IWS3E Advanced Programs Technology Insertion CAPT Sheila Patterson, USN PEO-IWS 3E NDIA Guns &...

IWS3E Advanced ProgramsTechnology Insertion

CAPT Sheila Patterson, USNPEO-IWS 3E

NDIA Guns & Ammunition / Missiles & Rockets Conference

14 April 2004

NDIA Conf 14 April 2004



Presentation Agenda Program Office Challenges Technology Insertion Cycle Tech Cycle Products Tech Insertion Activities Tech Insertion Way Ahead

STANDARD MISSILE

Technology Areas Sensors & Signal Processing Guidance, Navigation & Control Command, Telemetry & Data

Handling Ordnance & Propulsion Airframes and Divert Systems Power Systems Manufacturing/Test Equipment


IWS3E Advanced ProgramsIWS3E Advanced Programs

Dr. Sullins3TD

Tech DirIPA

Dr. Sullins3TD

Tech DirIPA

VACANT3TR

TECHREPO-5

VACANT3TR

TECHREPO-5

CAPT S. Patterson3E

Sys EngO-6

CAPT S. Patterson3E

Sys EngO-6

VACANT3P

Bus. OpsGS-15/O-6

VACANT3P

Bus. OpsGS-15/O-6

Joyce Woodward3I

INTERNATIONALGS-15

Joyce Woodward3I

INTERNATIONALGS-15

CAPT Murdoch3C

NSFSO-6

CAPT Murdoch3C

NSFSO-6

CAPT Lang3B

RAM/PHALANXO-6

CAPT Lang3B

RAM/PHALANXO-6

Clay Crapps3A

STD MSLGS-15

Clay Crapps3A

STD MSLGS-15

Frank TavennerClay Crapps (acting)

3LSLS

GS-15

Frank TavennerClay Crapps (acting)

3LSLS

GS-15

PEO IWS

CAPT Cramp3D

NSSPOO-6

CAPT Cramp3D

NSSPOO-6

Steering Committee Issues

Steering Committee Issues

Melissa KirkendallIWS 3DEP

Deputy (Acting)SES

Melissa KirkendallIWS 3DEP

Deputy (Acting)SES

CAPT OuttenIWS 3.0

O-6

CAPT OuttenIWS 3.0

O-6


IWS3E Advanced ProgramsTechnology Insertion CycleIWS3E Advanced ProgramsTechnology Insertion Cycle

USER-BASEDASSESSMENT

SystemsRequirements

TechnologyNeeds

NewTechnology

ProductImprovements

Real WorldPerformance

•User Community•TD/TDA•“Way Ahead”•Requirements Flow

•R&D/S&T•Industry•Government•Academia

•Program Office•Industry

•Industry•Fleet

TECHNOLOGYTRANSITION

TECHNOLOGYDEVELOPMENT

PROGRAMDESIGN & EVAL

PRODUCTIONAND USE


IWS3E Advanced Programs Technology Insertion Products

IWS3E Advanced Programs Technology Insertion Products

CYCLE STAGE PRODUCT ACTIVITIES

User-Based Assessment

Review & Comment

Continuous

Program Design & Evaluation

Review & Direct Special Analyses

Continuous

Technology Development

Focus Navy-Industry S&T Funding; Coord Joint Developments

SBIR, MANTECH, DACP, FNC, Planning & Coordination

Technology Transition

Develop & Direct Transition Projects

Planning for SBIR Transition

Production & Use Review & Assess Tech Benefits

Various Usage


IWS3E Advanced Programs Technology Insertion Activities

IWS3E Advanced Programs Technology Insertion Activities

Manufacturing & Production Five Year Plan

ManTech Issues Input & Coordination

SBIR Topic Input, Phase I Kick Off, Phase II Review & Support, And Phase III Planning

OSD Defense Acquisition Challenge Proposal Development And Support

FNC Project Planning

Technology Road Map Planning

PEO IWS “Way Ahead” Planning


IWS3E Advanced ProgramsManufacturing and Producibility

IWS3E Advanced ProgramsManufacturing and Producibility

• Radome Manufacturing

Process

• Common Control

Actuation System (CAS)

• Microstrip Circuit-Based

Impatt Transmitter

• Common Processor

• Lead-Free Technology

for Missile/Military

Application

• Manufacturable

Security Coating

• RF MEMS Manufacturing

• Moduless Design and

Manufacturing

• Rapid Prototyping of

MMIC’s

• S/A Devices

5

This overall manufacturing process development will end with the capability to provide radomes for production missiles. High surface finished closed graphite dies in vacuum molding can produce a near net shape radome that requires little to no finalfinishing for utilization as a radome. A ceramic composite withimproved performance properties produced to near net shape results in a radome more cost effective radome.

The Development Of A Manufacturing Process To Produce Ceramic Composite Radomes

Anticipated Process Improvement:

Pyroceram has been the ceramic radome material of choice for most missile systems for more than a decade. However, the manufacture of pyroceram is being phased out and within two years will no longer be available. It is critical to develop a new ceramic radome material that is ready for implementation within two years as well as meeting the property requirements for advanced missile systems.

The objective is to develop and demonstrate manufacturing processing to produce full size ceramic composite radomes. In a separate program, ceramic composites such as silicon nitride reinforced glassy/ nanocrystalline ceramic matrix composites are to be developed. This program objective is to develop and demonstrate a manufacturing process to produce radomes with the required surface finish and mounting methodology.

PROBLEM/ OBJECTIVE

ACCOMPLISHMENTS/ PAYOFF

In a team effort with Raytheon and MER Corporation, a processing methodology will be developed to produce ceramic composite radomes such as silicon nitride reinforced glassy/ nanocrystalline ceramic matrix. Pyroceram is produced in billets and expensively machined to shape. In this case, methodology that produces near net shape radomes will be developed which requires minimal surface finish for utilization.The manufacturing methodology will emphasize resin transfer type processing to produce the ceramic composite. Mounting methodology that accounts for the difference in coefficient of thermal expansion of the ceramic composite radome and metal missile body will also be developed.

Implementation and Technology Transfer:

The loss of pyroceram necessitates the requirement to produce radomes from new materials, which has a certainty to consist of a ceramic composite. Composites are readily manufactured by transferring a liquid matrix precursor into a reinforcement array. In this case, a liquid glass/ nanocrystalline ceramic will be melted and vacuum closed die molded to near net shape into radome configurations. The developed manufacturing process will be utilized to production produce radomes for production missile systems.

TIMELINE/ MILESTONE

FUNDING

Start Date: October 2003

End Date: September 2003

SBIR 0.4 M

Navy ManTech 2.6 M

PARTICIPANTS

Raytheon

MER Corporation

8

High Performance Common CAS

Anticipated Process Improvement:

Design a Common Control Actuation System (CAS) for several Air Intercept Missiles (AMRAAM, AIM-9X, ESSM).

PROBLEM/OBJECTIVE

ACCOMPLISHMENTS/PAYOFF

Evolves the BOM adding a common, cost efficient hardware solution while establishing the internal design capability in a key market area.

Implementation and Technology Transfer:

Exercise the Control Systems Development process;

Establish a consolidated set of performance, interface, and environment requirements;

Validate high risk areas early with common form factor;

Leverage tech demo CAS mechanism effort;

Develop common controller electronics.

Expected Benefits:

Commonality achieved in circuit design, circuit cards, motors, gear train, BIT philosophy, actuator motors, controller components.

TIMELINE/MILESTONE

Start date: TBD

End date: 30 Months ARO

FUNDING

Navy ManTech: $1.2M

Program Design / Qual Funds: $6-10M

PARTICIPANTS

Raytheon, Government Missile Programs

NAVSEA, NAVAIR

AFRL

11

Microstrip Circuit BasedI MPATT Transmitter

Anticipated Process I mprovement:

I MPATT diode based Solid State Transmitters (SST) that produce peak powers of over 1 KW have been demonstrated for use in missile seekers. These multi-stage transmitters use Raytheon’s combiner plate technology and precision machined cavity circuits to combine the power from several hundred individually packaged I MPATT diodes. A Raytheon I R&D program has developed a diamond substrate microstrip circuit that matches a single I MPATT chip. This planar circuit operates as an oscillator and provides RF performance equal to a cavity circuit.

The objective is to extend this single diode oscillator circuit to multiple diodes and to retune the circuit for amplifier operation. A Proof of Design (POD) transmitter w ill be constructed using these newly developed microstrip circuits. This POD transmitter w ill have reduced size, weight and production cost compared to a cavity based transmitter of equal performance.

PROBLEM/ OBJ ECTI VE

ACCOMPLI SHMENTS/ PAYOFF

This program will extend the single diode microstrip circuit to multiple diodes and to amplifier circuits. Since the microstripcircuits use photolithography rather than machining and mechanical tuning, critical tolerances are much tighter and lessassembly labor w ill be required for each combiner circuit. The microstrip circuit w ill also be smaller and lighter than a machined cavity. The program will design, fabricate and test a Proof of Design model of a high power I MPATT transmitter. This POD unit w ill be available for testing in prototype radar systems.

I mplementation and Technology Transfer:

Navy active seekers program and two-way links

Start Date: October 2002End Date: March 2004

TI MELI NE/ MI LESTONE

FUNDI NG

Navy ManTech: $2.8 M (SST POD unit)

PARTI CI PANTSRaytheon

Expected Benefits:

Both size and weight of the transmitter w ill be reduced by approximately a factor of 2.

The SST replaces the traditional TWT/ High Voltage Power Supply transmitter and TWT replacement at the end of its shelf life is eliminated thus providing life cycle cost savings.

1 KW I MPATT Transmitter using Cavity Combiner Circuits


IWS3E Advanced ProgramsSBIR Activities


Name Description Status

Plasma Drag Reduction for Missiles and Projectiles

Develop and demonstrate a prototype missile/projectile with on-board plasma drag reduction system

Phase II nearing completion, flight test planned

Advanced Tactical Telemetry Transmitter

Implement FM, SOQPSK, and multi-h CPM with FEC in 6 cu. In., >5 Watt unit

Phase II nearing completion. Option planned. Transition to SM-6 BLK I

Nondestructive Inspection of Thermal Batteries

X-ray and automated image analysis. Allows inspection prior to sealing.

Completing Phase I, Transfer to MDA for Phase II

Nondestructive Test for Missile Batteries

Impedance spectroscopy technique allowing in-situ measurement of SOH

Completing Phase I, Phase II approved





Thermal Batteries Fabrication Automation

Assists assembly of 500 pellet batteries for high voltage applications. Will demo at EP through FY05.

Phase I complete, MDA to award Phase II

Development of RBSN Based Materials for Next Generation Tactical Missile Radomes

Fabricate and test of silicone nitride material for high speed radome application

Phase I award approved

Cerablak Matrix CMCs for Next Generation Radomes

Fabricate and test of phosphate matrix CMCs for high speed radome application


Fiber Reinforced Ceramic Radome Material with Improved Resistance to Thermal Shock, High Temperature, and Erosion

Fabricate and test of green fiber CMCs for high speed radome application






Fiber Reinforced Ceramic Radomes for Next Generation Missiles

Fabricate and test of multiple ceramics and CMCs using gel-casting for high speed radome application


Radome Materials & Process for Long Flight Duration-High Speed Missiles

Fabricate and test of silcone matrix/silica fiber for high speed radome application


High Speed Multi-Axis Fiber Optic Sensor

Develop a multi-axis fiber optic strain sensor and high speed multiplexing system

Phase I nearing completion, transition to Phase II planned


IWS3E Advanced ProgramsDACP Activities

IWS3E Advanced ProgramsDACP Activities

Proposal Name Description Funding Requested Transition

Enhanced Optical System - RAM

Replaces window and other parts of optical assy

DACP Cost = $1.4M Cost Sharing = $4.6M

Transition is immediate to RAM P3I program

Ceramic Gel-casting Process for Tactical Missile Radome Fabrication

Process provide potential alternative to Pyroceram

DACP Cost = $1.8M Primary Acquisition Sponsor is AMRAAM

CAESAR - Condition And Environmental Sensing And Reporting System

Prototype system capable of optical measurement and storage of VLS environment

DACP Cost = $0.9M Primary Acquisition Program Is AEGIS BMD (SM-3)

Integrated Missile Harness-Fairing Assembly

Elect. Interconnect assy and fairing are fab'd as integrated unit

DACP COST = $1.63M Primary Acquisition Program is AMRAAM


Area Near Term(FY + 5)

Mid Term(FY + 10)

Far Term(FY + 20)

Sensors & SignalProcessing

Guidance, Navigation & Control

Command, Telemetry & Data Handling

Ordnance & Propulsion

Airframes & Divert Systems

Power Systems

Manufacturing & Test Equipment

CostReliability

- Aging InventoriesSafety

- IM Compliant- IFF

Producibility- International Standards- Parts Obsolescence- Increased Complexity

Performance- Reduced Target RCS- Advanced Target Countermeasures- Background/Clutter- Maneuvering Targets- Multiple Targets- Improved Lethality- Expanding Target Set- Increased Range & Velocity- Longer Flight Times

Interoperability- Joint Operations- Missile Link- DDX/SPY-X- Foreign Sales

Performance- All of Near-Term Plus:- Hypersonic Maneuvering Targets- Increased/Variable Range and Speed (Time to Target, Expanded Mission Areas)- Increased Peak Power

Interoperability- All of Near-Term Plus:- Battle Damage Assessment- Open Architecture- FORCEnet/GIG

Performance- All of Near & Mid-Term Plus:- Variable/Adaptive Signature Targets

Interoperability- All of Near & Mid-Term Plus:- Changing System Interfaces (Launcher, C4I, OA, etc)- Increased Autonomy and Adaptability (Reduced Warfighter Workload)

Continues Through Mid and Far-Term

IWS3E Advanced ProgramsRoadmap - Missile Technology Drivers

IWS3E Advanced ProgramsRoadmap - Missile Technology Drivers


Area Near Term(FY + 5)

Mid Term(FY + 10)

Far Term(FY + 20)

Sensors & SignalProcessing

Guidance, Navigation & Control

Command, Telemetry & Data Handling

Ordnance & Propulsion

Airframes & Divert Systems

Power Systems

Manufacturing & Test Equipment

Cost- Automated/Common Design, Manufacturing & Test- Manufacturing Yield Improvements

Reliability- Technology Refresh- Design for Obsolescence

Safety- MEMS S&A- IM Compliant Motors

Producibility- Battery Manufacturing & Test Improvements- Radome Manufacturing- Rapid Prototyping- Built in Test- Titanium Mirror Fabrication

Performance- Gimbaled Active/Semi-Active Seeker- Increased RCS Sensitivity- Increased G Airframe/AP- Improved Rear Receiver- Advanced ECM- RAM Uplink- Integrated Guidance & Control- Onboard Multi-Sensor Track Correlation- Enhanced IR Optical System- MEMS Fuze- Thin Celled Thermal Battery

Cost- Automated/Common Design, Manufacturing & Test- Common Distributed Architectures (Power & Data/Processing)- Open Architecture


Safety- IM Compliant Motors

Producibility- Lead Free Manufacturing- Anti-tamper Coatings

Performance- GPS/INS w/Anti-Jam- Improved ICG&F- Low Cost Ladar Fuze/TDD- Increase RCS Sensitivity- Advanced Radome- Improved ECCM- Very Thin Celled Thermal Battery

Interoperability- Tactical Telemetry- Link-16 Type Comm Link- Integrated Fire Control

Cost- Automated/Common Design, Manufacturing & Test- Common Distributed Architectures (Power & Data/Processing)- Open Architecture


Safety- IM Compliant Motors

Performance- Improved Algorithms for Adv ECM- Onboard Multi-Sensor Track Correlation and SIAP Data Fusion- Improved Lethality- Jet Reaction Control- Composite Airframe- High Thrust Divert System- Variable Thrust Motor- MEMS Airflow Shaping- Non Rigid Form Factor Energy Storage

Interoperability- Advanced Sensor-to-Weapon Link

IWS3E Advanced Programs Roadmap - Missile Technology

Evolution

IWS3E Advanced Programs Roadmap - Missile Technology

Evolution


IWS3E Advanced ProgramsTechnology Insertion Way

Ahead

IWS3E Advanced ProgramsTechnology Insertion Way

Ahead

Goal - Provide Advanced Tech Insertion Reqd to Meet Critical

Needs

Strengthen Foundation Improve Needs and Tech Base Assessment Capability

Increase Resources Available For Technology Transition Projects

Increase Access To Technology Information

Increase Technology Needs Outreach Efforts

Build On Success Broaden Participation In And Frequency Of Technology

Coordination Activities

Increase Cross-Program Communication And Project Coordination

Capability

Get Buy-in Via Joint Technology Investment Reviews

Increase Focus On Technology Transition

IWS3E Advanced Programs Technology Insertion CAPT Sheila Patterson, USN PEO-IWS 3E NDIA Guns &...

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