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

PHASE III DUAL USE APPLICATIONS: If Phase II is successful, the small business will provide support in transitioning the system for Marine Corps use in UH-1Y program and be an integrated capability in the AACUS installation kit. The small business will develop a plan to determine the effectiveness of the expeditionary ACHS system in an operationally relevant environment (Technology Readiness Level 7). The small business will support the Marine Corps with certifying and qualifying the system for Marine Corps use and shall also submit the system for certification. As appropriate, the small business will focus on scaling up manufacturing capabilities and commercialization plans. Private Sector Commercial Potential: This capability would have wide applicability for use on commercial helicopters for loading and unloading of internal cargo. This includes patients for air ambulances, providing supplies for humanitarian assistance as well as reducing manpower requirements for normal operations. Since it will be a kit applicable to multiple types of helicopters it will be applicable to all current helicopters as well as new designs. It will reduce the requirement for material handling equipment to load and unload the aircraft making the aircraft more capable and less costly to operate. Many commercial helicopters are single piloted require extra manpower for doing cargo type missions, this capability would reduce or eliminate that need.

REFERENCES:

1. NATO Standardization Agency. “Standard Interfaces of UAC Control System for NATO UAV Interoperability”. (9 November 2012). http://nso.nato.int/nso/zPublic/stanags/current/4586eed03.pdf

2. U.S. Department of the Army. “Operator's Manual: Army Model UH-1H/V Helicopters”. Figure 6-8, Cargo Compartment, Pg. 6-15. (15 February 1988). https://books.google.com/books?id=h3k-AAAAYAAJ&printsec=frontcover&source=gbs_ge_summary_r&cad=0#v=onepage&q&f=false -

KEYWORDS: Autonomy; Ground Vehicles; UGV; AACUS; Cargo; Utility

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

N171-088

TITLE: Nickel Aluminum Bronze for Additive Manufacturing Alloy Development

TECHNOLOGY AREA(S): Materials/Processes

ACQUISITION PROGRAM: EPE-17-03 Quality Metal Additive Manufacturing (Quality Made)

OBJECTIVE: Develop, optimize and demonstrate use of a nickel aluminum bronze (NAB) alloy composition optimized for the additive manufacturing process for large seawater components (>12"). The alloy must exceed the current mechanical and seawater corrosion resistance of cast NAB alloy C95800.

DESCRIPTION: The Navy extensively uses components of cast nickel aluminum bronze (NAB) in sea-water applications for their combination of strength, toughness, and corrosion resistance. Commonly used for large scale, small-production-quantity castings, NAB is challenging to consistently cast in complex geometries and in thin sections. Additive manufacturing (AM) allows for layer by layer fabrication from a digital design, and offers significant opportunities for complex geometries that may be difficult to achieve in a traditional casting.

Direct fabrication of AM components has been demonstrated with a wide variety of materials and technologies. Current bronze and copper alloys for AM often utilize post processing and impregnation for final part fabrication. There has been limited work in direct AM fabrication of bronze; however, efforts have focused on utilization of traditional casting compositions or welding analogs. Cast NAB alloys (ASTM B 148, UNS C95800) are generally slow cooled and precipitation strengthened, which may not be ideal for the rapid heating-cooling associated with direct AM fabrication. Additive manufacturing can have cooling rates >1000°C/s and unique processing conditions due to the cyclic heating/cooling in localized areas during fabrication. Similarly, conventional welding of NAB can result in severe distortion due to residual stress and residual stresses may be further exacerbated in the AM process. Lastly, cast NAB has significant natural seawater corrosion resistance, but introduction of microstructural variation in the AM process may result in changes in corrosion behavior.

These considerations for layer by layer fabrication can be increasingly complex for large scale components >12”. To realize fully the capabilities of AM, new NAB alloys for large scale fabrication must be developed specifically for the additive manufacturing process to enhance strength and ductility compared to traditional cast NAB, while maintaining corrosion resistance.

PHASE I: During Phase I, the small business will define and develop a concept/approach using computational tools for a new/optimized nickel aluminum bronze alloy composition for AM, targeting initial mechanical properties (strength, ductility, etc.) and effects on microstructure and phase precipitation as a function of thermal processing (heating/cooling rate). If awarded the Phase I option, the small business will demonstrate the feasibility of a new/optimized composition for feedstock material amenable to the additive manufacturing process on the small coupon level.

PHASE II: Based on Phase I results, the Phase II effort will develop, demonstrate and validate the proposed computational approach for new/optimized AM NAB composition(s). This will include demonstrating optimized alloy composition(s) in AM fabrication of large test builds >12” to obtain as-fabricated mechanical properties and microstructural/chemical characterization. Mechanical properties such strength, ductility, toughness, fatigue, etc. will be tested; distortion relative to the original test build CAD drawing will be measured. Microstructural/ chemical characterization such as grain size, porosity, phase identification/quantification, precipitate formation/segregation, chemical segregation, electrochemical response, etc. will be measured for the new/optimized AM NAB composition(s). Conventional "as-cast" NAB will serve as the baseline for fabrication/processing and material property improvement. The performer shall demonstrate strength/ductility and corrosion equivalent or superior to cast UNS C95800 properties. It is recommended that the performer work with bulk material vendors/OEMs to facilitate transition for Phase III.

PHASE III DUAL USE APPLICATIONS: Phase III will transition optimized alloy composition to commercial suppliers through bulk material vendors, OEMS, or other partnering agreement. Phase III will demonstrate AM optimized NAB alloy(s) and transition an AM technical data package to Warfare Centers and other DoD production/maintenance facilities. Private Sector Commercial Potential: Nickel aluminum bronze is widely used in the maritime industry and would benefit from this material and AM technology.

REFERENCES:

1. Howell, Paul R. On the Phases, Microconstituents and Microstructures in Nickel-Aluminum Bronze. http://www.copper.org/publications/pub_list/pdf/A1310-Microstructures-NickelAlumBronzes.pdf

2. Wong, Kaufui V. and Hernandez, Aldo. A Review of Additive Manufacturing. doi:10.5402/2012/208760 http://www.hindawi.com/journals/isrn/2012/208760/

3. ASTM B 148 https://www.astm.org/Standards/B148.htm-

KEYWORDS: additive manufacturing; casting; bronze; nickel aluminum bronze; sea water components; alloy development

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

TECHNOLOGY AREA(S): Information Systems

ACQUISITION PROGRAM: The USMC MRC-142 program and the Navy Digital Wideband Transmission System (DWTS) programs

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: Free-space optical, or laser, communications have a number of attractive features: 1) increased bandwidth, 2) difficult to deny, and 3) difficult to exploit. The objective of this proposal is to develop a free-space optical terminal with a multi-beam transmit/receive capability that can be deployed on USN/USMC platforms.

DESCRIPTION: Laser communications have a number of attractive features, but a multi-beam transmit/receive capability is needed on ships, helicopters or wide-body aircraft to create a mesh network using point-to-point optical links. Such a system has not been demonstrated, but a number of different core technologies are available to develop such a system. Beam director options include: gimbals with domes or large windows, Risley prisms with tight temperature control / pointing correction, and liquid crystal directors with low transmittance/maturity. A number of multiple access techniques currently exist. These technologies need to be seamlessly integrated together. The proposed SBIR activity will integrate a beam director with a laser source(s) and multiple access technologies into a terminal that supports 2 to 3 simultaneous bi-directional laser links. In addition to the number of links supported, the field of view, size, weight, power, throughput, and expected terminal cost are also important performance parameters. As a point of comparison, the Navy funded the development of a single-beam optical terminal (see Reference 1) with an optical antenna that was less than 1 cubic foot in size and less than 20 lbs. in weight. The Navy seeks to have a multi-beam capability (i.e., 2 or more simultaneous beams) within a comparable footprint.

PHASE I: A preliminary design for a multi-beam terminal is delivered in Phase I. The base period will be used to develop a preliminary terminal design that includes performance estimates for the number of links that can be supported, field of view, size, weight, power, throughput, and anticipated terminal cost. The option, if exercised, will be used to further refine the preliminary design to address any technical or performance risks that are identified. The Navy will then assess the technical merits of the proposed design and its suitability for potential installation on ships, aircraft, and ground vehicles (given their different size, weight, and power limitations) for Phase II selection. An airborne terminal is of particular interest to the Navy since ships do not typically operate within line-of-sight of each other. A successful design must also include how the point, tracking, acquisition, and stabilization is accomplished to enable operations from mobile platforms (e.g., ships in high sea states, ground vehicles move at speed, airborne platform acting as a relay).

PHASE II: The base period will test critical technical components to validate the maturity and expected performance of the proposed Phase I design. Mitigations for any technical issues that are discovered during the Phase II testing should be proposed, tested, and validated. A final design will be delivered at the end of Phase II base period, with an assessment of its expected performance based on the testing of critical components. The objective of the base period is to have a breadboard demo showing a proof-of-concept design.

The first option, if exercised, will improve the preliminary terminal design to address any technical or performance risks identified during the Phase II base period. Again, the objective of this option is to have a breadboard demo showing a proof-of-concept design that addresses the Navy's concerns with the original design.

The second option, if exercised, will fund the fabrication of a multi-beam optical terminal and initial testing to validate its performance. The objective of this option is to have a functioning terminal with sufficient test data to validate its performance in a relevant environment.

PHASE III DUAL USE APPLICATIONS: Phase III will assess the prototype terminal's performance as part of a TRL 6 or higher demonstration to support a transition. Phase III includes the installation of the terminal on Navy or USMC platform, with all of the required gimbaling for pointing and tracking, to support a demonstration at an appropriate experimentation venue. Depending on the Program of Record, that could include either a Trident Warrior exercise at sea or Bold Alligator, or some equivalent, USMC exercise. Private Sector Commercial Potential: The private sector uses optical communications systems between fixed (e.g., buildings) and/or mobile sites. Private companies (i.e., SpaceX and OneWeb) are involved in efforts to deliver Internet service via a constellation of satellites in low earth orbit. Optical communications between these satellites could potentially provide the high capacity backbone required to deliver broadband services to end users. All of these private sector applications could benefit from multi-beam, optical terminal technology.

REFERENCES:

1. Linda Thomas and Chris Moore, TALON – Robust Tactical Optical Communications, CHIPS Magazine, Oct. – Dec. 2014. http://www.doncio.navy.mil/CHIPS/ArticleDetails.aspx?id=5550

2. Hemani Kaushal and Georges Kaddoum, Free Space Optical Communication: Challenges and Mitigation Techniques, Jun 2015. http://arxiv.org/pdf/1506.04836.pdf

3. Aditi Malik and Preeti Singh, Free Space Optics: Current Applications and Future Challenges, International Journal of Optics Volume 2015, Sep 2015. http://www.hindawi.com/journals/ijo/2015/945483/-

KEYWORDS: Laser, Optical, Communications, Free-space, Multiple Beam, Multiple Access

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

N171-090

TITLE: Understanding AM Solidification Profile Effects on Material Inhomogenieties, Defects, and Qualification

TECHNOLOGY AREA(S): Air Platform, Ground/Sea Vehicles, Materials/Processes

ACQUISITION PROGRAM: Quality Metal Additive Manufacturing (Quality MADE) EPE FY17-03

OBJECTIVE: To develop a model relating the melting/solidification profile of metals/alloys to the metal/alloy microstructure during additive manufacturing (AM) processing. The model should describe how the melting/solidification profile influences the generation of microstructural inhomogeneities and defects as a function of power, speed and materials for a given AM process as a function of build depth. Process parameter correlation with different materials via integrated computational materials engineering (ICME) should be utilized so that defect and inhomogeneities can be minimized, part property variations within the component can be minimized, and its performance can be qualified.

DESCRIPTION: Navy acquisition programs are interested in reducing costs and reducing costly inventories, but need to be confident that the parts being manufactured by an AM process will meet qualification standards and provide use longevity with a high degree of confidence. Metal AM processes offer the potential to generate qualified parts quickly in order to maximize readiness of Navy air, sea and ground assets.

Various AM process-induced defects, spatial microstructural inhomogeneities, and induced stresses must be understood in order to minimize their occurrence and impact by AM process changes and post-processing. Melting and solidification is generally well-understood during casting processes, but melting and solidification profiles, effect of contamination, and chemistry control during AM processing, particularly for complex and thicker components, is 3-dimentional and is not well characterized. Heat transfer is relatively simple in the beginning, but as the part becomes larger and thicker there is concern that 3-dimensional heat transfer will modify the microstructure and subsequently the properties, of neighboring AM layers leading to distortions and possible sagging if the build plane is oriented improperly. Some AM processes produce smoke during the part build and it is unknown how the smoke may influence the AM build of a part, to what extent, if any, this “smoke” will contaminate the build pool (and if the build pool can be reused for subsequent AM builds of parts or not). Processing defects (e.g., micro-porosity and surface finish) dominate the fatigue properties of AM produced alloys. A strong anisotropy in fracture behavior was also noted and attributed to manufacturing defects. In addition, different metal AM methods impart diverse processing defects on alloys while properties of various alloys that will also influence AM processing variables. Using ICME (integrated computational materials engineering), models linking to materials/ processing/property/microstructure relationships can be created and developed to define the layer-by-layer heat transfer characteristics of given component geometry that will lead to models that will guide AM processes to produce more homogenous microstructures by modifying AM parameters during the build process. More uniformity in the AM build of a part will help define the steps towards component certification.

PHASE I: The small business needs to identify the types of 2D and 3D defects (mechanical and structural anisotropic, porosity, support material trapped between internal surfaces, etc.) and determine the causes of these defects. The melt/solid interface can be monitored in-situ or by taking an appropriate series of micrographs to determine heat flow characteristics of a component as a function of part depth. Topology optimization should be considered to identify the root cause of defects in an AM component and analyze the source and role a defects as a perturbation of AM process. Work should be done on AM processing of one alloy or metal. Analysis of the defects is suggested to be done by non-destructive processes such as optical tomography, thermographic analysis, ultrasonic monitoring or x-ray tomography. ICME should link AM process parameters with defect frequency and distribution in the component design, employ and prove feasibility of an approach for a metal AM method to replicate a simple component with a minimum dimensions of about 2-inch long by one-inch wide and one-inch thick with a minimum of flaws.

PHASE II: Based upon Phase I effort, apply ICME tools to metal AM processing, to predict design and processing parameter limits for a more complex component. Since most AM metal processes are layer-by-layer the organization needs to model the change in heat transfer as the layers are built on upon the other in an effort to minimize microstructural changes within the component. Work should be done on AM processing of one alloy or metal used during Phase I and also on a second metal or alloy to evaluate how changes in working materials may change AM processing parameters and resulting defect type and frequency. The process also needs to evaluate the surface roughness and dimensional accuracy of the AM component. The small business should utilize the results from Phase I to continue topology optimization of the AM metal process. Some mechanical testing should be done on an AM component and compared to a wrought component of similar size and shape to determine whether the frequency, distribution and type of defect influences component performance. Fatigue testing should also be considered for evaluation and comparison. Validation of ICME tools and predictive analysis capabilities will be analyzed by comparing the physical, metallurgical and mechanical properties of an AM component with a component currently fabricated by traditional means to validate optimization of the additive manufacturing process. An AM processing OEM should be consulted during Phase II.

PHASE III DUAL USE APPLICATIONS: Additive Manufactured will be transitioned into an application on a Navy platform. The OEM involved during Phase II will be part of the transition team. Phase III will include defining the additive manufacturing parameters for qualified full scale system production and establishing facilities capable of achieving full scale production capability of Navy-qualified components that have demonstrated process reliability and with a minimal of defects so that the component properties meet qualification standards. Private Sector Commercial Potential: The AM process offers the opportunity of conformal, and unique design not possible with more conventional fabrication processes. Proven AM process optimization leading to a minimization of process - and materials - derived defects would improve acceptance of AM for producing component for the Navy and for private industry. The use of AM could lead to more innovative designs capable of more efficiently removing heat because such designs could eliminate or severely reduce joints. AM processing of components that are qualified for Navy use could also be applied to commercial use. The use of AM could lead to more innovative designs capable meet ever-increasing demands on components for the Navy as such designs could eliminate or severely reduce joints. AM processing of components that are qualified for Navy use could also be applied to commercial use more quickly and less costly with parts are needed.

REFERENCES:

1. B.A. Cowles, D. Backman, “Advancement and Implementation of Integrated Computational Materials Engineering (ICME) for Aerospace Applications,” AFRL-RX-WP-TP-21010-4151.

2. W.E. Frazier, “Metal Additive Manufacturing: A Review” Journal of Materials Engineering and Performance, v.23(6) pp. 1917-1928 (June 2014).

3. M. F. Horstemeyer, “Integrated Computational Materials Engineering (ICME) For Metals”, John Wiley & Sons, Inc. 2012.

4. I. Gibson, D. Rosen, B. Stucker, Additive Manufacturing Technologies: 3D Printing, Rapid Prototyping, and Direct Digital Manufacturing, Springer, New York (2015).

5. T.J. Horn, Ola L.A. Harrysson, "Overview of current additive manufacturing technologies and selected applications", Science Progress, v.95 (3) pp. 255-282, (September 2012).-

KEYWORDS: Inhomogeities, defects, additive manufacturing, ICME, processing, quality control, qualification

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

N171-091

TITLE: Synthetic Vision System for Ground Forces

TECHNOLOGY AREA(S): Electronics, Human Systems, Information Systems

ACQUISITION PROGRAM: CMP-FY15-01: Accelerating Development of Small Unit Decision Makers

OBJECTIVE: This effort seeks to accelerate and enhance decision making for Marine Corps Ground Forces by developing a Synthetic Vision System (SVS) extension for head-mounted displays (HMDs) to provide training aids and situational awareness (SA) visualizations.