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Improved Extrusion and Milling Techniques
Navy SBIR 2008.2 - Topic N08-163 NAVSEA - Mr. Dean Putnam - dean.r.putnam@navy.mil Opens: May 19, 2008 - Closes: June 18, 2008 N08-163 TITLE: Improved Extrusion and Milling Techniques TECHNOLOGY AREAS: Ground/Sea Vehicles, Materials/Processes ACQUISITION PROGRAM: Architectures, Interfaces and Modular Systems (AIMS) The technology within this topic is restricted under the International Traffic in Arms Regulation (ITAR), which controls the export and import of defense-related material and services. Offerors must disclose any proposed use of foreign nationals, their country of origin, and what tasks each would accomplish in the statement of work in accordance with section 3.5.b.(7) of the solicitation. OBJECTIVE: Develop a manufacturing technique that will increase rate and quality of production for an irregularly shaped, high tensile strength extruded aluminum track used in the FlexTech Track System. DESCRIPTION: The FlexTech track system is constructed of an aluminum alloy through extrusion techniques. However, the strength of the alloy and configuration of the design increases the difficulty of extruding long runs of the track. The cost of extrusion equipment is significant, so the recapitalization of existing machinery in the proposed manufacturing technique would be more likely to be commercialized into metal working facilities. An innovative manufacturing technique is needed to mass produce this track to keep the tolerances within acceptable limits. Improved manufacturability of the FlexTech product would enable advancement of a concept which seeks to extend a ships useful service life. The track has undergone extensive redevelopment to facilitate improved production quality. Advancements in track design would be considered to increase the probability of success. FlexTech is a slot and hole configuration track system for holding equipment to the deck or bulkhead depending on the application. This permits the securing of heavy equipment within ship spaces without welding. The FlexTech Modular Track system is used to enable modularity and open architecture in new ship construction. Modularity and open architecture is a leading approach in the effort to create reconfigurable work spaces aboard ships. The worlds dynamic geo-political environment causes modern ships to be outmoded too quickly to keep up with the pace of change. Reconfigurable spaces will allow changes to ship functionality over the useful service life. A ship outfitted with FlexTech will be a reconfigurable open system. By enabling the rapid change of ship spaces, ship lifecycles can be extended significantly. PHASE I: Develop the proposed concept into a feasible manufacturing technique which supports the topic objective. Upon completion of the Phase I effort, a well-reasoned evaluation of the concepts and methods necessary to mass produce a quality track that meets tolerance limits would be expected. Investigate processes to determine the technical feasibility of an advanced manufacturing concept based in part on modern metal extrusion techniques that can be used to manufacture the FlexTech Track System. PHASE II: Conduct necessary Research and Development to advance concept. Field a working prototype to evaluate the manufacturing technique. To improve the probability of success in the new manufacturing technique some redesign of the track system may be considered. Based on current practices, develop an advanced manufacturing technique. The technique must meet approved tolerances for the track design and installation. In addition, the extrusion technique should be make use of existing extrusion machinery so that cost is kept to a minimum. PHASE III: Conduct qualification testing. The expected end-state will be Government purchase of FlexTech from the steel and ship building industries. The manufacturer of FlexTech will be the customer for the new manufacturing technique. The completed project should be commercialized to the defense and manufacturing industries to facilitate production of the FlexTech Track System. PRIVATE SECTOR COMMERCIAL POTENTIAL/DUAL-USE APPLICATIONS: Reconfigurable spaces are primarily applicable to warships which experience regular upgrades in mission technologies. However, the commercial shipping industry may also find benefit in the ability to modify payload spaces in order to adjust to evolving cargo and seasonal route changes. REFERENCES: 2. A. K. Sheikh and S. Z. Qamar. "A study of die failure mechanisms in aluminum extrusion." Journal of Materials Processing Technology Volume 134, Issue 3 20 March 2003, Pages 318-328. 3. A. K. Sheikh, A. F. M. Arif and S. Z. Qamar. "A probabilistic study of failures of solid and hollow dies in hot aluminum extrusion." Journal of Materials Processing Technology, 30 November 2004, Pages 1740-1748. 4. J. Phillips, T. Esposito. "Near-Net Extrusion: An Ideal Manufacturing Process for High - Strength Titanium Aerospace Components". 5. I. Gheorghe, Alu Menziken. "Latest Alloy Development Activities at Universal Alloy Corporation." UAC, Canton, GA. KEYWORDS: Extrusion, high tensile strength, aluminum, open systems, open architecture.
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