imast thrust areas

Mechanical Drive Transmission Technologies

Objective: Develop technologies which will assist in the enhancement, revitalization, and resurgence of the transmission industrial-base sectors of the United States. This is necessary for several reasons. It is essential that this particular industrial base remains viable, competitive and robust in order to effectively address U.S. Navy, Marine Corps and Department of Defense modernization and surge requirements.

Further, this industrial sector is critical to the national transportation infrastructure and, therefore, needs to remain responsive and competitive to address national interests. In order to achieve our objectives, iMAST needs to be recognized as a national resource.

Since it is the industrial sector that supplies the DoD with mechanical drive transmission components and systems, it is essential that this recognition be derived from both industry and government sectors alike. The broad technological objectives driving the research and development agenda of this thrust are noted as follows:

• REDUCE the weight of transmissions by at least 25%
• REDUCE vibration and noise by at least 10 dB
• INCREASE mean-time-between-removals (MTBR) by 20%
• INCREASE operating safety
• REDUCE procurement and operating costs (affordability)

Group Thrust Areas

• Drivetrain Technologies
• Advanced Manufacturing and Materials
  • Manufacturing Processes Machine Tool Development
  • Material Systems and Testing
  • Process Characterization
  • Equipment Characterization
  • Gear Manufacturing Simulation
  • Tooling Technology
• Metrology & Performance Prediction
  • High Accuracy Measurement Machines
  • Advanced Measurement Methodologies
  • Gear Performance Prediction (Vibration analysis)
  • Statistical Properties of Heat-Treatment Distortion

Materials Science Technologies
Objective: To focus the material science capabilities of ARL and Penn State to satisfy the manufacturing science and technology requirements of the Navy and the Marine Corps. The current material science technology portfolio contains three distinct areas:

• Advanced Coatings
• Polymer Matrix Composites
• Light-Weight, Wear Resistant Materials and Coatings
• Nanophase Material Technology

Advanced Coatings

• Wear Resistant Coatings
• Thermal Barrier Coatings for High-temperature Application
• Oxidation-resistant Coatings
• Corrosion-resistant Coatings
• Coatings for Micr-electronics Industry
• Net Shape Forming Coating Components
  • Electron Beam-Physical Vapor Deposition (EB-PVD) process has been extends in fabrication of net shape components. This process allows for tailoring the composition and microstructure of net shaped components in a cost effective manner.
• Optical and Non-linear Coatings
• Testing and Evaluation

Research capabilities:

• Three EB-PVD units including industrial prototype unit for high deposition rate
• Sputtering.
• High temperature vacuum and environmental controlled furnaces
• High temperature tribo-meter
• Materials characterization facility (SEM, X-Ray, TEM, and EPMA)

Polymer Matrix Composites - The capabilities in polymer matrix composites include:

• Design and Analysis
  - Linear & Nonlinear FEA/BEA
  - Active and Passive Acoustic Tailoring
  - Life Prediction
• Materials Characterization
  - Development of Test Protocol
  - Qualification of Naval Composites
  - Evaluation of Cavitation Resistant Coating
• Fabrication
  - Low Cost Processing
  - Sub- and Full-Scale Prototyping
  - Technology Transfer
• Quality Assurance
  - Ultrasonic NDE
  - Advanced Signal Processing
  - Specialty Standards
  - Component Inspection
• Structural Testing
  - Fixturing/Instrumentation
  - Prototype/Element Testing
  - Test Correlation

Light-Weight, Wear Resistant and Corrosion Resistant Materials and Coatings - capabilities in light-weight, wear resistant materials and coatings include:

• Spray Metal Forming - the production of unique high strength and/or high temperature resistant aluminum alloys
• High Velocity Particle Consolidation - an inexpensive low temperature deposition process that can produce coatings from 1micrometer to 20millimeters
• Friction and Wear Amelioration, Corrosion Resistant Materials and Lubrication Development
  - Testing and Evaluation of Materials and Material Processing
  - Development of Alternate Materials and/or Material Processing to Minimize/Eliminate Adverse Wear and Corrosion
  - Development of Alternative and Environmentally Benign Lubrication Systems

Nanophase Materials Technology - Nanophase materials development and testing capabilities include:

• Nanophase Powder Processing
• High Energy Nano-Powder Attrition
• Controlled Atmosphere Sintering Furnaces
• Vacuum Hot Pressing
• Nanophase Powder Microwave Sintering