TECHNOLOGY AREAS: Materials/Processes, Sensors

ACQUISITION PROGRAM: DD(X)

OBJECTIVE: The objective of the project is to develop and implement new, innovative approaches and techniques for the nondestructive inspection of thin, welded, marine aluminum structures.

DESCRIPTION: The Navy's Program Executive Office for Ships is leveraging the National Shipbuilding Research Program (NSRP) to effect change across the non-nuclear surface shipbuilding, modernization and repair enterprise by coordinating with U. S. shipbuilders to adapt and implement "World Class" commercial best manufacturing practices. The U.S. shipbuilding industry lags behind the global shipbuilding market significantly in adapting new technologies to long-standing inefficient manufacturing processes and improvement is this area is key to closing this gap.

This topic seeks innovative scientific and engineering solutions to inefficiencies in the long-standing nondestructive inspection methods for marine aluminum structures. The Navy has for many years limited the use of aluminum alloys in topside structures because of the potential for catastrophic damage due to fire and the frequency of fatigue cracks forming in these structures. Recently there has been a resurgence in the planned use of aluminum in Navy surface ships. As a result , shipbuilding and repair facilities will require improved methods of inspecting structures made from aluminum alloys. Portability, adaptability, precision and automation will be important attributes to consider in developing solutions.

Efforts cited within each research area are illustrative only and proposals dealing with other efforts within the described area of interest are also solicited. The research areas include aluminum nondestructive inspection technology that can:
- Provide rapid, non-traditional surface nondestructive testing of butt, corner and tee weldments for the presence of fatigue cracks
- Provide rapid non-traditional surface and subsurface inspection independent of the presence of surface coatings, various weld sizes, weld profiles and weld surface roughness
- Locate and map areas within a 5XXX aluminum alloy plate that has become sensitized due to extended high ambient temperatures and may be susceptible to accelerated corrosion attack
- Conduct rapid, non-contact, field inspection and provide documentation

Of particular interest are initiatives with a clear business case. Proposal should specifically describe the technology that will be applied to solve the problem, how it will be developed, what the specific benefit will be and how it might be transitioned into the shipbuilding industry. While NSRP members are available to provide guidance and assistance in the preparation of proposals and in the execution of efforts awarded from this solicitation, teaming or consulting with the shipbuilder and repair industry (both public and private yards) is not required and will not be a factor in proposal selection.

PHASE I: Demonstrate feasibility for improvements being developed and also identify impact upon shipbuilding affordability. Include a first order Return-On-Investment (ROI) analysis for industry implementation and estimate potential Total Ownership Cost (TOC) reduction. Establish Phase II performance goals and key developmental milestones.

PHASE II: Finalize the design, as appropriate, and demonstrate a working prototype of the proposed system. Perform laboratory tests to validate the performance characteristics established in Phase I. Develop a detailed plan and method of implementation into a full-scale application.

PHASE III: Implement the Phase III plan developed in Phase II in coordination with the shipbuilding and repair industry.

PRIVATE SECTOR COMMERCIAL POTENTIAL/DUAL-USE APPLICATIONS: The technology developed under this topic shall be directly applicable to current military and commercial shipbuilding operation and repair practices. The products developed should find wide use in most heavy industrial plant/processing facilities such as the power industry and will be marketable to the shipbuilding and repair industry.

REFERENCES:
1. NSRP ASE Strategic Investment Plan, available on line at http://www.nsrp.org
2. Repair Industry Contacts are available at http://www.usashipbuilding.com
3. US Naval Shipyard information is available at http://www.shipyards.navy.mil

KEYWORDS: shipbuilding; topside structures; affordability; aluminum alloys, nondestructive testing

TPOC: William Palko
Phone: (202)781-1732
Fax: (202)781-4570
Email: [email protected]
2nd TPOC: Russell Kok
Phone: (202)781-4137
Fax: (202)781-4747
Email: [email protected]

** TOPIC AUTHOR (TPOC) **

DoD Notice:   Between May 1, 2006 and June 13, 2006, you may talk directly with the Topic Author(s) to ask technical questions about the topics. Their contact information is listed above. For reasons of competitive fairness, direct communication between proposers and topic authors is not allowed starting June 14, 2006 , when DoD begins accepting proposals for this solicitation.

However, proposers may still submit written questions about solicitation topics through the SBIR/STTR Interactive Topic Information System (SITIS), in which the questioner and respondent remain anonymous and all questions and answers are posted electronically for general viewing until the solicitation closes. All proposers are advised to monitor SITIS (06.2 Q&A) during the solicitation period for questions and answers, and other significant information, relevant to the SBIR 06.2 topic under which they are proposing.

If you have general questions about DoD SBIR program, please contact the DoD SBIR Help Desk at (866) 724-7457 or email weblink.