TECHNOLOGY AREAS: Materials/Processes

ACQUISITION PROGRAM: PMS 392 In-Service Strategic and Attack Submarines; SEA-07L Sub Logistics

OBJECTIVE: Develop fixed and portable supersonic cold spray repair system that can be employed within NUWC Keyport (fixed unit) and Fleet Maintenance Activities (portable units) to salvage and restore expensive and hard-to-get consumable ship subsystem components. Examples include seawater pump components, air compressor components, and motor casings.

DESCRIPTION: Experience has shown that availability of castings and casting vendors is severely limited and at many times, the sole source for provision of these important components. An example is the Trident Trim Pump Priming Pump Vacuum Lobe, Cone, and Rotor assembly (NSN 4310-01-119-5384, 4310-01-119-5383, and 4320-01-064-7591 respectively). These units are expensive, and history has demonstrated receipt of units that receipt fail inspection and cannot be installed. Unit costs are $85K per set with a 24 - 48 week lead time; last shipment had 5 of 8 rejects due to high porosity). There are 17 sets of "F" condition assets shelved at IMF Bangor equating to $1.4M in unusable, consumable hardware. NUWC Keyport has investigated other repair techniques for these parts, but has not found a suitable method to date other the proposed cold spray application. Past demonstration of Supersonic Cold Spray Repair Systems on aluminum hardware in other DoD applications appears to be successful (Ref 1.) The prospects of developing systems to successfully repair materials of greater density (e.g. red brass and bronze materials used in the manufacture of these components) are highly probable. This project would complement NUWC Keyport's existing ONR-ARL/Penn State University Metal Deposition Projects, and align perfectly with Keyport's Technology Insertion Partnership with Puget Sound Naval Shipyard & IMF. For more information on Cold Spray Technology, see reference two.

PHASE I: Develop a conceptual design of multi-use Supersonic Cold Spray Repair tools (fixed and portable) that can be employed to salvage and restore consumable submarine and surface ship components such as pump lobes, impellers, cones, and motor casings.

PHASE II: Conduct beta supersonic cold spray repair applications of various metals, analyze beta samples for proper adhesion and strength properties; apply conventional engineering/manufacturing processes to ensure conformance. Conduct operational tests of repaired components using local test stands (when necessary) at Public Shipyards and Intermediate Maintenance Facilities.

PHASE III: Deploy supersonic cold spray repair systems to several Navy Repair Depots, install beta repaired parts on active U.S. Navy submarines and ships with NAVSEA and Type Commander authorization, conduct at-sea evaluation for 50 � 100 days, remove and inspect beta repaired parts to confirm process and validate system development.

NUWC Keyport personnel will work closely with the successful solicitor to assist in development of Cold Spray Repair Systems and processes; will provide adequate sample components with which to develop, test, and evaluate the repair systems, and ensure that test stands and other Government Furnished Equipment (GFE), where applicable, will be made readily available to help ensure success of this repair research project.

PRIVATE SECTOR COMMERCIAL POTENTIAL/DUAL-USE APPLICATIONS: This technology has great promise in refurbishing high dollar, complex, long lead time parts by restoring worn or damaged surfaces. This technology would have applications in the Commercial Ship Repair, Automotive, Petroleum, Natural Gas, and Electric Power Generation industries to repair turbines, wind power generating equipment, pumps & other mechanical components.

REFERENCES:
1. "Cold Spray Process Development for the Reclamation of the Apache Helicopter Mast Support," August 2009, P.F. Leyman and V/K. Champagne, U.S. Army Research Laboratory, Aberdeen Proving Ground, MD, Test Document ARL-TR-4922,
http://www.dtic.mil/cgi-bin/GetTRDoc?AD=ADA505530&Location=U2&doc=GetTRDoc.pdf

2. Centerline Supersonic Spray Technologies web site. www.supersonicspray.com

3. Agile Manufacturing Center for Casting Technologies (AMCAST); Dr. Kershed Cooper

4. SSN 688 Los Angeles Class Vertical Launch System Missile Tube Robotic Laser Cladding Repair System; Dr. Kershed Cooper.

5. Repair, Refurbishment, Restoration, and Reclamation (R-4) Project; Dr. Kershed Cooper.

6. Electron Beam Free Form Fabrication, "E-Beam" Project; Mr. John Carney.

KEYWORDS: Fixed; Portable; Supersonic; Cold Spray; Metal; Reclamation; Repair; Restoration; work closely with solicitor; ensure the ready availability of test stands and GFE; help ensure success.

** TOPIC AUTHOR (TPOC) **

DoD Notice:   Between November 10 and December 12, 2010, you may talk directly with the Topic Authors 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 December 13, 2011, when DoD begins accepting proposals for this solicitation.

However, proposers may still submit written questions about solicitation topics through the DoD's 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 (11.1 Q&A) during the solicitation period for questions and answers, and other significant information, relevant to the SBIR 11.1 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.