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October 16, 2018 | International, Naval

How the Office of Naval Research hopes to revolutionize manufacturing

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WASHINGTON — The Office of Naval Research awarded Lockheed Martin Oct. 1 a two-year, $5.8 million contract to explore how machine learning and artificial intelligence can make complex 3-D printing more reliable and save hours of tedious post-production inspections.

In today's factories, 3-D printing parts requires persistent monitoring by specialists to ensure intricate parts are produced without impurities and imperfections that can compromise the integrity of the part overall. To improve this laborious process, the Navy is tasking Lockheed Martin with developing multi-axis robots that use lasers to deposit material and oversee the printing of parts.

Lockheed Martin has multiple partners on the contract including Carnegie Mellon University, Iowa State University, Colorado School of Mines, America Makes, GKN and Wolf Robotics and Oak Ridge National Laboratory.

The contract covers what Glynn Adams, a senior engineer with Lockheed Martin, describes as the pre-flight model of the program's development. Initial work will focus on developing computer models that can predict the microstructures and mechanical properties of 3-D printed materials to generate simulation data to train with. Adams said the Carnegie Mellon team will look at variables such as, “the spot size of the laser beam, the rate of feed of the titanium wire [and]the total amount energy density input into the material while it is being manufactured.” This information helps the team predict the microstructure, or organizational structure of a material on a very small scale, that influences the physical properties of the additive manufactured part.

This data will then be shared with Iowa State, who will plug the information into a model that predicts the mechanical properties of the printed component. By taking temperature and spot size measurements, the team can also ensure they are, “accurately controlling energy density, the power of both the laser and the hot wire that goes into the process,” Adams said..

“All of that is happening before you actually try to do any kind of machine learning or artificial neural networks with the robot itself. That's just to try to train the models to the point where we have confidence in the models,” Adams said.

Sounds easy, right?

But one key problem could come in cleaning up the data and removing excess noise from the measurements.

“Thermal measurements are pretty easy and not data intensive, but when you start looking at optical measurements you can collect just an enormous amount of data that is difficult to manage,” Adams explained. Lockheed Martin wants to learn how shrink the size of that dataset without sacrificing key parameters. The Colorado School of Mines and America Makes will tackle the problem of compressing and manipulating this data to extract the key information needed to train the algorithms.

After this work has been completed, the algorithms then will be sent to Oak Ridge National Laboratory, where robots will begin producing 3-D titanium parts and learn how to reliably construct geometrically and structurally sound parts. This portion of the program will confront challenges from the additive manufacturing and AI components of the project.

On the additive manufacturing side, the team will work with new manufacturing process, “trying to understand exactly what the primary, secondary and tertiary interactions are between all those different process parameters,” Adams said. “If you think about it, as you are building the part depending on the geometric complexity, now those interactions change based on the path the robot has to take to manufacture that part. One of the biggest challenges is going to be to understand exactly which of those parameters are the primary, which are the tertiary and to what level of control we need to be able to manipulate or control those process parameters in order to generate the confidence in the parts that we want.”

At the same time, researchers also will tackle AI machine learning challenges. Like with other AI programs, it's crucial the algorithm is learning the right information, the right way. The models will give the algorithms a good starting point, but Adams said this will be an iterative process that depends on the algorithm's ability to self-correct. “At some point, there are some inaccuracies that could come into that model,” Adams explained. “So now, the system itself has to understand it may be getting into a regime that is not going to produce the mechanical properties or microstructures that you want, and be able to self-correct to make certain that instead of going into that regime it goes into a regime that produces the geometric part that you want.”

With a complete algorithm that can be trusted to produce structurally sound 3-D printed parts, time-consuming post-production inspections will become a thing of the past. Instead of nondestructive inspections and evaluations, if you “have enough control on the process, enough in situ measurements, enough models to show that that process and the robot performed exactly as you thought it would, and produced a part that you know what its capabilities are going to be, you can immediately deploy that part,” said Adams. “That's the end game, that's what we're trying to get to, is to build the quality into the part instead of inspecting it in afterwards."

Confidence in 3-D printed parts could have dramatic consequences for soldiers are across the services. As opposed to waiting for replacement parts, service members could readily search a database of components, find the part they need and have a replacement they can trust in hours rather than days or weeks. “When you can trust a robotic system to make a quality part, that opens the door to who can build usable parts and where you build them,” said Zach Loftus, Lockheed Martin Fellow for additive manufacturing. “Think about sustainment and how a maintainer can print a replacement part at sea, or a mechanic print a replacement part for a truck deep in the desert. This takes 3-D printing to the next, big step of deployment.”

https://www.c4isrnet.com/industry/2018/10/15/how-the-office-of-naval-research-hopes-to-revolutionize-manufacturing

On the same subject

  • Airbus threatens to leave Britain over Brexit trade relations

    June 26, 2018 | International, Aerospace

    Airbus threatens to leave Britain over Brexit trade relations

    By: Danica Kirka, The Associated Press LONDON — Aviation giant Airbus is threatening to leave Britain if the country exits the European Union without an agreement on trade relations, underscoring the concerns of business leaders who say the government is moving too slowly. Airbus, which employs about 14,000 people at 25 sites in the U.K., said it needs to know by the end of the summer what rules will govern its operations, or the company will “reconsider its long-term footprint in the country.” Airbus also says a proposed transition deal that runs through December 2020 is too short for the company to reorganize its supply chain. “While Airbus understands that the political process must go on, as a responsible business we require immediate details on the pragmatic steps that should be taken to operate competitively,” Tom Williams, CEO of Airbus Commercial Aircraft, said in a statement. “This is a dawning reality for Airbus. Put simply, a no-deal scenario directly threatens Airbus' future in the U.K.” While many business leaders have demanded clarity about the future with Britain set to leave the EU in nine months, Airbus' sheer size and role in the economy make it an influential voice in the Brexit debate. Airbus is the U.K.'s largest commercial aerospace company, a leading provider of military satellite communications and the biggest supplier of large aircraft to the Royal Air Force. It also has a significant impact on other companies, funneling an estimated £5 billion (U.S. $6.6 billion) to 4,000 U.K. suppliers, including big names like Rolls-Royce, as well as many smaller businesses. Darren Jones, the member of Parliament for the community where Airbus makes wings, attacked the government for listening to those who want the most hard-line form of Brexit and “not to the businesses that employ thousands of British workers, including Airbus.” “Thousands of skilled, well-paid jobs are now on the line because of the shambolic mess the government have created over the Brexit negotiations,” he said. Airbus, the biggest rival to U.S.-based aircraft-maker Boeing, has been a prime example of how European cooperation could lead to success in business. The German, French and Spanish governments own 26.4 percent of Airbus, which was created through the merger of German, French and Spanish aerospace companies. Prime Minister Theresa May's government reacted quickly to the Airbus statement, saying it was confident of getting a good deal and “we do not expect a no-deal scenario to arise.” But Williams said Airbus is frustrated after it tried to discuss its concerns with the government for 12 months and made little progress. “We've got to get clarity,” he said in an interview with the BBC. “We've got to be able to protect our employees, our customers and our shareholders, and we can't do that in the current situation.” The comments came as Airbus published an assessment of the risks Brexit poses to the company. The report shows that Airbus, like many modern companies, is particularly vulnerable to Brexit because of its international supply chain. Plants in several countries make specialized components, which are shipped back and forth across international borders as aircraft are assembled. Britain's membership in the EU makes this easy because goods move freely between the 28 member states, with no tariffs or other trade barriers. That will change after Brexit because Britain will not be a member of the EU's single market and customs union. While the U.K. government says it wants trade to be as frictionless as possible after Brexit, manufacturers are running out of time to plan for the future. Airbus said it is facing a variety of decisions, including whether to invest in future manufacturing capacity, the need to build up stocks of components in the event of border delays and how to ensure parts are certified by aircraft regulators in the future. Delays caused by a no-deal scenario could cost Airbus as much as €1 billion euros (U.S. $1.2 billion) of revenue a week, according to the risk assessment. “This scenario would force Airbus to reconsider its investments in the U.K., and its long-term footprint in the country, severely undermining U.K. efforts to keep a competitive and innovative aerospace industry, developing high-value jobs and competences,” Williams said. https://www.defensenews.com/industry/2018/06/22/airbus-threatens-to-leave-britain-over-brexit-trade-relations/

  • Contract Awards by US Department of Defense - Aug 1, 2019

    August 2, 2019 | International, Aerospace, Naval, Land, C4ISR, Security

    Contract Awards by US Department of Defense - Aug 1, 2019

    DEFENSE LOGISTICS AGENCY Tesoro Refining and Marketing Co., San Antonio, Texas (SPE602-19-D-0506, $348,692,953); BP Products North America Inc., Chicago, Illinois (SPE602-19-D-0514, $315,599,804); Par Hawaii Refining LLC, Houston, Texas (SPE602-19-D-0510, $271,274,321); Valero Marketing and Supply Co., San Antonio, Texas (SPE602-19-D-0504, $260,554,844); Equillon Enterprises LLC, doing business as Shell Oil Products, Houston, Texas (SPE602-19-D-0509, $228,126,037); BP West Coast Products LLC, Blaine, Washington (SPE602-19-D-0512, $157,502,370); U.S. Oil and Refining Co., Tacoma, Washington (SPE602-19-D-0513, $156,746,055); Petro Star Inc.,* Anchorage, Alaska (SPE600-19-D-0505, $110,836,555); Phillips 66 Co., Houston, Texas (SPE602-19-D-0515, $58,246,377); Epic Aviation LLC, Salem, Oregon (SPE602-19-D-0508, $38,905,276); and Sinclair Oil Corp.,* doing business as Sinclair, Salt Lake City, Utah, (SPE602-19-D-0507, $38,197,366), have each been awarded a fixed-price with economic-price-adjustment, indefinite-delivery/indefinite-quantity contract under solicitation SPE602-19-R-0703 for various types of fuel. These were competitive acquisitions with 21 offers received. They are one-year contracts with a 30-day carryover. Locations of performance are Texas, Illinois, Washington, Alaska, Oregon, Utah, and the Rocky Mountain Region of the continental U.S., with an Oct. 30, 2020, performance completion date. Using customer is Defense Logistics Agency Energy. Type of appropriation is fiscal 2019 defense working capital funds. The contracting activity is the Defense Logistics Agency Energy, Fort Belvoir, Virginia. Petro Star Inc.,* Anchorage, Alaska, has been awarded a maximum $52,630,968 fixed-price with economic-price-adjustment, indefinite-delivery/indefinite-quantity contract for JA1 jet fuel. This was a sole-source acquisition using justification 10 U.S. Code 2304 (c)(1), as stated in Federal Acquisition Regulation 6.302-1. This is a one-year contract with a 30-day carryover. Location of performance is Alaska, with an Oct. 30, 2020, performance completion date. Using customer is Air Force. Type of appropriation is fiscal 2019 defense working capital funds. The contracting activity is the Defense Logistics Agency Energy, Fort Belvoir, Virginia (SPE602-19-D-0517). Sysco Raleigh LLC, Selma, North Carolina, has been awarded a maximum $49,019,871 fixed-price with economic-price-adjustment, indefinite-quantity contract for full line food distribution. This was a sole-source acquisition using justification 10 U.S. Code 2304 (c)(1), as stated in Federal Acquisition Regulation 6.302-1. This is a 286-day contract with no option periods. Location of performance is North Carolina, with a May 16, 2020, performance completion date. Using customers are Army, Navy, Air Force, Marine Corps and federal civilian agencies. Type of appropriation is fiscal 2019 defense working capital funds. The contracting agency is the Defense Logistics Agency Troop Support, Philadelphia, Pennsylvania (SPE300-19-D-3230). Oshkosh Defense LLC, Oshkosh, Wisconsin, has been awarded a maximum $27,537,300 firm-fixed-price requirements contract for pneumatic tire wheel assemblies. This was a sole-source acquisition using justification 10 U.S. Code 2304 (c)(1), as stated in Federal Acquisition Regulation 6.302-1. This is a three-year contract with no option periods. Locations of performance are Wisconsin and New Jersey, with a July 29, 2022, performance completion date. Using military service is Army. Type of appropriation is fiscal 2019 through 2022 Army working capital funds. The contracting activity is the Defense Logistics Agency Land and Maritime, Warren, Michigan (SPRDL1-19-D-0130). (Awarded July 30, 2019) U.S. TRANSPORTATION COMMAND Crowley Logistics Inc., Jacksonville, Florida, has been awarded a contract modification, P00009, on contract HTC711-17-D-R003 in the estimated amount of $328,000,000. This modification provides continued surface transportation coordination services for the movement of freight within the continental U.S. and Canada under the Department of Defense Freight Transportation Services program to the Defense Logistics Agency and Defense Contract Management Agency. Work will be performed in the continental U.S. and in Canada. The period of performance is from Aug. 1, 2019, to July 31, 2020. Fiscal 2019 transportation working capital funds were obligated at award. This modification brings the total cumulative face value of the contract from $110,285,829 to $438,285,829. U.S. Transportation Command, Directorate of Acquisition, Scott Air Force Base, Illinois, is the contracting activity. AIR FORCE Raytheon Co., Woburn, Massachusetts, has been awarded a $36,250,251, firm-fixed-price contract modification (P00014) to previously awarded contract FA8730-17-C-0010 for the Qatar Early Warning Radar (QEWR). This modification is for procurement and storage of obsolescent spares in support of QEWR sustainment. The modification brings the total cumulative face value of the contract to $1,094,776,076. Work will be performed in Woburn, Massachusetts, and is expected to be completed by August 2023. This modification involves 100% foreign military sales to the country of Qatar. Foreign Military Sales funds in the amount of $36,250,251 are being obligated at the time of award. The Air Force Life Cycle Management Center, Hanscom Air Force Base, Massachusetts, is the contracting activity. Summers Concrete Contracting Inc., Hahira, Georgia, has been awarded a ceiling $25,000,000 indefinite-delivery/indefinite-quantity contract for repair airfield pavements. This contract provides for repair or alteration of airport runways and taxiways construction requirements. Work will be performed at Moody Air Force Base, Valdosta, Georgia; and Sebring, Florida, and is expected to be completed by July 31, 2024. This award is the result of a competitive acquisition with three offers received. No funds are being obligated at the time of award. The 23d Contracting Squadron, Moody Air Force Base, Georgia, is the contracting activity (FA4830-19-D-A001). Verdis-Takisaki JV, Coeur d'Alene, Idaho (FA4620-19-D-A007); National Native American Construction Inc., Coeur d'Alene, Idaho (FA4620-19-D-A010); Global-Northcon JV, Hayden, Idaho (FA4620-19-D-A011); and Imperial Construction NW LLC, Wapato, Washington (FA4620-19-D-A012), have been awarded a combined, not-to-exceed $23,000,000 indefinite-quantity multiple award task order contract for design-build construction efforts. Work will be performed at Fairchild Air Force Base, Washington, and is to be expected to be complete by July 31, 2024. These awards are the result of a competitive acquisition and eight offers were received. Fiscal 2019 operation and maintenance funds in the amount of $500 are being obligated to each company at the time of award. The 92d Contracting Squadron, Fairchild Air Force Base, Washington, is the contracting activity. L3 Technologies Inc., Link Training & Simulation Division, Arlington, Texas, has been awarded a $10,411,380 cost-plus-fixed-fee contract task order modification (P00011) to the previously awarded FA8621-19-6251 task order for F-16 aircraft simulator training program services. This contract modification will provide aircraft concurrency requirements for the M7.3 Operation Flight Plan to deliver medium and high-fidelity simulation capability to train pilots for the F-16 aircraft platform. The modification brings the total cumulative face value of the contract to $28,440,800. Work will be performed at Arlington, Texas, and is expected to be completed by March 31, 2021. Fiscal 2019 research and development funds in the amount of $800,000 are being obligated at the time of award. The Air Force Life Cycle Management Center, Wright-Patterson AFB, Ohio, is the contract activity. University of Dayton Research Institute, College Park, Dayton, Ohio, has been awarded a $9,800,000 cost-plus-fixed-fee, indefinite-delivery/indefinite-quantity contract. This contract provides enhancement and improvement to the non-destructive evaluation capabilities for aerospace structures and components. This contract promotes discovery and provides increased accuracy, precision, reliability and optimization of the material state awareness of aerospace materials. Work will be performed at Wright-Patterson Air Force Base, Ohio, and is expected to be completed by Aug. 3, 2026. This award is the result of a competitive acquisition and three offers were received. Fiscal 2019 research, development, test and evaluation funds in the amount of $304,000 will be obligated at the time of award via task order 0001. The Air Force Research Laboratory, Wright-Patterson Air Force Base, Ohio, is the contracting activity (FA8650-19-D-5230). ARMY Kinder Brothers Excavating Inc.,* Dexter, Missouri (W912EQ-19-D-0009); SYTE Corp.,* Chicago, Illinois (W912EQ-19-D-0007); Randy Kinder Excavating Inc.,* Dexter, Missouri (W912EQ-19-D-0008); and C&M Contractors Inc.,* Doniphan, Missouri (W912EQ-19-D-0006), will compete for each order of the $50,000,000 firm-fixed-price contract for all plant, labor, materials and equipment for construction of relief wells, repairs to existing relief wells and construction of earthen berms. Bids were solicited via the internet with four received. Work locations and funding will be determined with each order, with an estimated completion date of Aug. 20, 2024. U.S. Army Corps of Engineers, Memphis, Tennessee, is the contracting activity. Sehlke Consulting LLC,* Arlington, Virginia, was awarded a $9,999,500 order-dependent contract for financial management support services. Bids were solicited via the internet with one received. Work locations and funding will be determined with each order, with an estimated completion date of Aug. 9, 2024. U.S. Army Contracting Command, Aberdeen Proving Ground, Maryland, is the contracting activity (W91CRB-19-A-0001). P&S Construction Inc.,* North Chelmsford, Massachusetts, was awarded a $9,457,700 firm-fixed-price contract for construction of a small arms range at Westover Air Reserve Base, Massachusetts. Bids were solicited via the internet with two received. Work will be performed in Westover, Massachusetts, with an estimated completion date of Dec. 9, 2020. Fiscal 2016, 2017 and 2018 military construction funds in the amount of $9,457,700 were obligated at the time of the award. U.S. Army Corps of Engineers, Louisville, Kentucky, is the contracting activity (W912QR-19-C-0020). Nisou LGC JV LLC,* Detroit, Michigan, was awarded an $8,945,520 firm-fixed-price contract for construction of the aerial port facility at Grissom Air Reserve Base, Indiana. Bids were solicited via the internet with two received. Work will be performed in Grissom, Indiana, with an estimated completion date of Oct. 12, 2020. Fiscal 2015, 2017 and 2019 military construction funds in the amount of $8,945,520 were obligated at the time of the award. U.S. Army Corps of Engineers, Louisville, Kentucky, is the contracting activity (W912QR-19-C-0026). Navistar Defense LLC, Lisle, Illinois, was awarded a $7,766,045 firm-fixed-price contract for 4x4 cargo trucks, 6x6 general transport truck, 6x6 30 ton recovery wrecker and medium tactical vehicles general transport truck spares. Bids were solicited via the internet with one received. Work will be performed in Lisle, Illinois, with an estimated completion date of Sept. 27, 2020. Fiscal 2019 operations and maintenance, Army funds in the amount of $7,766,045 were obligated at the time of the award. U.S. Army Contracting Command, Warren, Michigan, is the contracting activity (W56HZV-19-F-0455). NAVY Lockheed Martin, Mission Systems and Training, Baltimore, Maryland, is awarded $18,849,765 for cost-plus award-fee order N62786-19-F-0055 against the previously awarded basic ordering agreement N00024-15-G-2303 to provide engineering and management services for LCS-15 post shakedown availability. Lockheed Martin will provide support of the following: 62,462 man-hours level of effort; and to provide the work specification, pre-fabrication and material. Work will be performed in Moorestown, New Jersey (37%); Mayport, Florida (35%); Hampton, Virginia (14%); and Washington, District of Colombia (14%), and is expected to be complete by January 2021. Fiscal 2013 and 2019 shipbuilding and conversion (Navy); and fiscal 2019 other procurement (Navy) funding in the amount of $13,631,677 will be obligated at time of award and will not expire at the end of the current fiscal year. The Supervisor of Shipbuilding, Conversion and Repair, Bath, Maine, is the contracting activity. BAE Systems Land & Armaments LP, Minneapolis, Minnesota, is awarded an $8,411,293 cost-plus-fixed-fee delivery order for MK38 Gun Weapon System Repair Program support. This contract action is for labor, material and services required to support the Gun Weapon System Repair Program in pre/post testing, removal/installation, refurbishment, fleet technical assistance, maintenance, training and fleet modernization of MK 38 machine gun system. Work will be performed in Norfolk, Virginia (29%); San Diego, California (27%); Yokosuka, Japan (16%); Manama, Bahrain (7%); Rota Spain (7%); Everett, Washington (4%); Tacoma, Washington (4%); Pearl Harbor, Hawaii (4%); and Pascagoula, Mississippi (2%), and is expected to be complete by September 2021. Fiscal 2019 operations and maintenance (Navy); and fiscal 2019 weapons procurement (Navy and Coast Guard) in the amount of $1,050,000 will be obligated at the time of award, and $750,000 will expire at the end of the current fiscal year. This delivery order was solicited as a sole source under basic ordering agreement N00174-18-G-0001 in accordance with 10 U.S. Code 2304(c)(1). The Naval Surface Warfare Center, Indian Head, Explosive Ordnance Disposal Technology Division, Indian Head, Maryland, is the contracting activity (N00174-19-F-0420). Leidos Innovations Corp, Gaithersburg, Maryland, is awarded an $8,208,133 performance-based, indefinite-delivery/indefinite-quantity, firm-fixed-price contract for Micro-processor En-route Automated Radar Tracking System (MEARTS). The contract is for the acquisition of hardware, software, logistics and on-call help desk support for MEARTS. The contract includes a single five-year ordering period and one six-month option to extend services in accordance with Federal Acquisition Regulations (FAR) Clause 52.217-8. The option period, if exercised, would bring the cumulative value of this contract to an estimated $8,737,303. Work will be performed in Charleston, South Carolina, and is expected to be completed by January 2025. An order utilizing fiscal 2019 operations and maintenance (Navy) funds in the amount of $605,690 will be obligated at time of award. Contract funds will expire at the end of the current fiscal year. This requirement was not competitively procured because it is a sole-source acquisition pursuant to the authority of 10 U.S. Code 2304(c)(1) only one Responsible Source FAR Subpart 6.302-1). Naval Information Warfare Center Atlantic, Charleston, South Carolina, is the contracting activity (N65236-19-D-1001). EFW Inc., Fort Worth, Texas, is awarded $7,228,544 for firm-fixed-price delivery order N68335-19-F-0006 against a previously issued basic ordering agreement (N00019-17-G-0014). This delivery order procures 15 Fast Characterization Tools, 15 Helmet Kit Modification Fixtures, 15 Ready Room Testers and 20 Night Vision Goggle Modification Kits for the V-22 Color Helmet Mounted Display System. In addition, this delivery order provides drawing packages and the upgrade of five Fast Characterization Tools. Work will be performed in Haifa, Israel (70%); and Fort Worth, Texas (30%), and is expected to be completed in October 2020. Fiscal 2017 aircraft procurement (Air Force); and fiscal 2019 procurement defense-wide funds in the amount of $7,228,544 will be obligated at time of award, $3,496,053 of which will expire at the end of the current fiscal year. The Naval Air Warfare Center Aircraft Division, Lakehurst, New Jersey, is the contracting activity. DEFENSE INTELLIGENCE AGENCY CoSolutions EIS JV LLC,* Sterling, Virginia, was awarded a labor hour contract (HMM402-19-F-0098) with an estimated total value of $10,000,148 to support intelligence training in Europe. Work will be performed at the Regional Joint Intelligence Training Facility at RAF Molesworth, United Kingdom; Patch Barracks, Stuttgart, Germany; and, on a temporary duty basis, at other locations in Europe and within the continental U.S. The expected completion date is July 31, 2024, if all options are exercised. Fiscal 2019 operations and maintenance funds in the amount of $1,713,015 are being obligated at time of award. This contract was solicited through a small business set aside and one offer was received. The Virginia Contracting Activity, Washington, District of Columbia, is the contracting activity. *Small Business https://dod.defense.gov/News/Contracts/Contract-View/Article/1923647/source/GovDelivery/

  • Army leaders see Latin America as backyard test bed for military tech

    October 11, 2023 | International, Land, Security

    Army leaders see Latin America as backyard test bed for military tech

    The region's proximity, partners and security challenges provide ways to test out new concepts and tech.

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