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2015 AFRL Presentation On Materials
2015 AFRL Presentation On Materials
AFRL Overview
1 May 2015
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AFRL AROUND THE WORLD
AFRL 711th Human International
Materials & Aerospace
Headquarters Performance Sensors Information Sites
Manufacturing Systems
Wing Rome Research Site, NY
London, UK
Wright-Patterson AFB, OH
Tokyo, Japan
Edwards AFB, CA Arlington, VA
Kirtland AFB, NM
AF Office of
Scientific Research
Eglin AFB, FL
Ft. Sam Houston, TX Santiago, Chile
Directed Space
Energy Vehicles Munitions
Eglin Air Force S&E Education
Base, FL
20% B.S.
33% Ph.D.
Employees Civilian Military
47% M.S.
Maui Research Site, HI Total 5,827 79% 21%
S&Es 3,455 80% 20%
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AFRL Major Research Facilities
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Turning Science Into Capability
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Technology Focus Areas
Weapons
$354M DE Counter-Electronics High Speed Strike High Velocity Penetrating Flexible Weapons
Munitions
Space and Nuclear
Deterrence
Affordability
& Sustainment
Electronic Warfare /
Electronic Protection (EW/EP)
Human Performance
$70M Autonomy Aerospace Physiology & Toxicology Training & Decision Making Tech
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AFOSR (Arlington) Technical
Departments
Quantum & Non- Information,
Dynamical Systems Complex Materials Energy, Power, and
equilibrium Decision, &
& Control and Devices Propulsion
Processes Complex Networks
Dynamics & Control Atomic & Molecular Systems & Software Natural Materials & Molecular Dynamics &
Computational Physics Complex Networks Systems Theoretical Chemistry
Mathematics Plasma & Electro- Low Density Materials Space Power & Propulsion
Research Areas
Dynamic Data-Driven
Optimization & Discrete Energetic Physics Application Systems GHz-THz Electronics Human Performance &
Mathematics Remote Sensing & Information Operations & Mechanics of Multi- Biosystems
Test & Evaluation Imaging Physics Security functional Materials & Energy Conversion &
Flow Interactions & Space Sciences Trust & Influence Microsystems Combustion Sciences
Control Electromagnetics Robust Decision Making Organic Materials Aerothermodynamics &
Multi-Scale Structural Ultrashort Pulse Laser- in Humans Chemistry Turbulence
Mechanics & Prognosis Matter Interactions Science of Information, Optoelectronics & Dynamic Materials &
Turbulence & Transition Biophysics Computation & Fusion Photonics Interactions
Laser & Optical Physics Mathematical & Aerospace Materials for
Computational Cognition Extreme Environments
Robust Computational Quantum Electronic Solids
Intelligence
https://community.apan.org/afosr/default.aspx
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Extramural Programs (OSD)
• Multi-University Research Initiatives
– Multi-disciplinary in focus
– Five years in duration, up to $1.5M/year
• Defense University Research Instrumentation Program
– Used by universities to purchase major pieces of equipment to
augment or develop research capabilities
– Up to $1.5M per award, but often less
• Centers of Excellence
– University-AFRL TD partnership to: (a) perform excellent research, (b)
strengthen AFRL in-house capabilities, (3) educate students and
provide opportunities for hiring the best of them
– Typically $1M/year for five years, but can be less
• Presidential Early Career Award in S&E
– Recipients must be within five years of their doctorate
– $200K/year for five years
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Extramural Programs
• Grants
– Approximately 1300 research grants at more than 200 U.S. universities
– Supporting over 1400 Principal Investigators, 3500 grad students, and
600 post-docs
• Young Investigator Program
– Early career grants for exceptional candidates
– On average, $120K/year for three years
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Intramural Programs
SBIR/STTR:
– Stimulate technological innovations
– Increase small business participation in
federally funded R&D
– Foster and encourage participation by minority and
disadvantaged firms in technological innovation
– Increase private sector commercialization of federally
supported R&D
STTR Specific:
– Foster technology transfer between small business
concerns and research institutions
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AF SBIR/STTR Projects
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AFRL Technical Directorates
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MATERIALS & MANUFACTURING
DIRECTORATE Workforce
1PhD
Total Workforce: 600
Number of Personnel
400 19 BS 18 MS
300
73 BS 120
PhD 200 107
107
91 PhD
PhD
100
MS
0
Civilians Contractors Military Materials/Metallurgical Eng.
Chemists/Chemical Engineers
Research Physicists
Mathematicians
Human Factors Engineers
Aero/Astro Engineers
Civil/Industrial Engineers
Biologists/Microbiologists
Mechanical Engineers
Computer Eng/Computer Sci
Electrical Engineers
Ops Research/Systems Eng
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Core Technical Competencies &
sub-CTCs
Materials State Assessment Materials for Survivability & Protection
Ceramic Matrix Composites Human Performance Assessment
Organic Matrix Composites Materials for ISR
Metals
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CoE: Bio-nano-enabled Inorganic/Organic
Nanostructures and Improved Cognition (BIONIC)
Cogno
Nano
1 mm
Hypersonics
− Survivable, fast-flying
− Defeat deep layered A2/AD strategies
Directed Energy
− High Power Microwave
alternative to kinetic weapons
− Lasers with air & ground
selectable effects & reduced
collateral damage
Autonomy
− Facilitates decisions at speed of computing
− Self awareness & troubleshooting intelligence
to aid mission performance
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AFRL/RX Engagement & Investment
in Additive Manufacturing
AFRL/RX AM Activities
• Major Historical Contributions (~$20M)
– F-15 Pylon Rib Substitution
– Qualification rules for implementation • A Defense-wide Manufacturing S&T team-led, Multi-
agency collaboration between industry, government
– AM Deposition Assessment and universities
– Ceramic AM for Casting Molds • Public-private partnership (Gov’t Investment $30M)
– Process Model Development • AFRL introduced the idea, established the institute,
manages the program, and maintains leadership role.
• Ongoing Major Activities (~$50M)
– Metallic AM Inspection Benchmarking for AF Major In-House Low-TRL Research
– Manufacturing Variability Quantification for Aerospace • Thermoset Composite Processing
• ICME Approach to Metallic AM
– Flexible Electronics Consortium Leaders
• Stretchable Electronic Materials
– Integrated Flexible Electronics & Packaging • Functional Ink Development
– DARPA Open Manufacturing • ORNL/MDF Partnership
– Metallic AM for Liquid Rocket Engines
– AM of Ceramic Cores for Airfoils
– Direct Part Mfg of HT Thermoplastic Composites
– Sustainment Opportunity Assessment & Risk-based Decision Tree
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AM Potential to the AF: Structures
Expanded Component Geometries Functionally-Embedded Structures
Multiple component families geometries are constrained by Embedding devices within structure could enable improved
conventional manufacturing capabilities, including ducting, fuel communication, real-time structural health monitoring, …
nozzles, heat exchangers and turbine airfoils
Today • Reliable, integrated electronics printed directly on structure
• Conformal antennas adapted into load-bearing structure
• Distributed electronics for flight-control feedback and
structural health monitoring
Future
Potential for
Potential for
• Part Consolidation
• Simplified manufacturing
• Lead-Time Improvements
• New sensing capabilities
• Performance Benefits
• Improved system performance
Raytheon
Future
• Information Overload
• Missed Intelligence
• Threat/Danger Missed
Direct RF-Optic
Integrated Power
harvesting, storage,
• Robust electronics in extreme
and management
environments (shock,
vibration, thermal)
Expected 1.5X – 3X
increase in flight endurance.
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Integrated Computational Materials
Engineering
Integrated Computational Materials Engineering (ICME) is the integration
of materials information, captured in computational tools, with engineering
product performance analysis and manufacturing-process simulation.
Emphasis on “I” and “E”
Manufacturing
Process Models
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Game Changing NanoTechnologies
- Ordering-Up Performance for Aerospace Dominance -
Nanotechnology1 Today’s Nano-enabled Aerospace Products2
Controlling materials from 1-100 nm Infrared sensors with enhanced sensitivity and range
Nano-Enabled
Processing Performance
Properties
materials on-demand Optical filters to protect the pilot from lasers
Structure
Integrated ISR
AFRL “Nano” Program1
$500K $4M $30M
Human Performance
Commercial3
$731B revenue3
From NanoTechnology to Technologies Exploiting Nano 32
SUMMARY
AFRL is a funding agency of world-class
aerospace R&D
AFRL is a world-class aerospace laboratory
with opportunities to partner and collaborate
AFRL has a vision for future technologies to
enable national defense & competitiveness
– Additive manufacturing
– Integrated Computational Materials Science and
Engineering (ICMSE)
– Hypersonic technologies
– Autonomy
– Directed energy
– Nano science and technology
Questions?
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AIR FORCE RESEARCH LABORATORY
Mission
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Materials and Manufacturing
Directorate… A National Asset
100 nm
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