Manufacturing Technology facilities

Advanced Fan Development Facility

Philadelphia, PA

Airflow measurement. Pressure measurements. Laser Doppler velocimetry. Flow visualization. Turbulence intensity. Autocad. Evaluation of commercial and MIL-SPEC fans for rating.

Automatic Test Equipment Lab

Picatinny Arsenal, NJ

The Automated Test Systems Division (ATSD) has assembled facilities to support the on-site development of Test Program Sets (TPS) for Weapon Systems. The facility occupies over 13,000 sq. ft. and houses over eighteen million dollars of equipment and material. The facility houses and utilizes the following Automatic Test Equipment (ATE) platforms: IFTE V3, IFTE V5, Aurora (Mantech VTS-1000), Marine Corp TETS, ADADS, AN/USM-410 EQUATE, AN/USM-465 (Genrad 2225A), DSESTS, Huntron, and DIT-MCO.

Calibration Laboratory and Repair

Seal Beach, CA

The Seal Beach Navy Calibration Laboratory (NCL) is a certified Type III laboratory operating in two geographical locations in Southern California. Our primary site is located at Seal Beach and a satellite site is located at Fallbrook. We provide quality fast turn-around calibration and repair services of electronic, physical, and mechanical test equipment and systems.

Energetics Manufacturing Technology Center

Indian Head, MD

Energetics include propellants, explosives, pyrotechnics, and reactive chemicals are critical to the performance and reliability of all weapon systems and, therefore, crucial to our Nation's defense. Applications include missile and rocket propulsion, stores separation, warheads, mines, mine/obstacle countermeasures, flares, decoys, fire suppression, and aircrew escape.

Experimental Fabrication Facility

Aberdeen Proving Ground, MD

Hot Air Decontamination Facility

Picatinny Arsenal, NJ

This facility provides for an environmentally compliant way to decontaminate scrap metal at ARDEC and provides a means of safe disposal/recycling. The 1350 cu ft oven is utilized to decontaminate metal/process equipment that has been exposed to energetic material. Per Army Decontamination Regulations, the XXX (3X) contaminated metal is elevated and maintained at temperatures over 500ºF for a period of 3 hours. This controlled heating process destroys the energetic contamination on the metal/equipment. This facility provides the Army with ability decontaminate material to a certifiable XXXXX (5X) contamination level by ARDEC Safety Office. It can decontaminate equipment with little to no disfiguration for safe reworking/welding/disposal, depending on type of metal and equipment configuration.

Instrumentation Development

Aberdeen Proving Ground, MD

Manufacturing Complex

Lakehurst, NJ

Navy Lakehurst has a 240,000 sq ft prototyping and manufacturing complex with over 300 computer controlled and conventional machines and 130 expert machinist, welders and trades artisans. Capabilities, in addition to machining and welding, include fabrication, electronics, heat treating, wood, fabric, plastic, packaging and preservation.

Mission Support Facility

West Bethesda, MD

The Mission Support Facility provides the industrial facility support (machinery and personnel) for machinery and support system fabrication. This includes structural, piping, high and low pressure welding, instrumentation, electrical and machinery installation/alignment.

Nanotechnology and Characterization Laboratory

Picatinny Arsenal, NJ

The facilities include a wide range of apparatus for production, potential scale up and characterization of nanostructures. Facilities for production of nanostructures includes: a chemical vapor deposition oven system for production of carbon nanostructures, radio frequency generated plasma systems to scale up production of metal nanoparticles, rapid expansion of saturated solution (RESS) of fluids for production of nanocrystals, as well as facilities to chemically make and coat metal nanoparticles in oxygen free environments.

New Equipment Training Center-Video Production Center

Picatinny Arsenal, NJ

Audiovisual Production Specialists prepare training/marketing media (CDs, DVDs) to include script writing, storyboarding, shooting, editing and final production preparation with narration and music. Video Production Capabilities:

Non Destructive Evaluation Facility

Picatinny Arsenal, NJ

This facility is used to nondestructively evaluate a wide variety of products and materials. Nondestructive Evaluation (NDE) is the examination of an object or material with technology that does not affect its future usefulness. NDE can be used without destroying a product or material. Because it allows inspection without interfering with a product's final use, NDE provides an excellent balance between quality and cost-effectiveness.

Physical Vapor Deposition Laboratory

Picatinny Arsenal, NJ

The PVD Research Facility can deposit refractory metal coatings on flat samples as well as cylindrical samples up to 12 in. long. The facility is currently being used to develop thick, refractory metal coatings for large caliber gun barrel sections. These coatings are subsequently characterized using a rigorous coatings characterization protocol. A novel “lock-lock” design has been integrated into this facility in order to perform thin film depositions with rapid turnaround. The “load-lock” design, coupled with our excellent characterization capabilities, enables the rapid optimization of coating properties including adhesion. This facility can also be utilized to perform PVD research for the aerospace, automotive, pressure vessel and piping, and chemical processing industries.

Potting and Encapsulation Facility

Picatinny Arsenal, NJ

In the potting and encapsulation facility, Engineers and Technicians have the ability to utilize specialized epoxy potting compounds and encapsulation materials. With combined experience of more than 75 years and a variety of compounds at their disposal, molding technicians are experienced in assembling and potting complex molds and black boxes. Our engineering team possesses an extreme proficiency in the design and qualification of devices and assemblies for High-G survivability and operation.

Primer and Tracer Laboratory

Picatinny Arsenal, NJ

The Primer & Tracer Laboratory allows for the development, integration and testing of new energetic formulations for primers and tracers for all calibers of ammunition (.22 caliber through 155mm).

Product Development Lab

Picatinny Arsenal, NJ

Prototype Fabrication Facility

Panama City, FL

The Mechanical Engineering and Prototype Fabrication Division maintains and operates the Prototype Fabrication Facility for the benefit of DOD customers. The facility is primarily used by mechanical engineers within the division developing proof-of-concept prototypes in support of all Station programs. It consolidates several shop functions into one modern, efficient building, providing climate control for high-tech and high-precision fabrication equipment as well as access to waterfront project assembly areas and Gulf testing platforms.

Pyrotechnic Pilot Manufacturing Facility

Picatinny Arsenal, NJ

This facility, in conjunction with the Pyrotechnic Laboratory, encompasses the entire range of R&D; related to pyrotechnic formulations and items including both processing and testing capabilities. Processing is done at the small pilot plant level and includes mixing, granulation and drying of pyrotechnic composition and consolidation and loading of powder into items. Test capabilities access the thermodynamic, kinetic, physical and storage stability characteristics of pyrotechnic compositions using assorted equipment. In addition, a flare tunnel with the most current equipment and instrumentation is used to measure the burn time, radiometric, photometric and spectral characteristics of a wide range of pyrotechnic items. This facility can provide quick development of novel pyrotechnic items and transition to production.

Radiological Analysis & Development Facility

Picatinny Arsenal, NJ

This facility is used to nondestructively examine items including explosives, and to investigate automated, real-time radiographic technology including neutron radiography, a 25-million volt (Mv) x-ray, image analysis, neural network, and computed topography systems. Shown here is the 2 Mv Linetron that generates x-ray beams with a selection of energies from 1 to 2 Mv and is indispensable in the radiographic examination of mid-range, high explosive ammunition (40mm through 105mm). It is useful in examining a wide range of items including fuzes, flares, rocket motors, and shells up to 155mm. These inspections are necessary to detect critical defects, such as cracks and voids in explosives and propellants and missing or improperly assembled parts in fuzes. The 180° panoramic X-Ray beam available from the 2 Mv system is put to maximum advantage through the use of a continuous, carousel-type conveyor. This heavy, precision-built system carries the items being inspected and X-Ray films through the X-Ray beam on a continuous basis without vibration or adverse motion. It permits the processing of large quantities of items in relatively short periods of time. The facility includes solid concrete walls two feet thick and 15 feet high, accommodating munitions items containing up to 5,000 pounds of explosives

Rapid Prototyping Facility

Panama City, FL

The Rapid Prototyping Facility utilizes a 3-D Systems Model SLA 3500 stereolithography machine for rapid prototyping of mechanical models. The process takes CAD files and creates high quality plastic parts using a laser to "draw" the cross-sections on the surface of a photo-curable resin. Maximum model size is 14-inch x 14-inch x 16-inch, but portions of models may be bonded together to create larger versions. The facility is operated by two mechanical engineering technicians who provide expertise in preparing CAD databases for prototyping and finishing the final products.

Rapid Prototyping Laboratory

Picatinny Arsenal, NJ

The ARDEC Rapid Prototyping (RP) Laboratory was established in December 1992 to provide low cost RP capabilities to the ARDEC engineering community. The Stratasys, Inc. FDM 3000 and 3D Systems, Inc. SLA-250 and SLA-3500Stereolithography Apparatus' are the workhorses of the Lab. This equipment makes it possible for engineers to rapidly acquire prototypes produced directly from their 3-D CAD models, hence reducing the time and cost associated with the design and evaluation of new munitions and weapons systems, as well as, improvements to existing systems in the field. Typical applications are:

Rotary Forge

Picatinny Arsenal, NJ

Cannon tube forgings are conventionally produced by press forging an ingot into a solid cylinder with approximate external dimension. Rotary forging produces hollow cannon tube forging, with dimensional control comparable to a machined press forging. The process has produced over 28,500 tubes in the lO5mm, l2Omm, and 155mm bore sizes. A heated preform is automatically transferred to the rotary forging machine, where it is automatically forged into a hollow tube, using numerical control. The machine uses a mandrel to control the internal diameter and four concentric hammers, with a capacity of 1100 tons force each, to shape the outside diameter. Tubes are forged in 8-12 minutes, employing two people. Conventional press forging would require 30 minutes and a crew of 5-6 people per tube.

Soldering Technology Laboratory

Picatinny Arsenal, NJ

As part of the Electronics Prototyping and Manufacturing Mission, of the Electronics and Prototyping Branch, the Semi-Automated, Surface Mount Technology (SMT) Soldering System greatly enhances the reliability and repeatability of the SMT soldering process. The design and function of the system is ideal for small-batch and test-run manufacturing, rework, and component replacement. Being operator-controlled, the system allows for rapid set-up, adjustment, and modification, in addition to being easily maintained. The system is fully capable of utilizing either solder paste "tack" or adhesive methods of component-to-board retention prior to soldering. Dedicated, recirculating air filtration is utilized to negate the need for outside venting of the soldering process.

Stereolithography Rapid Prototyping Facility

Newport, RI

NUWC Newport has two stereolithographs that use computer-generated solid model data to produce complex three-dimensional plastic parts in a fraction of the time usually needed for manufacturing. Parts are built by tracing one cross section of the model in a vat of liquefied resin using a laser beam. When the cross section is complete, the part is lowered and the next cross section is drawn. The process is continued until the part is complete. Complex shapes are easily and rapidly produced from several alternate resins. Close tolerances, smooth surface finishes, and relatively high strengths can be achieved, depending on the resin selection.

Technical Engineering and Calibration Laboratory

Hanover, NH

Tool Control Facility

Lakehurst, NJ

A facility to design, develop and stage customized toolboxes and documentation for critical maintenance of navy aircraft and SE. Contains unique integrated hardware/software to digitize toolkit configurations allowing rapid design updates. Hardware includes MasterCam workstation for design data, waterjet cutter for custom fabrication and a laser etch system for parts identification.

Tribology Test and Evaluation Laboratory

Wright-Patterson AFB, OH

Twin Screw Mixer/Fine Grind Facility

Picatinny Arsenal, NJ

The 40-mm Twin-Screw Mixer/Extruder (TSE) pilot plant is a continuous, remotely operated, flexible facility that can significantly enhance safety and environmental considerations during the processing of energetic materials. Personnel exposure to hazardous operations is substantially reduced, and equipment is in-place to recover solvents utilized during material processing. The facility is available to support a broad spectrum of mission-related Research and Development including new propellant, explosive and pyrotechnic formulation development, and insensitive munitions. The pilot scale TSE is co-rotating with fully intermeshing screw elements acting as a continuous mixer and compounder capable of continuously producing up to 50 lb/hr of energetic material. The facility is currently being operated to support a Life Cycle Pilot Process effort to demonstrate and validate a safe and reproducible process for the manufacture of black powder. Future work includes continuous processing of fast-core (GEN-2) propellants in support of the Future Combat System (FCS).

Vessel Plating Facility

Picatinny Arsenal, NJ

This facility was developed specifically to deposit high performance bore coatings inside long gun tubes. It can accommodate cylinders up to 26 feet in length and studies can be conducted on fluid dynamics in turbulent annular flows with strong magnetic fields causing heat and mass transfers. This facility is unique in that the cylinder whose interior is being plated actually serves as the plating vessel. This process negates the need to submerge the entire object into a potentially corrosive salt bath. The ends of the cylinder are capped and the plating solution is pumped through the cylinder. This is extremely effective in plating cylindrical objects when only the interior requires plating or the exterior cannot tolerate plating.

Vibration Testing & Analysis Support Facility

Philadelphia, PA

Maintaining several complete vibration data acquisition systems for supporting in-house/land-based and shipboard testing. Evaluation of new mounting/attachment techniques: accelerometers, mounting disks, and adhesives. Low noise cable fabrication. Maintaining several data/signal analysis and reduction systems for supporting in-house/land-based and shipboard testing. All vibration data acquisition equipment located and developed in the facility.

Welding and Production Metallurgy Facility

Picatinny Arsenal, NJ

This 6000 square foot facility represents the only welding laboratory of its kind within DA. It is capable of conducting investigations associated with solid state welding, overlay as well as other arc welding-related technologies. A new concept overlay band machine enables investigators to apply overlay rotating bands to projectile bodies of non-conventional design. The facility also features a state of the art production machine.

Welding Process and Consumable Development Laboratories

West Bethesda, MD

The Welding Process and Consumable Development Laboratories are a complete welding capability consisting of an Arc Welding laboratory (welding process development; weld simulation; weldability evaluation; and welding sensors and robotics); and a Welding Consumable Development laboratory (electrode production and wire fabrication prototype; flux evaluation; and moisture evaluation).