REFERENCES:
1) Alan Hathaway and Jeff Siewert (Arrow Tech Assoc, Inc) & Dr. Nubil Husseini and Laura Henderson (AMTECH, Inc.) “Design, Analysis, and Testing of a 5.56mm Polymer Cartridge Case,” Proceedings from the NDIA 2002 International Infantry & Joint Services Small Arms Section Symposium, Exhibition, and Firing Demonstration, web site: http://www.dtic.mil/ndia/2002infantry/index.html, Atlantic City, NJ, 13-16 May 2002.
2) C. Feng and Stacey Clark, “Malfunction and Failure Analysis Investigation of C26000 (Cu-30% Zn) Brass Cartridge Cases,” Materials Characterization, Vol. 32, pp. 15-32, January 1994.
3) Marlo K. Vatsong, “Composite Cartridge for High Velocity Rifles and the Like,” U.S. Patent No. 5,151,555, 29 September 1992.
KEYWORDS: polymer, cartridge case, small caliber weapon, medium caliber weapon
A03-045 TITLE: Configurable Tooling Systems for Complex Structures for Objective Force Survivability
TECHNOLOGY AREAS: Materials/Processes
OBJECTIVE: The need for optimized materials performances to meet ballistic damage tolerances in multifunctional materials has lead to a number of challenges in the fabrication of test articles for ballistic structures. A significant limitation of fabrication methods is the ability to adapt tooling to meet applicable uses and achieve high mechanical tolerances when switching between liquid molded and bonded ballistic structures and woven prepreg with bonded structures. It has been observed that tolerance variations in materials designs can lead to substantial changes in performance in a ballistic environment. Further, the additional need to replace damaged ballistic sections in the field environment require equivalently high tolerances, which will be difficult to achieve using current molding technologies, and decrease survivability and effectiveness of repaired ballistic structures. Current technologies are not available for rapidly developing replacement components at the depot level to sustain composite platforms. One solution could involve rapid prototyping and tooling technologies that could be implemented during fabrication and replicated for depot level to allow multiple technical components to be prepared in a single tool. The complexities of polymer matrix composites for ballistic structures have demonstrated that custom tooling or fixturing is required for vehicle surfaces, substructure, panel and hatch development, repair, and replacement. The time and cost burdens of these activities, even with traditional molding technologies, can often involve modification or repeated tool fabrication before the activity is completed. Currently available configurable tooling solutions do not allow fabrication of multiple material forms on a single platform, driving up development costs in the search of survivable structures. Further, whether the final tool set is for a single use or for repeated use, there are additional cost burdens for disposal or storage and maintenance of the tool sets.
DESCRIPTION: The Army is seeking innovative approaches that will significantly increase production rate and reduce program costs for vehicle structure developments and designs. Ideal tooling solutions might furnish "universal" tooling capabilities. For example a reusable, reconfigurable or reformable tooling system could: 1) take a precise and accurate impression from a master-qualified composite part; 2) provide a hardened tool that has physical properties tailored to reproduce the part from a variety of polymer-matrix composite materials systems; and 3) enable the hardened tool to be returned to a reformable, impression-taking condition after the production of one or more parts which are identical to a master-qualified replacement part.
A universal tooling system would meet the following criteria: 1) aid fabrication of parts at any scale, from 10 centimeters up to 10 meters in length/width/depth; 2) replicate compound-curved or complex shaped parts such as vehicular panels (hoods, doors, bumpers) or integral ribbing with corner radii of less than 10 millimeters; 3) be suitable for removable mandrel, insert or trapped-tool applications as for the repair or reconstruction of ducting or ribbed structures; 4) be durable enough to hold precise tolerances during hand fabrication and debulking processes including prepreg, roving, knit and woven material, and VARTM; and 5) tolerate, without deterioration, cure cycles of up to 375F.
PHASE I: Demonstrate, at laboratory or benchtop scale (10 centimeters minimum length/width/depth), approaches to creating one or more tooling material systems that can be formed into precise negatives of test shapes, that can be hardened to produce usable tools that will not degrade or lose tolerances under vacuum bag infusion processing. The tool should be returned to formability and be capable of repeated (>50 cycles) form/reforming without degrading or losing properties of conformability.
PHASE II: Develop and demonstrate a prototype tooling system which replicates a master-qualified composite part, in a composite materials system requiring autoclave cure up to 100PSI and 375F, with dimensions of 2 meter minimum for length and width, with one foot depth.
PHASE III: Phase III will require DoD component sponsorship. For successful advance to this phase, a successful Phase II proof-of-concept must have been demonstrated, and the program sponsor for this SBIR effort will have coordinated transition to demonstration/validation. The contractor must support a successful Phase III transfer by maturing the tooling system to a point for commercial viability including manufacturability and cost.
REFERENCES:
1) G. Shoeppner, "Analysis and Repair Design Tools," DoD Advanced Composites End-Users Conference, Wright Patterson Air Force Base, OH, 27-31 August 2001.
2). Plumer, J. R., J. McElman, N. R. Schott, S. B. Driscoll, "Design and Fabrication of FRP Truck Trailer Side Racks," Program Final Report AMMRC-TR-83-50, 1983.
3) G. Thomas, "Manufacturing Affordable Composite Structures for Ground Combat Vehicles, Defense Manufacturing Conference 1999, Session IV, Miami Beach, FL, 29 November - 2 December 1999.
4) Baker A. A.; Callus P. J.; Georgiadis S.; Falzon P. J.; Dutton S. E.; Leong K. H., "An affordable methodology for replacing metallic aircraft panels with advanced composites," Composites Part A: Applied Science and Manufacturing, May 2002, vol. 33, no. 5, pp. 687-696(10).
5) Cloud D.; Norton J. "Low-cost tooling for composite parts: the LCTC process," Assembly Automation, 12 October 2001, vol. 21, no. 4, pp. 310-317(8).
KEYWORDS: composite fabrication, vehicle armor, configurable tooling
A03-046 TITLE: Breathable, Chemical Resistant, Elastomeric Protective Clothing Material
TECHNOLOGY AREAS: Chemical/Bio Defense
ACQUISITION PROGRAM: PEO Soldier
OBJECTIVE: Design, synthesize, fabricate and evaluate an economical and lightweight chemical protective clothing that demonstrates flexibility, durability, and selectively permeable properties.
DESCRIPTION: The U. S. Army requires that all fielded systems be survivable in a chemical warfare environment. Butyl rubber is currently used for protective gloves because it is an excellent barrier material against chemical threats. Although butyl rubber is an excellent barrier, it does not allow water vapor transport needed for maximum comfort. Current protective clothing materials are based on activated carbon that is effective for chemical protection but can be heavy during long periods of wear, potentially placing a weight burden on the soldier. Outfitting the soldier in accordance with new Future Combat System (FCS) and Objective Force guidelines requires that the materials be lightweight and flexible, enabling the soldier to move freely. New advanced materials that are flexible, lightweight and selectively permeable will offer significant improvement in both reduced weight and reduced heat stress (increased water vapor transport) for the soldier. In an effort to address these multiple requirements, the Army Research Laboratory has developed a series of sulfonated tri-block copolymers. The novel polymers are comprised of polyisobutylene as a major component to afford inherent barrier properties to the block copolymer. The novel block copolymers exhibit flexibility over a broad temperature range and selectively permeable “membrane-like” characteristics. Although it is not required that a proposal for this solicitation specifically utilize the tri-block copolymer approach developed by the Army, this material is mentioned because it has shown some very desirable properties for breathable protective clothing such as high moisture vapor transport rates and flexibility at low temperatures.
PHASE I: Research efforts should focus on the design and synthesis of a copolymer/ionomer comprised in part of an impermeable block and an ionic block, that exhibit numerous properties that are critical for chemical protective field operations. These properties include: flexibility over a broad temperature range (~ -60ºC-100ºC), economical processing as membranes for coated or woven fabrics, gloves, tenting, or stacked fuel cells, exhibit high levels of water vapor transport and simultaneously block transport of organic compounds such as chemical warfare agents. Results from the Phase I effort should demonstrate the above characteristics and define a clear and feasible synthetic route that will enable production of the elastomeric membrane at the pilot plant level. The synthetic routes of preparing the polymer must be in accord with methods that are amenable to large scale domestic (U.S.) manufacturing facilities. That is, solvents used must be in compliance with environmental laws in the chemical and textile industries and an environmentally friendly route to manufacture such as water-based processing is preferred. Economic analysis shall be performed and outlined to determine the estimated cost to produce the membrane at pilot plant level. The elastomeric membrane should exhibit durability, flexibility and selective transport properties necessary for use in military field operations and chemical warfare environments. That is, the membrane should “breathe”, allowing water vapor to transport away from the soldier, thereby reducing heat stress, while simultaneously blocking penetration of harmful substances in liquid or vapor form. Water vapor transport values should be as a minimum, competitive with commercially available “breathable” fabrics used for sports and recreation.
PHASE II: With candidate materials identified in Phase I, the Phase II program should address scale-up of the elastomeric membrane as woven textile, gloves, or tenting. The copolymer shall be used in the fabrication of prototypes to include a coated fabric or woven fabric outer garment and breathable, elastomeric chemically protective gloves. Testing of the prototypes will be performed to demonstrate flexibility, durability, breathability, and protection against actual chemical warfare agents. Detailed fabrication procedures for the prototypes shall be established. Economic analysis shall be performed to determine the cost of fabricating a full body protective suit for military applications, utilizing the polymer membrane. All processing and fabrication procedures must be in compliance with environmental laws in the chemical and textile industries.
PHASE III Dual Use Applications: Successful development of the polymeric membrane may have numerous applications as biomedical materials that require selective water transport (i.e., wound dressings) and as alternative fuel cell membranes. Economically feasible chemical protective suits would be useful in numerous. Industries that could potentially benefit from commercialization include companies that supply raw materials, block copolymers polymers and fibers such as Shell Chemical and Dupont Corporations.
REFERENCES:
1. Lee, Yang and Wilusz; Polymer Engineering & Science, 1990, 36, 1217.
KEYWORDS: copolymer, membrane, ionomer, protective clothing, water transport, barrier, elastomer
A03-047 TITLE: Long Wave Infrared Acousto-Optic Materials
TECHNOLOGY AREAS: Sensors
ACQUISITION PROGRAM: PEO CHEM/BIO DEFENSE & NBC Defense Systems
OBJECTIVE: To develop novel materials for fabricating acousto-optic tunable filters in the 8-12 micron spectral region for multispectral and hyperspectral imaging applications as well as for remote sensing and monitoring of environmental pollutants and chemical and biological agents.
DESCRIPTION: The US Army Research Laboratory is seeking innovative approaches for the development of a no-moving-parts, electronically tunable spectral imaging system for 8 to 12 micron spectral region for a number of multispectral and hyperspectral applications for detection of targets, backgrounds, and stand off chemical and biological agents. Such a hyperspectral imager is based on using an acousto-optic tunable filter (AOTF). This long wave infrared (LWIR) technology is particularly relevant to detection of buried mines and is an essential part of achieving the hyperspectral imaging technology goals set in the Army's 3rd Generation Science and Technology Objective (STO). So far only a small number of nonlinear crystals have been identified that have high acousto-optic figure of merit and can be used in the fabrication of an LWIR AOTF. At the present time, only a couple of such crystals are grown (thalium arsenic selenide (TAS) and mercurous chloride) by a single source. In addition to the applications for designing AOTFs for high quality LWIR spectral imaging systems, there are a number of other commercial applications for designing active and passive optical components such as frequency doublers, polarizers, lenses, retarders, windows, etc. The first components of this work will be to develop novel anisotropic materials for designing AOTF cells operating in the long wavelength infrared spectral region (8-12 micron). These materials must be easy to work with, nonhygroscopic, have high acousto-optic figure of merit (M2), high birefringence, and relatively high transmission in the desired wavelength region. The second component will be integration of such AOTF cells with infrared imagers. Desired materials include tellurium, mercurous halides, and TAS.
PHASE I: Identify suitable materials, produce device quality material for the most promising candidate, study low-temperature properties of this material, and demonstrate an acousto-optic modulator in such a material for operation in 8 to 12 micron spectral region.
PHASE II: Optimize the growth parameters for candidate material, grow high quality crystals, fabricate an AOTF for operation in the 8 to 12 micron region at low-temperature, integrate this AOTF with high performance commercially available infrared imaging systems procured via government sources to demonstrate a hyperspectral imager operating in the 8 to 12 micron region with image processing capability. Delivery of an AOTF and high quality crystals is required.
PHASE III DUAL USE APPLICATIONS: Development of such material and devices is very important for a variety of civilian applications such as fabrication of various active and passive components as well as for applications in pollution detection, environmental monitoring and mapping, auto emission monitoring, better process and quality control in manufacturing of food, beverages, semiconductors, pharmaceuticals, petrochemicals, and better medical diagnoses.
OPERATING AND SUPPORT COST (OSCR) REDUCTION: Army can substantially reduce the cost of vehicle maintenance by real-time monitoring of exhaust plumes and the condition of engine oil. Also, the Army will have a no-moving-parts, compact multipurpose imaging spectrometer that so far does not exist.
REFERENCES:
1) M. S. Gottlieb, "Acousto-Optic Tunable Filter", Design and Fabrication of Acousto-Optic Devices, A. P. Goutzoulis and D. R. Pape, eds., Marcel
Dekker, New York, pp. 197-283 (1994).
2) N. Gupta, R. Dahmani, M. Gottlieb, L. Denes, B. Kaminsky, and P. Metes, "Hyperspectral Imaging using Acousto-Optic Tunable Filters," Proc.
SPIE 3780, pp. 512-521 (1999).
3) V. B. Voloshinov, "Elastic Anisotropy of Acousto-optic Interaction Medium," Proc. SPIE 4514, pp. 8-19 (2001).
4) D. Souilhac, D. Billeret, and A. Gundjian, "Photoelastic tensor of tellurium", Appl. Opt. 28, pp. 3993-3996 (1989).
5) N. B. Singh, D. Suhre, N. Gupta, W. Rosch, and M. Gottlieb, "Performance of TAS Crystal for AOTF Imaging" Jour. Crystal Growth 225, pp.
124-128 (2001).
KEYWORDS: cousto-optical interactions; acousto-optic tunable filters, acousto-optical devices, long wave acousto-optic materials, tellurium, mercurous halides, thalium arsenic selenide, TAS, Hyperspectral imager, polarization imager, chemical/biological agent detection, mine detection
A03-048 TITLE: Ultra-Compact Doppler LIDAR (Light Detection and Ranging) for Unmanned Aerial/Ground Vehicles
TECHNOLOGY AREAS: Battlespace
ACQUISITION PROGRAM: PEO Aviation
OBJECTIVE: Design and build an ultra-compact, Doppler LIDAR (LIght Detection And Ranging) for use on medium to light unmanned aerial/ground vehicles that has multi-use capabilities for remote sensing of volumetric vector winds, topography, and aerosol plume detection.
DESCRIPTION: Recent advances in solid-state lasers and compact signal processing systems have made possible new, ultra-compact “pocket” LIDAR systems for remote sensing of the environment. In particular, the operational needs for eye-safety have led to development of low-energy, high pulse rate laser systems operating in the short-wave infrared region. The use of airborne Doppler LIDAR has been demonstrated but with LIDAR systems that were too large for most UAV platforms. The development of “pocket” LIDAR systems enables the technology for use on medium to lightweight UAV/UGV platforms that will be part of the Future Combat System. The use of airborne Doppler LIDAR for real-time detection of air hazards such as wind shear, microbursts, and clear-air turbulence will greatly extend airborne operations and capabilities.
PHASE I: Develop an overall system design for a “pocket” Doppler LIDAR that includes a specification for laser source, transmitter/receiver, detection system, and signal processing.
PHASE II: Develop and demonstrate a prototype “pocket” Doppler LIDAR system. Conduct feasibility study to determine effectiveness in UAV/UGV operations.
PHASE III DUAL USE APPLICATIONS: This system could be used in a broad-range of military and civilian applications where information of 3-dim winds and turbulence are necessary, such as: airport operations, clear-air turbulence detection in-flight, and pollution monitoring.
REFERENCES:
1) J. Rothermel, et. al., "Remote sensing of multi-level wind fields with a high-energy airborne scanning coherent Doppler lidar," Opt. Express 2, 40-50 (1998).
2) M. J. Post, R .E. Cupp, "Optimizing a pulsed Doppler Lidar," Appl. Opt., 29, 4145-4158 (1990).
KEYWORDS: lidar, remote sensing, battlefield environment, wind sensing, topographic lidar, aerosols
A03-049 TITLE: Blast and Shock Damage Analysis
TECHNOLOGY AREAS: Ground/Sea Vehicles
OBJECTIVE: To develop a method/tool to characterize equipment failure to high frequency shock environments. This new tool shall be capable of analyzing full size equipment (that may be mounted inside a vehicle) to the effects of high frequency shock induced by a conventional blast/shock environment.
DESCRIPTION: Future Army systems are becoming more lightweight and thus are becoming more susceptible to the blast and shock effects of conventional weapons. The thinner walled vehicles allow a greater transmission of energy to the internal components and are also more vulnerable to rupture due to the blast environment. The Army has been utilizing computer aided design (CAD) modeling tools with complex survivability analysis tools, like MUVES S-2 (Modular Unixed-Based Vulnerability Estimation Suite) to determine the survivability of ground vehicles to conventional weapons effects for many years. The blast and shock effects from these weapons have largely been ignored because the ground targets have been so robust. The Future Combat Systems (FCS) will be a lighter weight system of systems and blast and shock effects will have a greater impact then ever before. A stand alone module that can determine the damage to vehicle equipment due to a blast/shock induced environment is needed to complete the overall MUVES-S2 modeling suite. Through physical damage, or functional loss, the degraded state of the impacted equipment will be used as input to the MUVES S-2 code for an overall system analysis.
The time duration for blast/shock environments of interest are typically in the range of .5 to 1.0 ms, with loadings in the range of several thousands of pounds per square inch.
PHASE I: 1. The contractor shall investigate the feasibility of a methodology/tool to determine the damage induced to Army equipment by a high frequency blast/shock environment. The damage can be either a physical damage or loss, or a loss of function of the equipment. The results shall be represented by an Equipment Fragility Spectra (EFS) as depicted in TM 5-855-1, or in a similar manner.
2. The contractor shall develop a preliminary version of this new method through the use of test cases and demonstrate how it can be linked to the MUVES S-2 computer code.
PHASE II: For Phase II, the contractor shall extend the Phase I methodology to the full capability of a productive tool for blast/shock analysis. The tool shall be capable of identifying the shock mitigation levels needed to reduce and/or eliminate damage and also be capable of using various shock mitigation values as input to the analysis. A complete verification and validation program should be incorporated in the development program with limited validation experiments being conducted to support the results. The contractor shall also demonstrate the prototype version on an actual Army system exposed to potential blast/shock environments. The new tool shall be a final design that meets the requirements set fourth in Phase I.
PHASE III DUAL USE APPLICATION: The new tool can be interfaced with the MUVES S-2 Computer code for greater survivability modeling for the Department of Defense. This new tool will also have a broad range of commercial applications. Not only will it directly impact blast/shock modeling capabilities, it will also enhance the commercial application of shock mounted equipment. Commercial sectors that will benefit from such a tool range from the airline industry to the computer industry. High frequency shock problems are becoming potential problems as equipment is more complex and lighter weight.
OPERATING AND SUPPORT COST REDUCTION (OSCR): Development of such a tool will greatly enhance the overall survivability analysis process. This increased capability will have great impacts upon the operation of equipment on the battlefield, and its survivability levels.
REFERENCES:
(1) MUVES Software Manual, June 7, 2001,
(2) MUVES Analyst's Guide, May 27, 1994.
KEYWORDS: blast, shock, survivability analysis, MUVES S2, ballistic shock
A03-050 TITLE: Research and Development of Stochastic Optimal Control Algorithms for Mobile Communications Systems
TECHNOLOGY AREAS: Information Systems
OBJECTIVE: The purpose of this SBIR is to solicit research and development of computational algorithms for stochastic optimal control of mobile communication systems with randomly time varying channels. The algorithms shall address the optimal energy-time allocation and admission control policies that maximize the expected system data throughput and minimize the expected system delay in a weighted combination manner.
DESCRIPTION: It is evident that the utilization of mobile communications systems has played a decisive role in the outcome of modern military operations at the tactical and strategic levels. In military applications, the communication channels of these systems are often randomly time varying and the arrivals of data are often random but bursty, partly due to the dynamic reconfiguration of transceivers in the battlefield environment (see [6], [7]). Due to the complexity of the physical problems, systematic and rigorous mathematical modeling and control of these networks are still in their infancy. Currently, the modeling and optimal control studies have only been done in an ad hoc manner for some simplified networks (see [3], [5]). In particular, heavy traffic and fluid flow analyses (see [1], [4]) have been used to provide diffusion approximations for some aspects of these problems and the dynamic programming principle (see [2]) has been used to characterize the optimal energy allocation and admission control policies for a simplified discrete-time satellite communication system (see [5]). The rigorous modeling and optimal control problems for the currently available commercial and military communication systems remain largely unsolved. Some important issues facing the military and industry include the effective management of these networks. These problems include the optimal energy and time allocation to the communication channels and the optimal admissible control of the channel users so that the mean data throughput will be maximized and the mean network delay will be minimized in a weighted combination manner. This SBIR topic solicits the application of research and the development of computational algorithms for the currently available optimal control policies in the form of computer software that can be implemented in the existing networks. The algorithms shall take into account partial as well as complete observable channel states and data queue size in each channel. The program is to be carried out in the following three phases.
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