National Defense Authorization Act gets China out of America’s skies

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  October 25, 2018 | International, Aerospace

  Battle over Air Force’s $1,300 coffee cups heats up

  By: Stephen Losey The Air Force, under fire for throwing down $1,280 apiece to replace in-flight reheating cups after their handles break, is pledging to use 3-D printing to get that replacement cost down to 50 cents. But Sen. Chuck Grassley, R-Iowa, is still wondering why these pricey water heaters are necessary in the first place, and plans to keep pushing the Air Force to find cheaper waysto warm up their coffee. The cups, which plug into outlets on cargo planes to reheat liquids such as water or coffee, have a faulty plastic handle that easily breaks when the cups are dropped. And because replacement parts for the cup are no longer made, the Air Force has had to order a whole new cup when the handle breaks. In an Oct. 2 letter to Air Force Secretary Heather Wilson, Grassley said that 25 replacement cups, each costing roughly $1,280 each, have been bought this year alone, for a total of roughly $32,000. The 60th Aerial Port Squadron at Travis Air Force Base in California spent nearly $56,000 to replace broken cups over the past three years. And the price is rising. Grassley noted that Travis said each cup cost taxpayers $693 in 2016. “Paying nearly $700 for a single cup is bad enough, but it's simply beyond reason to continue to pay ever-increasing prices for something as simple as a coffee cup that is so fragile that it needs to be constantly replaced,” Grassley said. “This latest example of reckless spending of taxpayer dollars gives me no confidence that the Air Force is taking real steps to reduce wasteful spending practices.” In an Oct. 17 letter to Grassley, Wilson said that “it is simply irresponsible to spend thousands of dollars on manufactured parts when we have the technology available to produce them ourselves,” once a supplier either stops producing those parts or goes out of business. Wilson said that in July, she ordered a new Air Force Rapid Sustainment Office to be created to find ways to develop and deliver parts at a fraction of the cost of traditional manufacturing methods. This office has recently shown it can 3-D print replacement handles for the reheating cup for about 50 cents each. Wilson told Grassley that this cup is specially manufactured to plug into aircraft systems, and because it connects to the aircraft, the replacements need to be certified as airworthy by the FAA. This has driven up the cost of buying 391 of these cups since 2016 to $326,785, Wilson said, or about $836 apiece. The water heaters are used on 59 KC-10s, 52 C-5s, and 222 C-17s, Wilson said. But with planes aging, and the average KC-10 at 34 years old, it's harder and harder to find replacement parts for those aircraft, she said. And the price tag for raw materials for those parts is also increasing, Wilson said, with copper and chrome plating costs have increased 180 percent since 2016. Wilson told Grassley that she and Chief of Staff Gen. Dave Goldfein have ordered the new sustainment office to look for items in the procurement process that it can self-produce, or other overpriced items that it can stop buying without hurting the Air Force's mission. Grassley was dissatisfied with Wilson's response, and said he will keep digging. “It leaves me with more questions,” Grassley said. “While I appreciate that the Air Force is working to find innovations that would help save taxpayer dollars, it remains unclear why it cannot find a cheaper alternative to a $1,280 cup. Government officials have the responsibility to use taxpayer dollars efficiently. Too often, that's not the case.” The Air Force also said that Air Mobility Command is no longer buying the heaters for large transport aircraft as they try to find more cost-effective solutions. https://www.airforcetimes.com/news/your-air-force/2018/10/22/battle-over-air-forces-1300-coffee-cups-heats-up

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  December 24, 2023 | International, Aerospace

  New in 2024: Who will win Air Force’s next-gen fighter contract?

  The Air Force also plans to dramatically increase spending on advanced engine research for NGAD.

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  October 16, 2018 | International, Naval

  How the Office of Naval Research hopes to revolutionize manufacturing

  By: Daniel Cebul 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