applicable technology concept is the Variable Shunt Reactor concept produced by SIEMENS (ref 2) though the size is more consistent with commercial power sub-stations than military ships. The Navy’s need for power may provide the groundwork for solving this problem in the future. However, the technology would need to focus on whole ship power from a single large-scale power supply vice the smaller scale 40-70 kW concept needed here. By implementing a rack-mounted solution for current unbalance correction, this technology can be installed in electronic systems that currently do not have the space for large devices. Uninterruptable Power Supplies (UPS) can eliminate power unbalance but they use too much space for energy storage to be used as a broad spectrum solution. Allowing multiple systems to utilize the same smaller scale hardware solution will reduce maintenance costs associated with spares as the number of units performing redundant functions can be reduced. Alternative approaches for architectural changes in the power distribution system as a whole show promise for the future but changing whole ship distribution for in-service and in-design platforms would be prohibitively expensive.

To satisfy power interface requirements defined in MIL-STD-1399/300B (ref 3), a three-phase current unbalance requirement is levied on the shipboard equipment. Source voltage balance is assisted by maintaining a current unbalance restriction for individual three-phase loads and by ensuring single-phase loads are distributed as evenly as possible across the three phases during installation of the shipboard electrical power distribution system. User equipment comprised of a combination of single-phase and three-phase loads shall have a resulting input three-phase line current unbalance not exceeding 3% of the user equipment rating under normal operating conditions and during normal operating modes. The Navy is looking for enabling technology as more Commercial-Off-the-Shelf (COTS) single-phase equipment is being fed from the Delta three-phase power source. Groups of single-phase loads connected to three-phase busses create an opportunity for excessive unbalance over some power lineups. Existing and previous unbalance mitigation approaches have included UPS and/or a power conditioner function to address or buffer current unbalance. It is desired that small businesses investigate processes and develop a device which will successfully address steady state and transient equipment current unbalance conditions of up to 12% such that no more than 3% unbalance is seen at the source connection.