advanced manufacturing: navy/dod...
TRANSCRIPT
Advanced Manufacturing: Navy/DOD Perspective
Khershed P. Cooper, PhD Program Officer, ONR Manufacturing Science
Faculty Development Needs for Advanced Manufacturing in the USA National Science Foundation, Arlington, VA, January 9th and 10th, 2014
Outline
§ Advanced Manufacturing
§ ONR—Manufacturing Science Program
§ Industry/DOD Perspec@ve § Summary
2
Advanced Manufacturing
§ Applica@on of innova@ve technologies to accelerate product development, customize products, increase produc3on efficiency, increase produc3vity, reduce cost
§ Rapid transfer of science and technology into manufacturing processes and products—PCAST, April 2010
§ Products—Technologically complex, high level of design, beGer/new/exci@ng, reliable and affordable, solve societal problems
§ Process Technologies—CAD/CAM/CAE, M&S, Precision, IT, Robo@cs, Intelligent Systems, Automa@on, Monitor and Control Systems, New Produc@on PlaMorms, Sustainable and Green Manufacturing, Mass Customiza@on, Mass Produc@on
§ Broader Impacts—Educa@on, Economy, Society
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Why Advanced Manufacturing?
§ US innova@on is focused on the front-‐end: R&D, it must also focus on the back-‐end: test-‐beds, demonstra@ons and ini@al produc@on phases § “Innovate Here, Produce There”
§ Manufacturing innova@on needs to be looked at from early-‐stage research through produc@on
§ Moving from research à prototype à product requires … § Solving engineering design problems
§ Overcoming produc@on and component cost problems
§ Building produc@on processes
§ Crea@ng an efficient produc@on system
§ Developing and applying new produc@on and product business models
§ Building a supply chain
§ Financing scale-‐up and scaling up produc@on to adapt to evolving market condi@ons
§ Educa3ng a workforce
4 Challenge is to close this gap
Meeting the Challenge
Develop close connec@on between research, design and produc@on phases § Produc@on phase provides constant feedback to research and design phases
§ Produc@on innova@on is most efficient when 3ed to close understanding of manufacturing processes
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Cul@vate new manufacturing “paradigms” to transform produc@on § Network-‐Centric Produc@on—embed IT advances throughout manufacturing value
chain
§ Advanced Materials—MGI, bio-‐manufacturing, light-‐weigh@ng, …
§ Mass Customiza3on—addi3ve manufacturing / 3D prin3ng
§ Nanomanufacturing—embed nano-‐features to enhance product performance
§ Efficiency—distribu@on, energy
Agency Perspective
Navy/DOD § Mission oriented § Enhance warfighter performance, augment plaMorm capabili@es § Shorten produc@on @me, reduce produc@on cost
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MRL 1 MRL 2 MRL 3 MRL 4 MRL 5 MRL 6 MRL 7 MRL 8 MRL 9
Applied Research
Basic Research
Advanced Technology Development
Component Development/Prototypes
TransiIon/MaturaIon
University SBIR/STTR ManTech
ONR Manufacturing Science Program
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Navy S&T Focus Areas § Power and Energy § Opera@onal Environments § Mari@me Domain Awareness § Asymmetric and Irregular Warfare § Informa@on Superiority and
Communica@on § Power Projec@on § Assure Access and Hold at Risk § Distributed Opera@ons § Naval Warfighter Performance § Survivability and Self-‐defense § PlaMorm Mobility § Fleet/Force Sustainment § Total Ownership Cost
Research Programs § Personal Power § Environmental Sensing § Network Sensing § Func@onal Materials § Image Analysis § Communica@ons and Networks § Intelligent and Autonomous
Systems § Informa@on Processing § Manufacturing Science
Near Mid Far
Focus
Broa
d Narrow Quick
ReacIon S&T
Discovery & InvenIon (Basic and Applied Science)
S&T
AcquisiIon Enablers (FNCs)
Leap Ahead InnovaIons (INPs)
45%
12%
30%
8%
Time Frame
ONR Investment PorMolio
S&T has long-term focus but is responsive to near-term Naval needs
ONR Manufacturing Science Program
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Vision § Fundamental principles for design, control and manipula@on of physical processes
at appropriate length scales to produce components with specified proper3es that form part of a useful engineered system
h f
Physical Model (dynamics) Measurement Model Observa@on
Vector
+ + + +
Z-1
Control Vector
Process Noise Vector Measurement Noise Vector
vk xk
uk
Xk+1
yk+1
nk+1
Cyber-‐enabled Manufacturing Systems
System-‐level IntegraIon
Research Thrust Areas
Direct Digital Manufacturing
(AddiIve)
Nanomanufacturing
Novel manufacturing approaches to … § Create new products to augment warfighter capability § Improve product quality and performance § Achieve design and produc@on flexibility § Shorten produc@on @me, reduce produc@on cost
Basic Research § Core, MURI, YIP,
DURIP
High Risk—High Payoff—Long Term
Applied Research § STTR/SBIR,
ManTech
Additive Manufacturing—Navy/DOD Benefits
Address Navy S&T focus area of Total Ownership Cost § PlaMorm affordability, life-‐cycle and sustainment costs § The price tags of Navy ships keep ascending as the number of vessels in the fleet
takes a dive -‐ “Navy’s Holy Grail: An ‘Affordable’ Ship,” Na3onal Defense Blog, Jan 2013
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The obvious … § Produce new and replacement parts on-‐demand as needed § Timely repair and refurbishment of worn and broken components
Adop@on is slow because of … § Cer@fica@on and accredita@on for cri@cal components § Valida@on and verifica@on of produc@on processes
Address Navy challenges … § Aging Systems—reverse engineering § Sea Basing—remote produc3on § Storage and Stockpiling—parts on-‐demand
Basic Research—Additive Manufacturing
10 Control of melt-pool and solidification
Basic Science § Transport
phenomena models
§ Process dynamics (disturbance) models
§ Closed-‐loop process control
§ Achieving precision and reliability
Direct Metal Dep. Sensing and Control
- 0 .5
- 0.4
- 0.3
- 0.2
- 0.1
0
Z(mm)
00 .5 1
1.52 2.5
3
X (mm)0.5
1
Y(mm)
1400
2000
1600
17761800.4
YX
Z
TEMP: 1600 1776 1800.4 2000
1 m/s
3D Model
Turbine Blade Cellular Structure
Basic Science § Controlled
direc@onal solidifica@on
§ Process maps for epitaxial growth
§ Achieve texture Scanning Laser Epitaxy
Previously fabricated layers
Remelted substrate
Laser beam
Melt pool Epitaxial grains
Powder layer
Motion
Microstructure Growth Melt Pool
Previously Fabricated Layers
Laser Beam Motion Powder Bed Remelted Layer
Single crystal turbine blade restoration
Applied Research—Additive Manufacturing
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Ship Model
STTR/SBIR Projects § Physical Scale Models for Signature Reduc@on and
for Stress and EM Environments
Capability § Direct manufacturing instead of hand assembly
from full scale ship and submarine models Submarine Model
3D PrinIng
ManTech Projects § 3D Prin@ng for Manufacturing; Agile Manufacturing Center for Cas@ng Technology; Mobile
Manufacturing and Repair Cell; Air Systems Maintenance and Air-‐worthiness
Capability § New, spare and replacement metallic parts on-‐demand; Small-‐lot size produc@on of high-‐value
metal cas@ngs; Repair and restora@on of high-‐value Naval components
Repair and Refurbish Rapid Cast
Reduce time, reduce cost, mission readiness
To make AM acceptable, we need advances in …
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Design § Alloys designed for addi@ve fabrica@on § Design tools for structure and component § Reverse engineering
Post-‐processing § Post fabrica@on processes to enhance
mechanical proper@es § Finishing to reduce surface roughness
Process § Computa@onally guided processes and
closed loop control § Integra@on of sensors and instrumenta@on
for real-‐@me process monitoring, NDE and control
§ Accurate, predic@ve process models for microstructure and proper@es
§ Hybrid processes, integra@on of processes
Technology § Accelerated qualifica@on and cer@fica@on
methods
AM Material § Fa@gue and other mechanical proper@es
comparable to wrought materials § Property database § Func@onally graded, locally controlled
features
Machine § Part-‐to-‐part and machine-‐to-‐machine
variability and repeatability
Areas of focus for research and education
Cyber-enabled Manufacturing Systems (CeMS)
Goal: Integrate compu@ng and communica@on capabili@es with monitoring and control in manufacturing -‐ dependably, efficiently and in real-‐3me
13 Physics-based models, sense, compute, control
AGributes of CeMS § Cyber-‐physical system methodology for co-‐design of control and computa3on systems § Customized computa3on architecture for real-‐3me control § Generalized template to incorporate measurements, models and uncertainty into control
Process and Measurement Model (Welding)
h f
Physical Model (dynamics) Measurement
Model Observation
Vector
+ +
+ + kx
1+kxku
kv1+kn
Control Vector
Process Noise
Vector Measurement Noise Vector
1+ky
Tf kkkkk !++=+ ),(1 vuxxxSample Period State Vector at Step n
State Vector at Step n+1 Due to significant process and measurement noise, the state vector needs to be estimated
Z-1
Ra@onale: New processes, product quality and performance, produc@on reliability and flexibility
Address Challenges § Dimensional Tolerance § Surface Finish § Composi@on § Microstructure § Thermal Gradient § Porosity, Cracking § Residual Stress
Universal or ‘Dream’ Machine
Make … § any object, with any geometry, any place, any @me § with any material and material sets § with suitable energy source or sources § in lot size of one or small lots, affordably § reliably, consistently, dependably
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Slogans § “Print me a _____” § “If you can draw it, you can build it” § “Cer3fy-‐as-‐you-‐build”
Vascular Structures
GRIN Lens Metamaterials
AuxeIc Materials
Internal Complexity
Geometric Shapes
AM presents unique design and manufacturing capabilities
Nanotechnology: Impact on Navy/DOD
Applica@ons § Sensors: CBRNE § Metamaterials: Antennae for Communica@on, EM & Acous@c Cloaking, Radar § Devices: Electronics, Electromagne@cs, Plasmonics, Terahertz Devices § Mul@-‐func@onal Systems
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Requirements § Reduced Size, Lightweight, Conformal, Robust, Reliable
PlaMorms § Aircrap, UXS, Ships, Submarines, Vehicles, Soldiers
ONR Basic Research in Nanomanufacturing
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3D Nanomanufacturing § Layer-‐by-‐layer / stereolithography § Serial or parallel processing § Op3cal enhancement / super focusing § 3D nanostructures, nanopaGerns
NanopaGerning § Nanoimprin3ng—mechanical, electrochemical § Op3cal Nanolithography—electrical field enhancement § Template Stripping—deposit and peel § Step and repeat / Large area processing § Wafer-‐scale / Roll-‐to-‐roll § 2D-‐2.5D nanostructures, nanoarrays
Varying Porosity Woodpile (Serial)
S. Che
n, UC-‐San Diego
FuncIonal Structures (Parallel)
S. Das, G
eorgia Tech
Fractal Antenna (S4 nanoimprinIng)
N. Fang, M
IT
X. Xu, Purdu
e
Hole Array (OpIcal Nanolithography)
S-‐H. Oh, M
inne
sota
Bull’s Eye GraIng (Template Stripping)
ONR Basic Research in Nanomanufacturing
17
High-‐rate Nanomanufacturing § Nanoprin3ng, Nanoimprin3ng, Nanocoa3ng
§ Con@nuous, web-‐based, roll-‐to-‐roll § Func@onal and mul@-‐func@onal systems § Membrane electrode assembly § Directed assembly of func3onal materials § System-‐on-‐film
Roll-‐to-‐Roll
Wireless Conformal BMI
Digital signal processing
Memory
Electrode
Amp ADC
Large area MxN sensor array
Battery
CPU and wireless
transmitter (silicon chip)
Power management
+
-
Flexible electronics (this work)
Silicon electronics (conventional)
control
Existing EEG system Proposed EEG system
Electrode sheetFlexible electronics
...... ...
Circuit, Device Layout
D Frisb
ie, U
Minn
Assembly Using MagneIc Fields
Hybrid Photovoltaics
C. Osuji, Yale
Industry/DOD Perspective
§ Harvest and foster most appropriate technologies available to meet current and future needs of customer (e.g., DOD) § Not newest, not most interes3ng, … most appropriate § Technology inser3on needs to be compelling
§ View advanced manufacturing as enabling technology to solve problems (e.g., parts-‐on-‐demand, de-‐icing)
§ Need R&D to overcoming barriers to tech transfer and commercializa@on
§ Need a viable manufacturing base
18 How can universities contribute?
Summary
Advanced Manufacturing § Use innova3ve technologies for rapid product realiza3on, customiza3on,
produc3vity, affordability § Challenge: Transi@oning from research to prototype to market
19 Plenty of Opportunities for Research and Education
ONR Manufacturing Science Program § Addi@ve Manufacturing—Disrup@ve Technology § New way of designing and making things § Challenges: Develop reliable systems, explore novel structures
Industry/DOD Perspec@ve § Technology inser@on needs to be compelling § Overcome tech transfer and commercializa3on barriers