Joint Technology Exchange Group

CMTC Brief

November 05, 2003

Gary W. Schuerfeld
Chairman, The Composites Consortium

This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing
Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
 • Scheduled Topics
– Overview of Composites Manufacturing
Technology Center (CMTC)
– Overview of Ongoing Projects at the
CMTC
– Overview of Future Composites
Applications and Vision for the US Navy

This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing
Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
 Composites Manufacturing
Technology Center
Overview

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Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
 Composites Manufacturing
Technology Center

 One of Nine US Navy MANTECH Centers

• Managed by SCRA’s Applied Research and

Development Institute (ARDI)

• Technical Work Performed by The Composite

Consortium (TCC)

• Wide Scope of Activities Possible:

Science and Technology MANTECH

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Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
 Composites Manufacturing
Technology Center

• Sponsor: ONR MANTECH Program

• Award Date: October 2000

• Contract Period: 5 Years

• Contract Amount: Contract Ceiling : $120M

ONR Core Funding : $ 60M

• Contract Type: Cooperative Agreement

This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing
Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
 US Navy Centers of
Excellence (COE)
Institute for Manufacturing and
National Center for Excellence in
Sustainment Technologies
Metalworking Technology
(IMAST)
(NCEMT)
Penn State, PA
Johnstown, PA
Electro-Optics Center
(EOC) Electronics Manufacturing
Kittanning, PA Productivity Facility (EMPF)
Philadelphia, PA

Best Manufacturing
Practices Center of
Excellence (BMP)
College Park, MD

Navy Joining Center

Energetics Manufacturing
(NJC)
Technology Center (EMTC)
Columbus, OH
Indian Head, MD

Center for Naval

Shipbuilding Technology
(CNST)
Charleston, SC

Seneca, SC

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Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
 Composites Manufacturing
Technology Center

SCRA
Corporate
Offices

This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing
Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
 Composites Manufacturing
Technology Center

• Personnel
• Henry E. Watson - ARDI and CMTC: Executive Director
• Jim Sabo - CMTC: Technical Director
• Skip Wharton - ARDI: Director of Finance and Procurement
• Jada Gates - ARDI: Senior Contracts Manager
• Rhett Cheatham - ARDI: Projects Administrator
• Ivan Snell - CMTC: Director, Special Programs
• Gary Schuerfeld - CMTC: Chairman, The Composites Consortium
• Lillian Rumsey - ARDI: Coordinator
• Lesley Morrison - ARDI: Administrative Assistant
• Dr. Art West - ARDI: Technical Director

• Headquarters
934-D Old Clemson Highway
Eagles Landing Professional Park
Seneca, South Carolina 29672
Phone: 864-653-7590
Fax: 864-653-7434

This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing
Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
 CMTC/TCC Structure

Through a cooperative agreement with the Office of Naval

Research (ONR), the Applied Research and Development
Institute (ARDI), an operating unit of the South Carolina
Research Authority (SCRA), manages the Composites
Manufacturing Technology Center (CMTC) located in Seneca,
South Carolina.

The CMTC chairs The Composites Consortium (TCC), an

organization of industry-focused, balanced team of prime
contractors, composites industry suppliers, universities, and
institutes. Through the Navy’s Manufacturing Technology
Program (MANTECH), as well as other directed DoD funding,
TCC members are able to perform on a wide range of
Government projects across all service branches.

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Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
 CMTC/TCC Structure

Technical Advisory Board Executive Steering Committee

(TAB) (ESC)

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Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
 TCC Technical
Advisory Board (TAB)

–What is the Technical Advisory Board?

• The Technical Advisory Board (TAB) is an assemblage of key
composites technical experts from within The Composites
Consortium (TCC). Each TCC member organization appoints
one technical representative to the board.
–What does the Technical Advisory Board do?
• The TAB assists in the development of a Composites
Manufacturing Technology Center technical strategic plan,
advises and assists the Center’s Technical Director with the
process of MANTECH project development, attends reviews of
projects within their area of expertise, consults on technical
issues within a specific area of expertise, and by identifying
composites manufacturing technology needs and priorities. In
addition, the TAB may assist the CMTC in the selection of
proposals if multiple proposals are received for a given project.

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Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
 TCC Technical
Advisory Board (TAB)
Alliant Aerospace Company
Atlantic Research Corporation
ARC Technologies, Inc.
Bell Helicopter-TEXTRON, Inc.
The Boeing Company
Clemson University
Composite Solutions, Inc.
General Dynamics
(Electric Boat, Land Systems,
Bath Iron Works)
Goodrich Corporation
Lockheed Martin Corporation
Mississippi State University
Michael Blair 210 State Route 956 (801) 775-1722 michael_blair@atk.com
M/S: WV01-10
Rocket Center, WV 26726-3548
John Sparks 5945 Wellington Road (703) 754-5371 john.sparks@arceng.com
Gainesville, VA 20155
Judith Snow 11 Chestnut Street (978) 388-2993 jsnow@arc-tech.com
Amesbury, Mass 01913
Ken Nunn PO Box 482 (817) 280-3435 knunn@bellhelicopter.textron.com
Plt 1, Drop 1701
Ft. Worth, TX 76101
Randy Southmayd Advanced Mfg. Research & (314) 232-4770 randy.a.southmayd@boeing.com
Development Phantom Works
PO Box 516
Mail Code S2761007
St. Louis, MS 63166-0516
Larry Dooley College of Engineering and Science (864) 656-3200 dooley@clemson.edu
Riggs Hall
Clemson University
James Lovejoy 1940 Old Dunbar Road (803) 822-8493 jlovejoy@csisc.com
West Columbia, SC 29172
Dr. Jeff Hall General Dynamics Electric Boat (860) 433-7300 jhall@ebmail.gdeb.com
Dept. 341, Sta. J88-9
75 Eastern Point Road
Groton, CT 06340
Ron Kestler 11120 S. Norwalk Blvd (562) 906-7356 ron.kestler@goodrich.com
Santa Fe Springs, CA 90670
Morris Scales PO Box 748 (817) 935-1761 morris.r.scales@lmco.com
Fort Worth, TX 76101
Wayne Bennet College of Engineering (662) 325-2270 wayne@engr.msstate.edu
Mississippi State University
PO Box 9544
Mississippi State, MS 39762

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Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
 TCC Technical
Advisory Board (TAB)

Northrop Grumman Newport News
Northrop Grumman Integrated
Systems
Chris Duer Dept E30, Bldg 1744-5 (757) 688-0430 Chris.duer@ngc.com
4101 Washington Avenue
Newport News, VA 23607
Eric Barnes One Hornet Way, 9L20/W2 (310) 331-3753 eric.barnes@ngc.con
El Segundo, CA 90245-2804

Northrop Grumman Ship Systems Walter Whitehead PO Box 149 (228) 872-7312 john.whitehead@ngc.com
Mail Station 7000-02
Pascagoula, MS 39568
Pennsylvania State University – Kevin Koudela PO Box 30 (814) 863-4351 klk121@psu.edu
Applied Research Laboratory State College, PA 16804-0030
Raytheon Company Bill Scheck 1151 E. Hermans Road (520) 794-1018 wgscheck@raytheon.com
PO Box 11337
Bldg. 805, M/S D4
Tucson, AZ 85734-1337
Robert C. Byrd Institute (RCBI) Tom Minnich 1050 Fourth Avenue (800) 469-7224 tminnich@rcbi.org
Huntington, WV 25701
Sikorsky Aircraft Corporation Stephen Varanay 6900 Main Street (203) 386-4351 svaranay@sikorsky.com
PO Box 9729
Stratford, CT 06615-9129
SPARTA Composites, Inc. Joel Zuieback 10540 Heater Court (858) 455-1650 Joel_zuieback@sparta.com
San Diego, CA 92121
Specialty Materials, Inc. Rich Caruso 1449 Middlesex Street (508) 393-7868 rcaruso@specmaterials.com
Lowell, MA 01851
Structural Composites, Inc. Eric Greene 86 River Drive (410) 263-1348 EGASSOC@aol.com
Annapolis, MD 21403
Touchstone Research Laboratory Michael Brown The Millennium Centre (304) 547-5800 mlb@trl.com
R.D. 1, Box 100 B
Triadelphia, WV 26059-9707

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Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
 TCC Technical
Advisory Board (TAB)

Virginia Polytechnic Institute and
State University
Wake Forest
York Technical College
Al Loos Virginia Tech Center for Composite (540) 231-4713 aloos@vt.edu
Materials and Structures
Department of Engineering Science
and Mechanics
Mail Code 0219
320 Norris Hall
Blacksburg, VA 24061
Dr. David Carroll Wake Forest University (336) 758-5530 carrolld@wfu.edu
214 Olin Physical Laboratory
PO Box 7507
Winston Salem, NC 27199
Ed Duffy 452 South Anderson Road (803) 327-8012 duffy@york.tec.sc.us
Rock Hill, SC 29730

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Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
 Executive Steering
Committee (ESC)
- What is the Executive Steering Committee?
• The Executive Steering Committee (ESC) is a group of senior level managers from
within the Composites Consortium (TCC). The 8-member ESC is composed of two
TCC representatives from each of the following four groups:
– Members who are primarily aerospace contractors,
– Members who are primarily shipbuilding or ocean structures contractors,
– Members who are research universities/institutes/laboratories, and
– Members who are primarily supplier contractors or technology suppliers.

• ESC members are nominated and elected by member companies of The Composites
Consortium (TCC).

- What does the Executive Steering Committee Do?

• The ESC provides overall coordination for technical reviews and technology
transfer. In addition, the ESC (1) Reviews all CMTC issues to be submitted to the
Navy MANTECH database, (2) Assists in the development of the technical strategic
plan for TCC, and (3) Assists the Executive Director of the CMTC in maintaining and
coordinating support for TCC, identifying additional sources of funding, marketing
TCC to potential customers,

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Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
 Executive Steering
Committee (ESC)
ESC Company ESC Member Company Address Phone E-mail
Alliant Aerospace Company Michael Blair 210 State Route 956 (801) 775-1722 michael_blair@atk.com
M/S: WV01-10
Rocket Center, WV 26726-3548

Bell Helicopter-TEXTRON, Inc. Walter PO Box 482 (817) 280-2107 wsonneborn@bellhelicopter.textron.

Sonneborn MS: 1322 com
Ft. Worth, TX 76101

Northrop Grumman Newport News David P Rice 4101 Washington Avenue (757) 688-1762 David.Rice@ngc.com
B905/7
Newport News, VA 23607

Northrop Grumman Integrated Systems George One Hornet Way, 9L20/W5 (310) 331-7101 rodgege@mail.northgrum.com
Rodgers El Segundo, CA 90245-2804

Northrop Grumman Ship Systems William Chair - Naval Postgraduate School (831) 656-2546 wasolita@nps.navy.mil
Solitario 777 Dyer Rd
M/S 97
Monterey, CA 93943

SPARTA Composites, Inc. Joel Zuieback 10540 Heater Court (858) 455-1650 Joel_zuieback@sparta.com
San Diego, CA 92121

Touchstone Research Laboratory Michael Brown The Millennium Centre (304) 547-5800 mlb@trl.com
(ESC Chairman) R.D. 1, Box 100 B
Triadelphia, WV 26059-9707

York Technical College Bob Kosak 452 South Anderson Road (803) 325-2865 kosak@yorktech.com
Rock Hill, SC 29730

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Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
 Current TCC Status

• The Composites Consortium

– 25 Current Members
• Research Universities
• Weapons Platform Primes
• Specialty Fabricators
• University Affiliated Research Centers (UARC)
• Training & Education Organizations

– Supports All Weapon Platforms

• Aerospace (Including Unmanned Vehicles)
• Surface Ships and Vehicles
• Undersea
• Land Vehicles
• Space Structures

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Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
 Current TCC Members

• Alliant Aerospace Company • Northrop Grumman Ship Systems

• Atlantic Research Corporation • Pennsylvania State University - Applied
Research Laboratory
 ARC Technologies, Inc.
• Raytheon Company
• Bell Helicopter – TEXTRON, Inc.
 Robert C. Byrd Institute (RCBI)
• The Boeing Company
• Sikorsky Aircraft Corporation
• Clemson University
• SPARTA Composites, Inc.
• Composite Solutions, Inc.
 Specialty Materials, Inc
• General Dynamics Corporation
(Bath Iron Works, Electric Boat, Land Systems) • Structural Composites, Inc.
• Goodrich Corporation • Touchstone Research Laboratory
• Lockheed Martin Corporation • Virginia Polytechnic Institute and State
• Mississippi State University University

• Northrop Grumman Newport News  Wake Forest University

• Northrop Grumman Integrated Systems • York Technical College

 New Members

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Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
 TCC Member Locations
Alliant Aerospace GD-Bath Iron Works

ARC Technologies

Specialty Materials

Boeing
Sikorsky
GD-Land Systems

Boeing

ARL/PSU
NGIS
RCBI
Goodrich
GD-Electric Boat
TRL
NGNN
Virginia Tech

Atlantic Research

Wake Forest

York Tech
NGIS
Composite Solutions

SPARTA Clemson Univ.

Goodrich
Raytheon
SCI
Bell Helicopter
NGSS
Mississippi State

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Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
 CMTC Website

http://cmtc.scra.org

TCC Info
Page

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Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
 Composites Manufacturing
Technology Center
Ongoing Projects

Distribution Statement D: Distribution authorized to U.S. DOD and U.S. DOD Contractors only, for administrative and operational use. WARNING - This
document contains technical data whose export is restricted by the Arms Export Control Act (Title 22, U.S.C. SEC 2751 et seq.) or the Export Administration
Act of 1979, as amended, Title 50, U.S.C., App 2401, et seq. Violations of these export laws are subject to severe criminal penalties. Disseminate in accordance
with the provisions of DOD Directive 5230.25 and OPNAVINST 5510.161.
The Marine Composites Technology Center Spence Center for Composites Technology
West Melbourne, Florida Columbia, South Carolina

TECHNOLOGY TRANSFER CENTERS

York Technical College TTC THRUST

York, South Carolina
Transfer innovative, defense-critical
composites manufacturing
technology skills from development
programs to widespread applications,
and to assist in ensuring the
affordability of composites for Navy
use
 Technology Transfer
Centers

• Accomplishments
– York Technical College
• Developing a New Navy Training Course
“Introduction to Composites” Aimed at
Maintenance/Repair Personnel
• Performed a Survey of Existing Navy Composites
Training and Certification Programs at Three Main
Aviation Maintenance Depot Locations
• Conducted DACUM’s (Develop A CUrriculuM) for
Composite Repair Training and Certification
Programs at Cherry Point, North Island and Oceana
Naval Air Stations.

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Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
 Technology Transfer
Centers

• Accomplishments
– Spence Center for Composite Technology
• Sponsored a Conference Entitled “Navy-
Commercial Partnerships for World Class
Manufacturing.”
• Developed a Training Manual for the Safe Handling,
Use, and Disposal of Composites Materials
• Developed Manufacturing Processes for the
Production of Radomes using Flouroalaphatic
Cyanate Resin and Astroquartz Fiber

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Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
 Technology Transfer
Centers

• Accomplishments
– Marine Composite Technology Center
• Conducted A Resin Infusion Demonstration at the
Composite Fabricators Association (CFA)
International Symposium on Vacuum Infusion
Processing and Resin Transfer Molding
• Developed Booklet: “Alternative Approaches to
Closed Molding”, a Primer of VARTM-type Infusion
Processing Methods
• Developed Booklet: “Potential Composite
Applications for Oliver Hazard Perry Class Frigates”,
detailing Composites Solutions for Fleet Corrosion
Issues.

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Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
 PROJECT OBJECTIVE
Develop, demonstrate and
document improvements to the
wet filament winding process as
applied to pressure vessel
fabrication
AIM-9X

COMPOSITE PRESSURE VESSEL FABRICATION

PROJECT TEAM
Atlantic Research Corporation

ROI = 24:1
 Composite Pressure
Vessel Fabrication
• Project Number: A0937
• Performing Activity: Atlantic Research Corporation
• Start/End Dates: 04/99 – 12/03
• Primary Benefit: Provides manufacturing technologies that will substantially
reduce the costs of high-performance composite pressure vessels to a level where
they will be competitive with metal pressure vessel alternatives.
• Objective: Develop, demonstrate and document improvements to the wet filament
winding technology as applied to pressure vessel fabrication.
• MANTECH Cost: $1,789K Cost Share: $267K
• Implementation Cost: None
• Systems Impacted: AIM-9 SIDEWINDER, RAM, SM, HELLFIRE
• Implementation: ARC to provide improved WFW technology prior to AIM-9X
EMD

Technical Achievements: Benefit Analysis/ROI

Expected Unit Cost ROI = 24:1
• The Fiber Damage Assessment task, a precursor to fiber wet- • Investment 40
out, was completed. – ManTech Program: $1.79M
• The fiber tensioner, spreader, and resin bath systems integrated • Unit Cost Analysis
system was delivered and mounted onto an ARC filament – GFE MK-36 Steel Motors: $8000 30

Millions Saved
winder and is functional. – Upgrade to AIM-9X: $6823
– Motor Unit Cost: $14,823
• NDC Corp. traveled to ARC for installation and calibration of – Projected Procurement of 6680 AIM-
a gamma gage system. 20
9X and 1500 RAM (USN & FMS)
– Total Cost Avoidance: $37.5M
Status: • Warfighting Return
10
– IM Compliance
• CECMT issued stop work order February 2001
• Lives Saved MANTECH cost = $1.79M
• Project restarted under CMTC January 2002. • $2.5B Past Carrier Damage
• The extended interruption in the contract is requiring – Composite Case Required to Meet
some duplication of effort to relearn programming of the Missile Performance Goals FY1 FY2 FY3 FY4 FY5
new control software and to restart the project. Fiscal Year
 Composite Pressure Vessel

Composite Pressure Vessel Fabrication

• 4” JANNAF Tubes
– Testing of Tubes from the Baseline Winder
Completed.
– Three Tubes from the ManTech Winder
Tested. Additional Tubes Being Fabricated
for Test
– Statistical Analysis After All Tubes Tested
• 6” Hydroburst Bottles
– Two ManTech Winder Bottles
Wound/Prepared for Hydroburst
– Additional Bottles Being Fabricated
• Problems With ManTech Winder Delayed
Project Approximately 2 Months

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Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
 Gantry Trolley

Composite Gantry/Trolley Type Structures

• At the NSWC/CSS Station in Panama City, FL

• Composite Barge Was Being Considered for Test Pond

• Customer Determined Composite Barge to be High

Technical, Cost & Schedule Risk

• Customer Specified Steel Barge

• Barge/Building Installation Completed: Dedication

Ceremony 09 September 2003

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Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
 Gantry Trolley

Aerial View of Old Barge 26’x38’

Acoustic Test Facility

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Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
 Gantry Trolley

New Barge (30’ x 60’) w/Building

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Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
 Gantry Trolley

New Barge (30’ x 60’) w/Building

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Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
 PROJECT OBJECTIVE
Automate the Z-fiber installation
process eliminating the concerns
of manual insertion and provide
additional cost savings to the
F/A-18E/F.

AUTOMATED INSERTION OF Z-FIBER FOR COMPLEX SHAPES

PROJECT TEAM
Northrop Grumman
Aztex, Inc.

ROI = 1.4 w/o Partial Depth

 Automated Insertion of
Z-Fiber for Complex Shapes
Prototype • Project Number: A1007
Automated • Performing Activity: Northrop Grumman Corp., El Segundo, CA; Aztex
Insertion Head • Start/End Dates: 10/01 – 01/04
(End-Effector)
• Primary Benefit: Significant improvements in composites affordability and
increased system performance for advanced composite structures.
• Objective: To automate the Z-fiber insertion process on F/A-18 E/F
eliminating production and quality assurance concerns related to the manual
insertion variability and fatigue.
• MANTECH Cost: $2.68M Cost Share: $721K
Current Manual
• Implementation Cost: TBD
Insertion Head
• Systems Impacted: F/A - 18 E/F and derivatives, other vehicles with joined
composite parts
• Implementation: Initially a/c FF- 108 (5 parts), fully a/c FE-120 (all 37 parts)

Technical Achievements: Benefit Analysis/ROI

Expected ROI = 4.5:1
• Prototype end-effector head designed, fabricated and • Benefit Analysis Assumptions 8
delivered for concept proofing and troubleshooting. • Makes a/c effectivity
• Prototype end-effector head demonstrated on flat panel • All identified parts captured 6
hat-stiffened composite parts.
• 400 total aircraft purchased
• Initial coupon testing displays promising results for a

$Million
maturing technology. • Increase in aircraft build from
4
36/yr. to 48/yr. for FY 05.

s
• Benefit Analysis Results
Status:
• Initially $12K saved per a/c 2 MANTECH cost =
• Machine systems/customer requirements document ultimately $30K saved per a/c $2.68M
finalized.
• ROI calculation
• Automated machine builder procurement specification
contract currently in bidding process. • Significant savings over projected FY04 FY05 FY06 FY07 FY08
a/c program lifetime with partial
depth insertion implemented. Fiscal Year
 Z-FIBER AUTOMATED
INSERTION
Mechanical Fastener Attachment Advanced Attachment with “Z-Pins”

Requires: Requires:
• Pre-Curing of Multiple Details • Integration of Composite Lay-ups
• Drilling/Countersinking of Fastener Holes • Installation of Z-Pins Prior to Cure
• Application of Liquid Shim • Backside OML Sealing
• Wet Installation of Fasteners

Pre-Cured Composite Co-Cured Composite

Radius Block Hat Stiffener

Pre-Cured Co-Cured
Composite Skin Composite Skin

Demonstrated Benefits .011” Dia. GR/BMI Z-Pins

(420 pins/in2)
 Reduced Touch Labor
 Reduced Weight
 Reduced Part Count
 Reduced Defect Count
 Increased Interlaminar Capability
 Improved Damage Tolerance
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Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
 Z-FIBER AUTOMATED
INSERTION

Complex
Curvature
Components

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Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
 Z-FIBER AUTOMATED
INSERTION

6-Axis
Gantry
Automated
Insertion
Equipment

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Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
 PROJECT OBJECTIVE
Improve the affordability of SiC-C
composite engine exhaust
components by streamlining and
optimizing the manufacturing
production process.

F- 414 Engine

SiC-C COMPOSITE FLAPS AND SEALS

PROJECT TEAM
Goodrich Corporation

ROI = 6.58
 Manufacturing Technology for SiC-C
Composite Flaps and Seals
Status:
• Anticipated Project start September 2002
Project Tasks:
• Task 1: Reduce CVD Cycle Time
– Combine Pyrolysis and Carbonization Steps
– Measure The Effect Upon Composite Densities And
Mechanical Properties
• Task 2: Substitute Low Cost Fiber and Alternate Resin/Filler
System
• Task 3: Validate Process Improvements
– Manufacture Engine Hardware Panels
– Generate Mechanical Properties
• Task 4: Manufacture a Set of Engine Hardware
• Task 5: Engine Test Hardware (GEAE Funded)
• Project Number: A1013
• Performing Activity: Goodrich Corporation
• Start/End Dates: 09/02 – 08/04
• Primary Benefit: Reduced Cost for F414 Engine Exhaust and Seal Components
• Objective: Identify, and Validate for Production, a Lower Cost SiC Fiber/Prepreg
Resin System and Develop Process Modifications That Will Reduce the Cost and
Cycle Time of the Carbon Vapor Deposition (CVD) Process.
• MANTECH Cost: $856K
• Implementation Cost: TBD
• Systems Impacted: F/A-18 Hornet
• Implementation: Process Changes Will Be Submitted to GEAE Engineering for
Review. GE Will Fund Engine Testing Under Their F414 Development Engine
Testing Program. Commitment has been obtained from NAVAIR F414 IPT to
Support Engine Qualification Tests
Benefit Analysis/ROI
• Benefit Analysis Assumptions
– Based on 520 Engine Sets
– Estimated Cost Savings of $9.8K Per Engine
– Spare Parts Are Not Included in Analysis
• Benefit Analysis Results
– Cost Savings of $5,078K Over 520 Engines
• ROI = ($9,768 X 520) / $856,000 = 5.93
 PROJECT OBJECTIVE
Develop an improved composite
protection layer for ship main
propulsion shafts that will afford
corrosion protection over a
twelve-year docking cycle.

PROPULSION SHAFT COMPOSITE SURFACE TREATMENT

PROJECT TEAM
Newport News Shipbuilding
NSWC Carderock Division
Norfolk Naval Shipyard
Portsmouth Naval Shipyard
Puget Sound Naval Shipyard

ROI = >10:1 Over 5 Year Cycle

 Propulsion Shaft Composite
Surface Treatment
Status:
• Anticipated Project start September 2002
Project Tasks:
• Task 1 - Manufacturing Process Development
• Task 2 - Peel Testing/Environmental Conditioning
• Task 3 – Manufacturing Trials & Scale Test Shaft Fabrication
• Task 4 - NSWCCD Testing of Scale Shafts
• Task 5 – Planning for RCOH 70 and CVN 77
• Task 6 – Repair Procedure Development
• Task 7 – Technology Transfer to Navy Shipyards
• Project Number: S1012
• Performing Activity: Northrop Grumman Newport News; NSWCCD; Puget Sound,
Portsmouth and Norfolk Naval Shipyards
• Start/End Dates: 09/02 – 05/05
• Primary Benefit: An Improved Shaft Coating System Will Help the Navy Achieve
a 12-year Docking Cycle while Reducing Shaft Life Cycle Costs.
• Objective: Develop an Improved Composite Protection Layer for Ship Main
Propulsion Shafts That Will Afford Corrosion Protection for Twelve Years.
• MANTECH Cost: $1,441,700
• Implementation Cost: $16,460 - $49,500 Fabrication Cost Increase Per Shaft
• Systems Impacted: CVN 68 Class Nuclear Aircraft Carrier; CVN77 & CVNX Next
Generation Nuclear Aircraft Carriers; DDG-51
• Implementation: Approvals Secured From SEA 05Z12, SEA 05Z2, NSWCCD
SSESDET / Code 9323, SEA 05M1, PMS 312D, CNAP N43 for the CVN-70
RCOH availability. Tech Transfer/Training to Navy Shipyards
Benefit Analysis/ROI
• Benefit Analysis Assumptions
– Repair Cost Extrapolated From Shipyard Repair Cost Estimates for Current
Shaft Covering Practices (Does Not Include Submarines).
– 383 Shafts on Surface Ships Replaced or Repaired Every 7 Years (on Average).
– $64,000 - $192,450 Repair Cost (Relative to the Shaft Size) Per Shaft Every 7
Years ($33,966,825 Total Estimated Repair Cost Savings Every 7 Years)
– $16,460 - $49,500 Fabrication Cost Increase Per Shaft ($519,730 Total
Fabrication Cost Increase Every 7 Years)
• Benefit Analysis Results
• $34 Million Cost Avoidance Over 7 Years
• 5-Year ROI = 5/7 x ($33,966,825 – $519,730)/$1,395,000 = 16
 PROPULSION SHAFT
SURFACE TREATMENT

Polysulfide Coating Application Polysulfide Coating Application

Application of GRP Overwrap Application of GRP Overwrap

This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing
Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
 PROPULSION SHAFT
SURFACE TREATMENT

Carderock Development of
Scale Shaft Evaluation
Progress Continues on the
“Four Square” Test
Apparatus and Test Facility

This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing
Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
 PROJECT OBJECTIVE
Develop a manufacturing
process to incorporate
composite structural armor into
the EFV troop ramp door
reducing the weight by 20%
and eliminating the costly
appliqué armor system

EXPEDITIONARY FIGHTING VEHICLE TROOP DOOR

PROJECT TEAM
General Dynamics Land
Systems
ARL Penn State

ROI = 14.3 : 1
 EXPEDITIONARY FIGHTING
VEHICLE TROOP DOOR
Status:
• Anticipated Project start August 2002
Project Tasks:
• Task 1 – Redesign & Analysis (Cost Share Task)
• Task 2 – Manufacturing Process Development
• Task 3 – Machining, Assembly, and Quality
Assurance/Inspection
• Task 4 – Ballistic Testing (Cost Share Task)
• Task 5 – Fabrication of Prototype #1
• Task 6 – Process Optimization
• Task 7-9 – EMD Vehicle E2, E3 and E5 Hardware Fabrication
• Project Number: C1011
• Performing Activity: General Dynamics Land Systems; ARL Penn State
• Start/End Dates: 08/02 – 06/04
• Primary Benefit: Reduced Cost and Reduced Weight for the EFV Rear Door
Assembly.
• Objective: Develop a Manufacturing Process to Incorporate Composite Structural
Armor Into the EFV Troop Ramp Door Reducing the Weight by 20% and Eliminating
the Costly Appliqué Armor System
• MANTECH Cost: $ 920K Cost Share: $ 325K
• Implementation Cost: The Manufacturing Technology Developed Is Not Expected
to Require New Facilities.
• Systems Impacted: Expeditionary Fighting Vehicle (EFV)
• Implementation: A commitment has been obtained from the EFV Hull Mechanical
Systems IPT Lead (Mr. Michael Lange) to support the installation and testing of the
prototype assemblies on EMD vehicles E2, 3 and 5.
Benefit Analysis/ROI
• Benefit Analysis Assumptions
– Number of Vehicles = 1013
– Cost Savings of $5K per Door
– Value of Weight Savings = $100 per Pound x 80 lbs/door = $8,000
– Assembly, Logistics and Other Potential Cost Savings Not Included
• Benefit Analysis Results: Total Cost Savings of $13,169K
• ROI = (1013 vehicles x $13,000 per vehicle)/ $919,500 = 14.3
 PROJECT OBJECTIVE
Develop affordable and reliable
manufacturing process that
address the specific embedment
fabrication issues while
concurrently assessing the
process impact on structural
and electrical performance.

AFFORDABLE INTEGRATED STRUCTURAL APERTURES

PROJECT TEAM
Northrop Grumman AEW/EW
Northrop Grumman Ship
Systems

ROI = 7.53:1
 Affordable Integrated
Structural Apertures
• Project Number: A1042
• Performing Activity: Northrop Grumman Integrated Systems
• Start/End Dates: May 2003 – January 2006
• Primary Benefit: Reduced Cost and Reduced Weight for the Satellite Communications
Antenna System for the E-2C Aircraft
• Objective: Develop Affordable And Reliable Low-pressure Autoclave And Vacuum Bag
Cure Hand Lay-up Manufacturing Processes That Address Specific Embedment
Fabrication Issues While Concurrently Assessing The Process Impact On Structural And
Electrical Performance.
• MANTECH Cost: $ 1,980K Cost Share: $ 600K
• Implementation Cost: Est. $5M E-2C Program Production Non-recurring Cost
• Systems Impacted: E-2C Hawkeye
• Implementation: This Project Is Part Of The E-2C (PMA231) Technology Insertion
Plan To Enhance The Overall Airborne Early Warning Capability For Advanced
Hawkeye Program.

Status: Benefit Analysis/ROI

• Project Started 20 May 2003; Kickoff Meeting 04 June 2003
Project Tasks:
• Task 1: Embedded Antenna Type Downselect
• Task 2: Manufacturing Development
• Task 3: Subcomponent Fabrication
• Task 4: Demonstrate Repairability, Electrical Performance
• Task 5: Fabricate 2 Full-Scale Articles
• Task 6: Validate Cost/Weight Benefits
• Benefit Analysis Assumptions
– Number of Vehicles = 223 (Includes Spares & Retrofits)
– Acquisition Cost Savings of $50K per Aircraft
– Value of Weight Savings = $300 per Pound x 20 lbs/Unit = $6K
– Recurring Cost Savings of $20K per Year (Maintenance Labor Savings and
Reduced Fuel Consumption)
– 10 Year Service Life
– $5,000K E-2C Program Non-Recurring Cost
• Benefit Analysis Results: Total Cost Savings of $57,100K
• ROI =$57,100K/($2,580K + $5,000K) = 7.53
 Affordable Integrated
Structural Apertures

Embedded Antenna Secondary Embodiment:

Advanced Hawkeye Embedded IFF Elements

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Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
 Affordable Integrated
Structural Apertures

1/5 Scale Advanced

Hawkeye Rotodome
Mockup

Radar Elements

Graphite/Epoxy Skin

Fiberglas Skin

This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing
Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
 PROJECT OBJECTIVE

Address the need for a more

affordable, carrier-capable
airframe leading to an
alternate, low risk, more
affordable J-UCAS airframe
product.

J-UCAS CONCEPT EXPLORATION

REQUIREMENT
Current airframe designs and
manufacturing capabilities must
be improved in order to meet J-
UCAS affordability goals.

PROJECT PERFORMERS
Boeing Company
Northrop Grumman
 CAI Phase III – J-UCAS
Concept Exploration
• Performing Activity: The Boeing Company
Northrop Grumman Corporation
Start/End Dates: 11/02 – 12/03
• Primary Benefit: Improved airframe design and manufacturing
capabilities to meet UCAV-N affordability goals
• Objective: Competing contractor teams compete to identify promising
design concepts, manufacturing and assembly approaches
• Project Cost: $635,170 (Combined Northrop and Boeing Project Cost
Including Cost Share)
• Systems Impacted: A new family of unmanned aerial vehicles
• Implementation: Technologies developed and partially demonstrated
on the MANTECH project will be further validated, qualified, and certified
during execution of the J-UCAS SDD program

Problem: Project Tasks:

The U.S. Navy plans to develop and field a new family of unmanned
aerial vehicles to fulfill a variety of mission needs including long
range surveillance, communications node, and deep precision strike.
While considerable attention is being given to technologies such as
integrated avionics, communication capabilities, and sensor suites,
very little is being done to address the need for a more affordable,
carrier-capable airframe. Current airframe designs and
manufacturing capabilities such as those employed on the F/A-18
E/F and JSF must be improved in order to meet J-UCAS
affordability goal
• Documentation of J-UCAS product requirements (this defines the
engineering requirements for J-UCAS products)
• Documentation of J-UCAS baseline (this defines the cost and weight
metric to which progress will be measured and compared
• Identification of alternate design, manufacturing and assembly concepts of
the airframe
• Development of maturation plans for candidate technologies required in
order to realize the alternate concepts
• Documentation of detailed plans for further development and demonstration
of the most promising candidates (this will be the Project Planning
Document for the follow-on SDMD effort)
 J-UCAS CONCEPT
EXPLORATION

J-UCAS Concept Exploration

• Task Order Issued to Boeing on 02 January 2003
- Kickoff Meeting Held 09 January 2003 at NAVAIR, Pax River
- Customer Outbrief Held 21 May at Boeing, St. Louis
- Final Report Submitted 30 June 2003
• Task Order Issued to NG on 4 April 2003
• Kickoff Meeting Held 14 May 2003 at NAVAIR, Pax River
• CE Phase Completion Date 15 December 2003
J-UCAS Systems Design and Manufacturing Development
• Project Planning Meeting Held 24 June, 2003 at NAVAIR, Pax
River
• CMTC Evaluating Boeing Proposal
• Mid- to Late-Q1 GFY04 Project Start Anticipated

This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing
Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
 PROJECT OBJECTIVE
Develop and implement producible
and cost effective steel-to-
composite adhesive joining
technology meeting requirements
of the USS Zumwalt Class Land
Attack Destroyer

LARGE MARINE COMPOSITES-TO-STEEL JOINTS

PROJECT TEAM
• SCRA CMTC
– Boeing Company
– ARL Penn State
• NJC
Bolted Joint Used in
DD21 Bonded – Bath Iron Works
Composite Topside
Joint Concept
Demonstration Program – Northrop Grumman Ship Systems
 LARGE MARINE COMPOSITES-to-
STEEL JOINTS

• The composite deckhouse is a key component in the DD(X) design and

requires a composite to steel connection.
• Current composite-to-steel joints are accomplished by mechanical
fasteners. This attachment scheme has inherent performance and cost
deficiencies.
• Bonded joint identified in DD-21 Phase I by both Blue and Gold Teams as
needed technology to enhance design performance.
• A MANTECH project was proposed and approved by the LIPT to develop
an adhesive bonded joint for composite to steel material combinations.

This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing
Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
 LARGE MARINE COMPOSITES-to-
STEEL JOINTS

• Phase I: Assessment and Review of Composite-to-Steel Adhesive

Joints (Complete)
• Phase II: Joint Development (Complete)
• Phase III: Joining Process Validation/Qualification
• Phase IV: Adhesive Technology Implementation at Shipyards
E-Glass fabric/Vinyl
Ester facesheets

Machine
surface to fit

Key Project Development Activities Outer

moldline
tool
Balsa
Core
steel scarf
joint

• Design and Functional Requirements Tool

surface

• Material characterization Machine or grind surface

to mate steel joint

• Joint design and analysis Composite

Part

• Manufacturing/ Process Development

• Nondestructive Inspection Development Weld from Weld from

•
this side this side
Repair Development Paste
adhesive

• Technology Transfer/ Implementation

Steel “H” Steel deck
section stiffeners

This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing
Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
 PROJECT OBJECTIVE
Meet advanced critical weight
and performance requirements
by developing processes to
manufacture and validate
integrated and bonded
airframe primary structures

CAI: INTEGRATED AND BONDED STRUCTURES VALIDATION

PROJECT TEAM
Boeing-St. Louis
Boeing-Seattle
Lockheed Martin
Bell-Textron
Northrop Grumman
 PROJECT OBJECTIVE
Develop manufacturing/assembly
procedures for composite DDX
modules that satisfy structural and
electronic performance
requirements using a resin system
that meets fire, smoke and toxicity
requirements of MIL-STD 2031SH

MODULAR OUTFITTING TECHNOLOGY

PROJECT TEAM
Northrop Grumman Ship
Systems
Bath Iron Works
NSWCCD
Others?
Project Funding
MANTECH: $2.715M
Cost Share: $3.614M
 Modular Outfitting Technology
Status: Anticipated Project Start Q4 GFY03
Problem Statement
Existing outfitting techniques involve installation of shipboard
electronic systems and habitability items individually during the
ship assembly process. This method is labor intensive, risks
damage to the equipment, and frequently requires multiple
assembly, testing, and disassembly of items (both at vendor and
then upon ship installation).
Solution:
The Box-in-a-Box concept is a revolutionary new approach to
ship construction, in which components could be installed and
tested in a standardized module at the vendor, and then
transported to the shipyard and installed as a complete unit.
• Project Number: S1048
• Performing Activity: Northrop Grumman Ship Systems; Bath Iron Works
• Start/End Dates: September 2003 – August 2004
• Primary Benefit:
• Objective: Develop a VARTM Process That Achieves Structural And Electronic
Performance Requirements Using A Resin System That Satisfies Fire, Smoke And
Toxicity (FST) Requirements of MIL-STD 2031SH
• MANTECH Cost: $ 2,715K Industry Investment: $ 3,614K
• Implementation Cost: The Manufacturing Technology Developed Is Not Expected
to Require New Facilities.
• Systems Impacted: DDX and Future Surface Combatants
• Implementation: As This Approach Is Baseline For The DDX Design, The Box-in-
a-box Modules Will Be Installed On The DDX Lead Ship.
Benefits:
• Benefits the Navy and industry. Like modules are less costly than
complex, unique modules used today;
• Streamlined supply chain - eliminates non-value added steps of repeated
assembly/test/disassembly;
• “Plug and Play” technology reduces man-hours required for technology
upgrades and retrofitting;
• System Integrator participation in the outfitting, and testing of electronic
combat system spaces;
• Reduced weight composite modules improve ship KG.
 MODULAR OUTFITTING
TECHNOLOGY

Modular Outfitting Technology

• Surface Strike Affordability Initiative Funding
• 15 Month Duration Project Will be Conducted in Two Phases
– Phase 1: Module Design (Cost Share) and
Manufacturing Process Trials
– Phase 2 Go/No Go Decision
– Phase 2: Optimization of Down-Selected
Manufacturing Process and Testing (MANTECH and
Cost Share)
• Deliverables: Two Composite Modules
– Enclosure #1 For Equipment Installation And Ship
Integration Validation.
– Enclosure #2 For Qualification Testing And
Destructive Testing.

This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing
Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
 PROJECT OBJECTIVE
Develop fabrication processes for
large scale, multifunctional
composite panels that incorporate
fire resistant materials and
ceramic armor solutions for
applications such as the
integrated MFR radar house/mast
and deck edge elevator doors.
CVN 21 WEIGHT REDUCTION

PROJECT TEAM
Northrop Grumman Newport News
Northrop Grumman Ship Systems
ARL Penn State
General Dynamics Land Systems

Project Funding
MANTECH: $900K
Cost Share: TBD
 CVN 21 WEIGHT REDUCTION

CVN 21 Composites Applications for Weight Reduction

• Project Submitted by PEO Aircraft Carriers
• Project Duration 12 Months
• Tasks:
– Task 1: Design for Manufacturability
– Task 2: Process Development
– Task 3: Scaled-Fabrication Process Demonstration
– Task 4: Process Optimization
– Task 5: Full-scale Hybrid Panel Fabrication
• Implementation on CVN 21 and Possibly Backfit on
Nimitz Class During RCOH

This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing
Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
 PROJECT OBJECTIVE
Develop and refine integrated
bleeding manufacturing
technology for the in-situ
fabrication of thick, doubly
curved submarine cover
plates.

SUBMARINE COVER PLATES

PROJECT TEAM
NG/Newport News
GD/ Electric Boat
Virginia Tech

ROI = 13:1
 Composites Manufacturing Technology
for Low Cost Submarine Cover Plates
• Project Number: S1023
• Performing Activity: General Dynamics Electric Boat; Northrop Grumman
Newport News; Virginia Tech
• Start/End Dates: 08/02 – 10/03
• Primary Benefit: Reduced Acquisition Cost for Submarine Cover Plates and
Positive Impact on Shipyard Schedule.
• Objective: Develop and Refine Integrated Bleeding Manufacturing Technology for
the In Situ Fabrication of Thick, Doubly Curved Submarine Cover Plates.
• MANTECH Cost: $ 324K Cost Share: $ 49.4K
• Implementation Cost: The Manufacturing Technology Developed Is Not Expected
to Require New Facilities.
• Systems Impacted: Virginia Class Submarines With Backfitting Potential to Los
Angeles, Ohio and Seawolf Class Submarines
• Implementation: On the SSN774, First Ship of the VIRGINA Class. Implemented
As a Modification to the Existing Drawings, Material Specifications, and QC
Inspection Plans. NAVSEA PMS450 to Fund Qualification Testing.

Status: Benefit Analysis/ROI

• Project Initiated 03 October 2002 • Benefit Analysis Assumptions
• Number of Submarines: 10
Project Tasks:
• Number of Large/Small Cover Plates: 5/15
• Task 1 - Preliminary Material Evaluation (Cost Share Task)
• Cost Savings for Large/Small Cover Plates: $49,500/$12,500
• Task 2 - Manufacturing Process and Design Development
• Benefit Analysis Results: $4 ,250K Cost Savings
• Task 3 - Fabricate Manufacturing Prototype
• ROI = 10 x ((5 x $49,500) + (15 x $12,500))/ $324,000 = 13.1
• Task 4 - Manufacturing Evaluation of Prototype
• Task 5 - Limited Material Validation Testing (Cost Share Task)
• Task 6 - Qualification Testing (NAVSEA PMS450)
 SUBMARINE COVER PLATES

Submarine Cover Plates

• Cytec WR 24/754, a Single Sided Prepreg, Down-Selected and
Material Characterization Completed.
• GDEB Completed Finite Element Analysis Confirming that
Mechanical Properties Obtained from the Integrated Bleeding
Process Will Meet Design Requirements.
• NGNN Fabricated a Male Mold from a Dihedral Pod Splash

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Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
 SUBMARINE COVER PLATES

Submarine Cover Plates

• NGNN Fabricated 2 of 3
Prototype Manufacturing
Demonstration Articles.
• Virginia Tech Modified Their
3DINFIL Process Simulation
Software to Reflect
Integrated Bleeding
Fabrication Processing
Parameters.
• Optimized Processing
Parameters Developed from
the Simulation Model Will Be
Used During Manufacture of
the Third Prototype.

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Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
 Composites Manufacturing
Technology Center
Future Applications

This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing
Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
 CURRENT COMPOSITES
IMPLEMENTATION

• Examples of Wet Navy Composites

Implementation
– Topside Structure
– Ventilation Ducts
– LPD-17

This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing
Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
 CURRENT COMPOSITES
IMPLEMENTATION

• Examples of Wet Navy Composites

Implementation
– AEMS Mast
– Mine Hunter Rudder
– Joint Modular Lighter System
– Composite Sail

This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing
Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
 SHIPBOARD APPLICATIONS

• Issues Related to the Application of Shipboard

Composites Technology
– Fire, Smoke, Toxicity (FST)
– EMI/Lightning Strike
– High Temperature Requirement
Key Issues

– Initial Costs
– Repair Technology
– Joining
• Composites to Composites
• Composites to Steel
– Ability to Inspect

This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing
Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
 SHIPBOARD APPLICATIONS

This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing
Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
 COMPOSITES IMPLEMENTATION
OPPORTUNITIES

• Composites Implementation Opportunities

– Near Term (1-2 Years)
• Composite Drains & Gratings
• Composite Pumps
• Composite Piping
• Composite Storage Tanks (Water, Fuel, Oil)
• Composite Ducts and Fans
• Composite Doors & Hatches
• Composite Galley Deck & Catwalk

from: CMTC Composites Technology Roadmap

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Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
 COMPOSITES IMPLEMENTATION
OPPORTUNITIES

• Composites Implementation Opportunities

– Intermediate Term (2-5 Years)
• Propulsion Components
– Rudders
– Shafts
– Propellers
• Radar Fences
• Bulkheads
• Blast Deflectors
– Long Term (5-8 Years)
• CVNX Carrier Island
• Virginia Class Advanced Sail
• DDX Topside from: CMTC Composites Technology Roadmap

This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing
Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
 FUTURE COMPOSITES
APPLICATIONS

New USN Interest in High Speed

• High Speed Craft Innovative Hull Forms
• High Speed Ships Lightweight Materials
• Composites
Surface Combatants • Aluminum
Amphibious Lightweight/High
Logistic Output Propulsion
Units
Range of Speed
High Speed Transit (40 to 50 knots)
Amphibious
Logistics
High/Low Speed Operations (10 to 50 knots)

This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing
Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
 FUTURE COMPOSITES
APPLICATIONS

AIRCRAFT TECHNOLOGY

Concept: Use of Aircraft Technology

on Small Fast Surface Combatants
- Weapons Against Small Boats
- Communications
- EW Systems
- Radars

This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing
Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
 FUTURE COMPOSITES
APPLICATIONS

MODULAR MANNED AND UNMANNED SHIPS

MANNED

UN-MANNED

UN-MANNED
 FUTURE COMPOSITES
APPLICATIONS

HYBRID HULL FORMS

Mission Station A
(57mm Gun)

Mission Station E Mission Station B

16 Cell VLS Option
(Mission Station D) Mission Station C
Mission Station D

CATAMARANS

Mission Station D (P/S) Mission Station B (P/S)

Mission Station C Mission Station A
(57mm Gun)

Aviation/UAV Payload
RAM Launcher 57mm Gun

Mission Station D (P/S)

Mission Station B (P/S) 16 Cell VLS
Aft Payload Midships Payload (Stbd & Port) Fwd Payload
Payload Option

SURFACE EFFECT SHIPS (SES)

Mission Station A SMALL FAST SURFACE COMBATANT HULL FORMS

Mission Station C
 FUTURE COMPOSITES
APPLICATIONS

ANTENNA CONFIGURATIONS

EHF/GBS - Receive/Transmit VHF Dipole Antennas

Ku Band - Receive/Transmit GPS Antenna

ESM Antennas Radar/JTIDS/HF Receive/UHF LOS Antennas

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Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
 CONCLUSIONS

– Composites Gaining Recognition as Necessary Technology

to Meet Mission Requirements on New Navy Platforms
– Historical Resistance to Implementation of Composites on
Navy Platforms is Being Replaced With Composites
Specified as Baseline in New Designs
– Advanced Manufacturing Methods Allowing Composites to
Approach Cost Equivalency to Conventional Metal
Structures
– Additional Work On-going Addressing Materials and
Design Issues Related to:
• FST
• Repair
• Inspection

This document contains material which is proprietary to the South Carolina Research Authority (SCRA) and the Composite Manufacturing
Technology Center (CMTC). No reproduction or disclosure of this material is permitted without the express written consent of SCRA CMTC.
Contact Information:
Gary W. Schuerfeld
Composites Manufacturing Technology Center
934D Old Clemson Highway
Seneca, SC 29672
(864) 653-7590 x20
schuerfeld@scra.org

Questions…
http://cmtc.scra.org Discussion…