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7 Phase I Selections from the 12.2 Solicitation

(In Topic Number Order)
Proto Manufacturing Inc
12350 Universal Drive
Taylor, MI 48180
Phone:
PI:
Topic#:
(734) 946-0974
William S. L. Boyer
DLA122-001      Selected for Award
Title:Dual Mode Residual Stress Profiling System for Forgings
Abstract:Forgings contribute to important efficiencies in structural weight, parts count and fatigue resistance in aerospace structures. Designers of aircraft and turbine engines know of the positive, but sometimes negative effects of residual stress (RS) fields in forgings as evidenced by dimensional warping during production. This problem causes costly scrap during machining because of unexpected warping. Some machined forgings may pass acceptance but require considerable clamping during final assembly to meet dimensional requirements. Clamping may cause unforeseen problems by introducing unfavorable RS fields, leading to fatigue and stress corrosion cracking (SCC) in service. These insidious problems are often difficult to discover and quite difficult to repair during sustainment operations. It is more cost-effective to minimize built-in RS in forgings and prevent warping and cracking. The Proto NDE/I system will exploit x-ray diffraction (XRD) technologies to nondestructively discover and help manage the conditions leading to these problems. Proto will capitalize on its recent research with energy dispersive (EDXRD) and angle dispersive (ADXRD) XRD technologies and demonstrate the capability to measure near-surface RS reliably in forgings. This capability will enable designers and producers of forgings as well as OEMs and the DOD to manage RS distributions and consistently produce high quality forgings.

Scientific Forming Technologies Corporation
2545 Farmers Drive Suite 200
Columbus, OH 43235
Phone:
PI:
Topic#:
(614) 451-8322
Wei-Tsu Wu
DLA122-001      Selected for Award
Title:Advanced Forging Manufacturing Innovations
Abstract:Forging process is widely used in the manufacture of critical mission sensitive components that require high strength and better consistent performance in service conditions. Process modeling for forging processes has been very successful in the last three decades. Modeling forging process serves us a virtual tryout tool and it offers lot more details about the forging process and parts than an expensive, time consuming shop floor trial would. Forging modeling results provide vital information regarding material flow, die fill, potential defect formation, tool failure and microstructure evolution. With increasing complexities of the forged geometries and push for near net shape forging, it is challenging to design an optimum forging progression that will result in reduced material and processing cost while maximizing the quality and robustness of the forged component. Optimization techniques can be effectively used in forging process modeling to achieve the desired goal of reducing the cost while maximizing the quality of the forged product. Sensitivity analysis will help in understanding how variabilities and uncertainties associated with the key processing variables and material properties will impact the forging process design. While manufacturing process modeling capabilities are mature, forging process optimization and sensitivity analysis to evaluate the robustness of forging process and part design is still at a nascent stage. Scientific Forming Technologies Corporation (SFTC) develops and supports forging process modeling system, DEFORM, which is widely used by the forging industry around the globe for the past 20 years. In this project, SFTC is proposing to systematically extend optimization techniques and sensitivity analysis to forging process modeling. During Phase I, SFTC will investigate a modeling framework that enables optimization of the forging processes which will help in minimizing the overall cost of the forging including material input weight and processing cost. SFTC will also investigate the application of sensitivity analysis for forging process modeling, paving the way for robust process design, which may lead to reduced scrap and rework cost. Phase I tasks will demonstrate the technical viability and commercialization potential of forging process optimization methods.

VEXTEC Corporation
750 Old Hickory Blvd Bldg. 2, Suite 270
Brentwood, TN 37027
Phone:
PI:
Topic#:
(615) 372-0299
Robert Tryon
DLA122-001      Selected for Award
Title:Advanced Forging Manufacturing Innovations
Abstract:It is increasingly difficult for companies to enter the spare parts business. To produce a spare part, the manufacturer must recreate the form, fit and function of the original part, which can be especially difficult with high strength forged metal parts. There are processes available to the forging engineer to recreate the geometry and material chemistry of original part; however, getting the part to function safely with the same durability as the original can be extremely difficult. This is because durability is governed by the material microstructure and the materialís microstructure evolves during the manufacturing process creating numerous variations. The traditional method of determining durability is expensive laboratory testing. The Phase I objective is to determine feasibility of a software product that can be used by forging manufacturers, OEM and fleet owners to predict the durability of their forged parts without extensive testing. VEXTEC will work with our OEM partner to identify attributes that are particular to forging that need to be addressed in the software product. Phase I will determine the feasibility of addressing the first order effects such as geometry, residual stress, microstructure and in-service loads. During the Phase I option period, a detail architectural plan will be completed for the software to be developed in Phase II.

AMERICAN ENERGY TECHNOLOGIES CO
220 W. Campus Ct., Unit D
Arlington Heights, IL 60004
Phone:
PI:
Topic#:
(847) 414-6788
Igor V. Barsukov
DLA122-002      Awarded: 11/8/2013
Title:20-year Lithium Primary battery for Missile-Implantable Corrosion Monitoring Systems and as Primary Power Sources for mini-UAVs
Abstract:American Energy Technologies Co., a woman-owned small business concern of Illinois will partner with Lockheed Martin Corpís Missions Systems and Sensors and with Analog Devices, in order to develop and demonstrate a new and improved primary battery capable of delivering up to two thirds of the energy density of gasoline as employed in an internal combustion engine, and up to 6.5 times the specific capacity reported to date for the most advanced Lithium-Ion batteries. The development effort seeks to produce one of the highest energy density battery systems in the market of conventional chemical batteries. The end product will have a calendar life of 20 years, and will represent a maintenance-free, safe, flight worthy, environmentally benign design. Application of new generation conductivity enhancement additives, along with the precise engineering of porosity in electrodes, and with other optimizations, will boost systemís projected power density to values comparable to those of Lithium-ion batteries. Cell performance during Phase I shall be established in the BR2450 coin and in the cylindrical 32650 cells of new and improved interior design. Phase 1 Option will focus on prototyping of a 24VDC battery module so as to be able to conduct full scale testing in the targeted end-use devices.

Eskra Technical Products, Inc.
2595 Hwy I
Saukville, WI 53080
Phone:
PI:
Topic#:
(262) 268-1750
Rodney LaFollette
DLA122-002      Selected for Award
Title:Advanced Battery Technologies and Manufacturing Process Improvements
Abstract:Using a solvent free electrode manufacturing process, several different electrochemical couples will be tested using the C123 sized cell as the test bed. Both rechargeable and primary chemistries will be processed using the solventless electrode process that was successfully developed under a previous proof of concept BATTNET program effort. This effort will demonstrate the application of the process to many types of lithium batteries.

Giner, Inc.
89 Rumford Avenue
Newton, MA 02466
Phone:
PI:
Topic#:
(781) 529-0546
Castro S.T. Laicer, Ph.D.
DLA122-002      Selected for Award
Title:An Integrated Li-ion Battery Manufacturing Process for Improved Safety and Decreased Battery Cost
Abstract:Commercial separators for Li-ion battery applications consist of microporous membranes that prevent contact between electrodes and enable free ion flow in the cell. Major drawbacks of these separators include their complex manufacturing process which adds cost to the battery and insufficient protection against thermal runaway reactions at elevated temperatures. This project addresses these limitations by developing a more cost-effective manufacturing process that yields separators with substantially improved thermal stability at extreme cell temperatures. To demonstrate the use of these separator in Li-ion batteries, Giner also proposes a new type of hybrid cell that takes advantage of high-energy and high-power capabilities of batteries and capacitors in a single device by combining a symmetric capacitor and a rechargeable battery in one unit cell. Preliminary data is shown on some materials that have already been successfully fabricated and tested.

Reactive Innovations, LLC
2 Park Drive, Suite 4
Westford, MA 01886
Phone:
PI:
Topic#:
(978) 692-4664
Edward J. Salley
DLA122-002      Awarded: 11/15/2013
Title:Low Cost Production of Carbon Monofluoride (CFx) for Lithium Batteries
Abstract:Li/CFx primary batteries are considered to be a superior choice for military applications that require long life, light weight and very low self-discharge. The high cost of current carbon monofluoride materials, however, adds significantly to the total cost of the battery. Reactive Innovations, LLC (RIL) proposes to develop a method to produce CFx materials with over a 50% cost saving. The process is based on a novel rapid diffusion method that will reduce fabrication time, increase production rate, and ultimately provide a significant cost savings to the military. In the Phase I program, RIL will build a prototype reactor and produce 100 grams of CFx material demonstrating feasibility of the technology. Comparable electrochemical performance to state-of-the-art CFx materials in lithium cells will be demonstrated in the Phase I. In the Phase II program, RIL will scale up the CFx production to multi-kilogram level, demonstrate a minimum cost savings of 50%, examine stability, and fabricate D-cell batteries with the generated CFx powder in collaboration with a battery manufacturing partner.