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Agile Manufacturing Research & Development-ARL AM Update-

Rob Carter, Ph.D.

Chief, Materials Manufacturing Technology Branch

410-306-0864,

robert.h.carter32.civ@mail.mil

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The Right Part

The Right Place

The Right Time

By-Design

The Right Part

The Right Place

Material

The Right TimeProcess

On-Demand By- Design Model

ARL AM Vision

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Near Term

•Optimized Materials

•Process Modeling

Mid Term

•Novel Feedstock

•Optimized Processing

Technologies

• In-Situ Characterization

Far Term

• Indigenous Mat’ls

•Responsive Mat’ls

•Process Control

Feedback Loop

• Intrinsically Certified &

Qualified Parts

•Predictive Property

Modeling

Near Term

•CONUS Based

•Depots/Arsenals

Mid Term

•Agile, Expeditionary

Manufacturing

Facilities

•Transition to

Traditional

Manufacturing

Facilities

Far Term

•CONUS & OCONUS

•Battlefield Capable

to Reduce Logistics

Burden

Near Term

•Topology Optimization

•Design Optimization

for Material, Size,

Weight and Properties

Mid Term

•Hybrid / Graded

Materials and Process

•Structural & Fracture

Critical Components

•Business Case / Cost

Modeling/ Optimization

Far Term

•Manufacturing Parts

Organic to the Soldier

or Platform

ARL AM Vision-Execution

The Right Part

The Right Place

The Right Time

By-Design

Near Term

•Digital Repository for

Need Base Parts

Mid Term

•Repairable Design

• Informatics based need

•Warfighter Training

•Manufacturing On-

Demand, On-Site, and

As-Needed

Far Term

•Autonomous, Agonistic

Manufacturing Systems

•Predictive failure

modeling

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TRL 9

TRL 8

TRL 7

TRL 6

TRL 5

TRL 4

TRL 3

TRL 2

TRL 1

POWDER SYNTHESIS MODELING & SIMULATION

PRODUCTION SCALE-UP

CONSOLIDATIONCHARACTERIZATION & TESTING

Multi-Particle InteractionNano and High Strength Al

UH-60 Sump Repair

DMS&T &

Army

Mantech

AMRDEC

NAVAIR

AFRL

TIPS

DLA

TMR

SBIR

ARL CII

ONR

Industry

AF RIF MEO T7631

Reactive Materials Shaped Charge Liners

Flexible Robot Environment

Powder 10,000lbs/month

0

20

40

60

UTS,ksi

YS,ksi

%EL

annealed

T4-T451

T6-T651

cold sprayed

> UTS than Wrought

Near Term - Cold Spray Research

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Mid Term - ARL AM EFFORTS

Manufacturing

APPLICATIONSHigh Performance

Structural Components

MATERIALS AND MANUFACTURING

SCIENCEAM Research

Characterization Modeling and Simulation

Post-Processing (HT, HIP, Machining, Surface Finish)

FeedstockIn-situ

Sensing andControl

Laser

Benchmarking

• Topology Optimization• CAD• Physics based Support

Structures

• FEA• Microstructure

based Prediction of Mechanical Properties

Process Models• Micro Scale (Powder/Meltpool)

• Solidification, Thermodynamics, Phase Field, Microstructure Prediction and Evolution

• Continuum• Process Modeling, Thermal

Histories, Residual Stresses, Distortion, Microstructure based Prediction of Mechanical Properties

3D Scanning and CAD Generation

Materials/Feedstock Development

Qualification and Certification

EXPEDIENT MANUFACTURING

In-theater Capabilities

Powder productionCryomilling and Atomization

Optimized Material designComputational Thermodynamics

NIST Test Artifact

AM Components• Mechanical Properties• Porosity/Defects,

Residual Stresses, Distortions/Geometry

Performance

Design Tools

Processing/Microstructure/Property Relations

Powder Bed

Powder/Wire Fed

Photocure

Novel Processes

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Scalable Lethality

Adaptive Protection

Identification of available resources

Quartermaster List/ Prepositioned stocks

Indigenous Sources

Solar

Battle Damage Scrapyards

Waste Streams

Expedient Counter

Measures

• Combination of chemical, biological, and mechanical processing

• Energy and materials scavenged from environment/processes

Smart Sensors

Far Term - Agile and Expeditionary:

Deployable and Threat Responsive

Power

Programmable

electronics

Water

Replacement & Repair

Fuel

Raw Materials to Final Product in New Factories

Use Manufacturing S&T to further ARL’s Mission – Discover, Innovate, and Transition

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How?

Transformation PrinciplesFlow, Agility, Quality, Efficiency & Effectiveness

Create flexibility and

agility to make

workforce changes to

keep pace with rapidly

evolving technologies

and national security

requirements

Onsite collaboration

with academia and

industry through

layered security

process; ARL as

anchor within

community

Enable greater sharing

of specialized facilities

between agencies,

private sector partners,

and experiment with

new models for

modernizing labs

Implement strategies

and policies that

support exploitation of

science and transition

to small business and

entrepreneurs

ATTRACT AND RETAIN

BEST & BRIGHTEST

OPEN

CAMPUSES

SHARED MODERN

FACILITIES

INNOVATION

PRACTICES

Piloting a New Laboratory Business Model

Responding to the National Security Challenges of the 21st Century

7

Open Campus is to

augment ARL’s resources

through open

collaboration.

Research Centers will be

stood up in areas of

particular interest.

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OVERVIEW

The Center for Agile Materials Manufacturing

Science (CAMMS) will lead research focused on

discovery, innovation, and maturation of materials

and manufacturing science to permit agile,

adaptive, and mobile processing for a highly flexible

and expeditionary manufacturing capability to

quickly produce tailored parts and components.

PARTICIPANTS

Open to national and defense labs, universities, and

industry

CONCEPT OF OPERATION

The CAMMS is ARL’s Open Campus focal point for

government, industry, and academia to innovate

processing for manufacturing science.

COLLABORATIVE FOCUS

• Manufacturing and processing science

• Manufacturing process-to-microstructure modeling

• Development of novel expeditionary

manufacturing techniques, processes, and

technologies

• Process characterization-based performance

estimator using a probabilistic approach

• Rapid, in situ certification of additively

manufactured parts

POINT OF CONTACT

Robert Carter

Materials Manufacturing Technology Branch Chief

Weapons and Materials Research Directorate

410-306-0864, robert.h.carter32.civ@mail.mil

Center for Agile Materials Manufacturing Science

BENEFITS

• Access to ARL’s strong capability in physical and

mechanical metallurgy, physical ceramics,

materials processing, polymeric materials,

materials modeling, and manufacturing science

• New materials and feedstocks for high

performance parts

• Specifications and standards published for

materials and processes developed by the Center

• Access to pilot scale manufacturing facilities to

prove out processes for niche and military

applications

UNIQUE FACILITIES

• Additive Manufacturing Laboratory Suite

‒ Selective laser sintering

‒ Hybrid additive manufacturing system

‒ Cold spray systems

• Characterization and Computational Tools and

Nondestructive Evaluation (NDE) Capabilities

‒ X-ray Computed Tomography suite

‒ Scanning and transmission electron microscopy

• Specification and Standards OfficeCT with In-situ Mechanical Testing

Additive Manufacturing Laboratory Suite

MIL Specifications

and Standards