Success Story records

AFRL Improves CFD Analysis Methods

AIR FORCE RESEARCH LAB

AFRL and Aerosoft, Inc., developed a post-processing tool that gives engineers a better way of analyzing solutions obtained using computational fluid dynamics (CFD). This new analysis method provides a greater understanding of CFD results at a fraction of the cost of traditional methods.

AFRL Blast Protection Experts Enhance Blast Resistant Window and Glazing Technologies

MATERIALS & MANUFACTURING DIRECTORATE

During recent conflicts, the United States has seen a dramatic increase in the use of improvised explosives as methods of warfare and terrorism. The AFRL Materials and Manufacturing Directorate's Force Protection Branch, located at Tyndall AFB, FL., is pursuing blast mitigation technologies for buildings and expeditionary structures that will help minimize the casualties caused by a terrorist explosive attack. This type of technology is particularly important because the vast majority of injuries and fatalities caused by an explosive are the result of flying glass and wall debris. ML's Range Operations and Support Group has two reaction structures at Sky Ten with the capability to expose up to eight windows and/or wall systems at one time to a 1,000 pound TNT charge. The Range Control building on site is a hardened concrete structure which protects researchers, visitors and data acquisition equipment during detonations. Range Control is a two minute walk from the detonation site and has multiple live video feeds with vantage points outside and inside the reaction structure. Trials executed at the range are monitored and controlled from a master control board with over 100 channels available for recording critical scientific data during and after explosive detonation. In addition, the trials are also visually recorded using high-speed digital and traditional video which is edited to provide researchers with another tool to analyze results.

Port Security Barrier Technology

NAVAL FACILITIES ENGINEERING SERVICE CENTER

The Port Security Barrier System is a fencing barrier system designed to protect ships and port facilities. The system consists of a floating fence constructed of a synthetic net with a steel base, and is moored with deadweight anchors. The barriers can have a gate, or multiple gates, that can be opened and closed by security personnel. From concept to steel prototype, the process for the current barrier design took approximately eight months. NFESC tested the barrier designs in wave tanks at the U.S. Naval Academy, building 1:56 and 1:10 scale models in which the barriers were put through the worst-case environmental conditions. A full-scale test with a 38 foot remote control boat was used, and the data was studied carefully using numerical modeling techniques. The net result was a demonstrated effectiveness against high-speed boats, and proven in-water operational performance with a simple, low cost design. Each fence is specifically designed for each location. It rises eight feet above the water surface. HOI will continue to modify and improve this technology to create the best port barrier system available.

Oil Spill Early Detection and Warning

SPAWAR SYSTEMS CENTER, PACIFIC

To control damage caused by oil spills, an immediate and effective response is required. However, before any response can be mounted, the spill must be detected and responders notified. To address this need, five environmental scientists from the Space and Naval Warfare Systems Center (SSC) in San Diego developed the “Underwater Spectroscopic Detector” that provides rapid, reliable spill detection. The invention includes fluorescence-based sensors deployed just below the water to detect increased hydrocarbon concentration. When detection occurs, a radio signal is transmitted to a base station computer and designated responders are alerted via an automated phone call. SSC San Diego entered into a licensing agreement with Applied Microsystems, a company that designs and manufactures water quality monitoring instrumentation. Applied Microsystems was able to integrate the new technology into an oil spill early warning system called Spill-Sentry. The system includes spill detection buoys for deployment in the field and a PC-based reporting/coordinating station. Buoys communicate with the base station via cable, radio or satellite and transmit data at user-defined intervals. Data are then analyzed to determine if a spill has occurred. If a spill is detected, automatic alarms notify the appropriate personnel to respond.

Differential Pressure Flow Sensor Technology

NAVSEA INDIAN HEAD

An engineer at the Naval Sea Systems Command (NAVSEA) Indian Head Division developed a differential pressure flow sensor to measure the speed of submarine-launched torpedoes. Wickford Technologies realized that the invention had multiple uses in the commercial arena, and signed an exclusive contract with the Navy to produce the sensor. The device is most easily adapted for use by sailboats. Wickford's first market for the sensor is racing sailboats that need to measure flow of water to determine speed.

Integrated Circuit Design and Fabrication Technology

SPAWAR SYSTEMS CENTER, SAN DIEGO

Integrated circuits are the hearts and brains of computer hardware that provide command, control, communications, computers, intelligence, surveillance and reconnaissance (C4ISR) capabilities. Designing and fabricating such circuits is part of the mission of the Space and Naval Warfare Systems Center (SSC) in San Diego, CA. One use of such circuits is for electronic display of information. Reducing the size and weight of such circuits, as well as the number of required electronic connections, is important. Three SSC San Diego scientists patented a new integrated circuit that produces an extremely bright micro-display, while eliminating millions of interconnections between the display and its control circuitry. The work advanced under a Cooperative Research and Development Agreement between Optron Systems, Inc. and SSC San Diego. The goal is to offer improved imaging and video in virtual presence applications for the warfighter. Radiant Images, Inc., a spinoff from Optron Systems, Inc. formed to commercialize a high-resolution color display for Naval use. This technology also promises dual-use applications for emergency service personnel such as law officers, firefighters and paramedics, who can utilize imaging systems in the field to provide situation assessment updates as they work to contain emergencies.

Genomic Sequence of the Human Malaria Parasite

NAVAL MEDICAL RESEARCH CENTER

The Naval Medical Research Center provided expert scientific guidance and leadership in collaboration with an international group of genome centers and funding agencies in publishing the complete genomic sequence of the human malaria parasite, Plasmodium falciparum. The completion of the malaria genome was recognized by Science as the third most important scientific breakthrough of 2002. The Malaria Genome Project provides the complete blueprint of one of the world’s deadliest infectious diseases, as well as a major threat to U.S. military forces.

Advanced Solid State High Repetition Rate Modulator

OFFICE OF NAVAL RESEARCH

Diversified Technologies Inc.(DTI) adapted its patented high-power, solid-state, modulators and control systems to develop the Navy’s AN-SPG/60 fire control radar upgrade kit. The kit modernizes the radar’s transmitter section by replacing older vacuum tube devices with high voltage switching modules, gate drives, and interface electronics. The kits are currently installed and operating in the US Navy fleet with a similar program for the AN/SPQ-9A radar soon entering production.

SeliTherm Therapeutic Warming System

NAVAL MEDICAL RESEARCH CENTER

SeliCor, Inc. developed and produces the SeliTherm therapeutic warming system. The system is based on recently patented technology developed by the U.S. Navy's Naval Medical Research Center and licensed exclusively to SeliCor. The heart of the Seli Therm system is a helical coil design. This system combines traditional radio-frequency diathermy, a widely accepted means of delivering therapeutic warming, with an all-new mode of delivery. The result is a medical device that makes core warming of deep body-tissue easier, safer, more effective, and more economical than ever before. Initially, the product will be available only to clinicians, but because it is exceptionally easy and safe to use, the system will eventually be made available directly to patients by prescription for in home use.

Fiber Optic Technology

NAVAL RESEARCH LABORATORY

CorActive High-Tech Inc. recently signed a partially exclusive patent license agreement and a Cooperative Research and Development Agreement with the Naval Research Laboratory focusing on the commercial manufacturing and future development of NRL’s infrared fiber technology. The work was conducted at NRL by a research team headed by Drs. Ishwar Aggarwal and Jas Sanghera. NRL’s partner, CorActive Inc., is an independent developer and manufacturer of advanced Specialty Optical Fiber products for customers in the telecommunications, sensor, defense, and security, industrial, medical and aerospace industries.

Plasma Arc Waste Destruction System

NAVSEA CARDEROCK

The Carderock Division of the Naval Surface Warfare Center (NSWCCD) and PyroGenesis developed a Plasma Arc Waste Destruction System (PAWDS) for shipboard use. The use of NSWCCD and PyroGenesis technology resulted in an efficient and compact design with the ability to dispose of a vast variety of unsorted ship garbage unlike any existing shipboard incinerator. PAWDS operates at extreme temperatures so that combustion is almost complete with very little pollutants exhausted into the environment.

Advanced Concepts in Hull Array Beamforming

NAVSEA CARDEROCK

Applied Hydro-Acoustics Research, Inc. (AHA) has developed a new sonar beamforming technique for the Navy surface combatant hull-mounted array. The technique consists of a new method for adaptive beamforming (ABF). The Short-Time Adaptive Broadband Beamformer (STABB) algorithm differs from traditional ABF techniques by operating over a broad frequency range and having the ability to rapidly respond to changes in the acoustic noise field. The rapid adaptation characteristic enhances performance in the face of active reverberation and close-aboard fast moving targets.

Remote Fiber Optic Sensors for Gaseous and Liquid Environments Based on Surface Enhanced Raman Spectroscopy

OFFICE OF NAVAL RESEARCH

Raman spectroscopy provides a unique fingerprint of the vibrational modes of a substance, and is similar to infrared spectroscopy in this regard. However, unlike infrared, Raman employs visible or near-infrared laser light to address the sample that is efficiently transmitted over conventional silica optical fibers. Cables up to 200 meters long have been employed with limited signal loss. This capability is a result of a compact sampling probe with microoptical components, developed and patented by EIC Laboratories. The RamanProbe™ probehead eliminates Raman scattering originating from the silica fiber optics and completely filters the laser wavelength prior to detection. A further feature of this probe is that it focuses the laser light several millimeters past the probe tip. This allows high quality Raman spectra to be obtained through the walls of transparent and translucent containers with little interference from the container materials themselves (e.g., glass, polyethylene, brown glass, etc.).

Advanced Modular Gun Design

NAVSEA DAHLGREN

Applied Ordnance Technology (AOT) has developed a high velocity, high pressure, large caliber test gun that incorporates a separable chamber using AOT’s extended Long Range(XLR) gun design. AOT’s objective is to provide the Navy with the Advanced Modular Gun Demonstrator, a test and evaluation gun based on the XLR design, that is capable of testing advanced gun technologies. The XLR gun was developed in conjunction with Advanced Power Technology, Inc., and offers an innovative approach to loading, chamber sealing, chamber/barrel connection and recoil. The design consists of a high-velocity, smoothbore gun incorporating multiple separable large-volume chambers and a segmented barrel. The key innovation involves the use of a separable chamber bridged by a single-use chambrage sealing cartridge in a high pressure, large caliber gun. The development of the XLR Gun recently advanced with the successful evaluation of the chambrage sealing cartridge in a sub-scale Proof of Concept test at a 60,000 psi chamber pressure. AOT is currently working on a full-scale, full pressure test to evaluate the separable chamber in a relevant gun environment.

Collision Avoidance Systems for the Expeditionary Fighting Vehicle

MARINE CORPS SYSTEMS COMMAND

Enhanced maneuverability in the littorals in the presence of both natural and man-made hazards is an essential requirement for executing the Ship to Objective Maneuver. Maneuverability of the Expeditionary Fighting Vehicle (EFV) can be significantly enhanced by integration of an on-board, real time collision avoidance system (CAS). Areté Associates has demonstrated the utility of a grazing incidence lidar (optical radar) to detect floating obstacles, shallow bottoms, and submerged targets at significant standoff ranges. The CAS will be demonstrated on the EFV.

High Speed, Dual-Mode Missile Radome (HiSMR)

NAVAIR PATUXENT RIVER

As the Navy continues to make communications advancements, antenna bandwidth requirements increase. With the use of higher frequencies and higher missile speeds, the housing of the antenna, called the radome, must meet new materials challenges. The radome must maintain mechanical and electrical properties at higher temperatures. ATK Composites has developed Ceramic Matrix Composite (CMC) materials that show an excellent combination of electrical, mechanical, and erosion-resistance properties suitable for radome structures that can experience temperatures up to 2500°F.

Multiple Mode Noncooperative Hard Target Identification LADAR Systems

NAVAIR CHINA LAKE

Coherent Technologies, Inc. (CTI) has developed a new laser source that identifies difficult targets at extended distances. This first-of-its-kind transmitter utilizes innovative 1.5 micron wavelength eyesafe laser technology. The transceiver architecture is best utilized in long range detection and noncooperative target identification (NCTID) via microDoppler vibrometry. An innovative compact diode-pumped solid-state laser is used to drive a coherent injection-seeded solid-state Raman ring resonator that produces adaptive waveforms to optimize sensor performance for a given target. The success of CTI’s laser technology has resulted in multiple Air Force follow-on contracts to mature the technology and to provide comprehensive studies for advanced tactical airborne applications.

Aircraft Weapons Bay Flow Simulation Model

NAVAIR PATUXENT RIVER

An internal aircraft weapons bay, when exposed to freestream flow, experiences an intense aero-acoustic environment in and around the bay with loads as high as 160 to 180 decibels. High acoustic loads significantly reduce the life of aero-structures in the bay and damage sensitive electronic components. These loads disrupt the store separation process by inducing unfavorable moments on the store. Aircraft design engineers have been challenged to develop innovative suppression methods to control the acoustic environment in the weapons bay. Further, control of the aero-acoustic environment surrounding cavities exposed to high-speed flows has been the subject of several recent investigations. CRAFT Tech has developed a Hybrid Reynolds-Averaged Navier-Strokes Large Eddy Simulation (RANS-LES) model for the prediction of weapons bay aero-acoustics. The technology has aided in the design of control systems to minimize dynamic loading on the weapons bay structures and ensure the safe separation of stores for naval platforms.

Autopilot Development for Micro Air Vehicles

AIR FORCE RESEARCH LAB

During 2003, AFRL contracted Procerus™ Technologies to develop the Kestrel [version] 1.45 autopilot. This unit included features to enable autonomous flight, a data link interface, three servo position commands, and a Global Positioning System (GPS) input interface. It weighed 40 g and test-flew in UAVs weighing under 1 lb. In 2004, Procerus created the Kestrel 2.0 autopilot, a more capable autopilot weighing just 16.7 g. The Kestrel 2.0 autopilot includes the sensors and interfaces required for a functional and easy-to-use UAV. The unit’s three accelerometers, three temperature-compensated rate gyros, GPS interface, pressure transducers for airspeed and altitude, and four servo outputs enable autonomous flight with GPS navigation. A modem interface allows users to upload new waypoints and download sensor data. Engineers made provisions for an integrated payload system by including payload communication and control and supplying electrical power at 3.3 V and 5 V.

AFRL Provides World-Class Virtual Flight Support

AIR FORCE RESEARCH LAB

AFRL provided world-class virtual flight test support during an evaluation of a promising Global Positioning System antijam technology called Beamstar, an enabling technology with direct application to the Electronic Systems Center Joint Precision Approach and Landing System program. AFRL researchers successfully completed the 3-week test program under a Cooperative Research and Development Agreement with Radix Technologies, Inc. Beamstar is a candidate technology for several high-visibility Department of Defense programs that require highly robust, highly accurate position information for automated aerial refueling and land/sea aircraft landings.

Low-cost Lightweight, Night Vision Capability for Hand Launched UAV System

NAVAIR CHINA LAKE

Bodkin Design & Engineering, LLC (BD&E;) developed the world's first miniature uncooled infrared camera. The Infrared Microcam provides high-resolution thermal images that equal those available from costly cryogenically cooled cameras. The lightweight sensor head (3" x 3.9" x 3.2" weighing 7.0 oz.) uses a high resolution (320 x 240 pixel) uncooled focal plane array. This microbolometer array operates at room temperature, eliminating thermal stress and the cooler's power drain. The camera has no moving parts, making it highly reliable and compact. Its patented tethered sensor head permits it to be placed in smaller spaces than previously possible, thereby enabling new applications for thermal imaging. Designed for and demonstrated on the Hand-Launched Pointer UAV (Unmanned Aerial Vehicle), the camera's compact rugged design, low power drain (4.5 watts), and wide operating temperature range (-20 to 60 °C.) enables its use across a wide range of demanding environments. The highly sensitive camera responds to temperature differences smaller than 0.1 °C, and captures video-like imagery at high frame rates (30Hz) without blooming, blurring, or trails.

Biometric Security Systems

ARMY RESEARCH OFFICE

Current commercially available biometric systems are not accurate or robust enough to meet the demanding requirements of a field deployable, tactical-grade identification system for mission critical security applications. The solution developed by Ultra-Scan Corporation utilizes the proven effectiveness of ultrasonic fingerprint imaging technology pioneered by Ultra-Scan to simultaneously image and match two adjacent fingers for rapid and positive identification.

All Digital Receiver

OFFICE OF NAVAL RESEARCH

HYPRES has produced the world’s first All Digital Receiver (ADR) based on Superconducting MicroElectronics (SME). ADR is designed to demonstrate the ability to directly digitize and process multiple Joint Tactical Radio System (JTRS) waveforms simultaneously from a single wideband digital sample, at an extremely high speed (40 GHz). HYPRES calls this process "Digital RF" as it combines for the first time, analog-to-digital and digital signal processing on the same device, running at the same 40 GHz clock speed. SME technology exceeds the processing capabilities of the best semiconductor analog-to-digital technology and greatly improves the performance of the JTRS and other military communication systems. The research was accomplished in collaboration with the State University of New York at Stony Brook, and other leading universities.

Natick Develops Power-Generating Textiles Through Photovoltaics

NATICK SOLDIER SYSTEMS CENTER

Photovoltaics (PVs) have been known for many years as a promising technology that converts (“free”) light energy into electricity with no noise, moving parts, fuel consumption or pollutant emissions. Natick Soldier Center (NSC) has been developing new lightweight and conformal solar cells through an Army Science Technology and Objective (STO) program. The development of a new and very promising dye-sensitized nanocomposite PV technology is at the forefront of this program. The technology is based on light-harvesting dyes that are adsorbed onto titanium dioxide nanoparticles

Vein Viewing Technology Provides Life Saving Imagery For Battlefield Wounded

AIR FORCE RESEARCH LAB

Scientists from the Air Force Research Laboratory Materials and Manufacturing Directorate (ML) have invented, developed, patented and licensed a breakthrough medical technology, a Vein Viewing device that can be used to see beneath the skin and through body sections to show the vasculature, the network of blood veins in the body, in a broad range of lighting conditions. Due to the technology's potential for a broad range of civilian medical uses, ML established a Cooperative Research and Development Agreement (CRADA) with InfraRed Imaging Systems (IRIS) Inc., of Columbus, Ohio, to manufacture and market the technology to the medical industry, and to expand the technology to solve other critical medical challenges. IRIS has gone on to further develop the technology and create a product, the IRIS Vascular Viewer, for commercial release.

Intelligent Power Management System (IPMS)

ARMY CERDEC - FORT MONMOUTH

The IPMS provides an automated monitoring and control capability for load management in Army shelters and vehicles, especially those found performing command and control missions. A flexible architecture for intelligent power management suitable across multiple vehicle or shelter platforms, IPMS provides on-the-fly intelligent circuit breaker functionality and system-level load management based on set priorities. Additional investment in IPMS and related technology developments as a direct result of transition from Phase II to Phase III now totals over $9.4M. The first Phase III commercialization success involves a contract for Customs Manufacturing & Engineering, Inc., CME to conduct System Development and Integration Testing of robust IPMS implementations for Program Manager Tactical Operation Centers (TOC) and Product Manager Platforms. These common IPMS implementations are being fully integrated into several platforms found in the Standardized Integrated Command Post System (SICPS) configuration.

AFRL Applies Voice Recognition Technology to Aircraft Maintenance

AIR FORCE RESEARCH LAB

Applying voice recognition and activation technology to the aircraft maintenance environment increases the accuracy of data, decreases the time required to input data, and ultimately enhances the effectiveness of technicians. Improved data accuracy means that historical maintenance data becomes more meaningful and useful for analysis purposes. In terms of time and effectiveness, voice recognition and activation technology dramatically decreases the time it takes a maintainer to document maintenance actions, ensures the timeliness of status information, and often decreases the manpower needed to complete particular maintenance tasks.

Army Sergeant’s Inspiration Leads To Battlefield Medical System

ARMY MEDICAL RESEARCH AND MATERIEL COMMAND

Army medic Sgt. Tommy Morris was frustrated as he sat on a rocky hillside in Macedonia in 1993. Faced with keeping track of medical information on his warfighters, keeping up his stock of supplies, and hauling around heavy medical texts, he kept thinking to himself, “There has to be an easier way.” On the battlefield, it is crucial for first responders to have current medical information at the point of care. Soldiers were getting injured or sick for various reasons, and none of that information was captured unless the service member received care at a combat support hospital. Thus, Sgt. Morris created the BMIST. The BMIST is a point-of-care diagnostic tool for first responders. It captures basic data from a medical encounter. Medics put in the symptoms, and BMIST comes up with a treatment plan based on the user’s skill level.

Army Medical Researchers Invent Vaccine to Fight Anthrax

ARMY MEDICAL RESEARCH INSTITUTE OF INFECTIOUS DISEASES

Anthrax is considered the No. 1 biological weapon threat. It can be transmitted through inhaling the spores, a cut in the skin, or eating contaminated food. Inhaled anthrax is by far the most hostile form, with 90% or greater of these cases resulting in death. In 2001, five Americans died from anthrax inhaled from contaminated mail. Anthrax infection can be cured with antibiotics, but in cases of the inhaled form, by the time symptoms appear it is often too late to treat the patient.

Commercialization of Composite Structure Design Technology Moves Toward Broad Industry Use

AIR VEHICLES DIRECTORATE

Officials from the Manufacturing Technology (ManTech) Division, and the Air Vehicles Directorate, announced recently that key structural analysis software developed under the Composites Affordability Initiative (CAI) team banner, will be commercialized by ABAQUS, Inc., ensuring the long-term viability of the government/industry investment in advanced structural analysis tools. Typical finite element analysis has been used to predict where and under what conditions a structure will fail. In order to increase the confidence to use advanced composite structural designs (being matured under CAI), improvements to this predictive capability have been successfully pursued. However, initial failure of a structure is not the only concern. Users are also concerned about how the damage will progress in order to understand the full impact of damage and the durability of the structural design. The Virtual Crack Closure Technique (VCCT) was developed by Boeing under contract with the CAI team. VCCT plays an important role by providing unprecedented capability for the design of aerospace structures involving composites. Under ManTech leadership, Boeing developed, refined and proved the VCCT approach for predicting the reliability of major composite structural components over the past several years. Boeing and ABAQUS, Inc. have applied for a patent on VCCT. ABAQUS, Inc., will market the technology commercially.

AFRL Delivers C-17 Emergency Escape Door to Warfighter

AIR FORCE RESEARCH LAB

AAAI endeavors to streamline the design process by involving both the material manufacturer and the airframe manufacturer in all phases of product development. AFRL teamed with Alcoa, Boeing, Lockheed Martin, and Northrop Grumman with the ultimate goal to cut the installed cost of aluminum aerostructures by at least 50% and reduce associated maintenance requirements, achieving lower life-cycle costs while increasing performance. The C-17 escape door was the fi rst AAAI effort.

AFRL and Industry Partner Develop Braiding/Filament Winding Work Cell

AIR FORCE RESEARCH LAB

AFRL successfully executed several phases of a Small Business Innovation Research contract to develop an advanced multiaxis braiding/filament winding work cell. The technology work cell has proven its ability to cut costs and improve the efficiency of manufacturing processes that scientists use to enhance the durability and safety aspects of critical, primary, load-bearing jet engine structures.

AFRL and MDA Transfer Composite Gimbal Technology to HDTV Camera Systems

AIR FORCE RESEARCH LAB

AFRL and the Missile Defense Agency (MDA) funded efforts to develop lightweight, low-cost, composite gimbal technology to improve on-orbit and airborne pointing accuracy. These efforts resulted in the technology’s transfer to commercial high-definition television (HDTV) camera systems, two of which are in regular use. Six National Football League (NFL) telecasts and the 2005 Academy Awards employed the gimbal for their respective programs.

Enterprising Composite Design and Structural Analysis Tool deployed to Rotorcraft Industrial Partner

AIR FORCE RESEARCH LAB

AFRL researchers and their on-site contractor, the University of Dayton Research Institute (UDRI), developed a unique composite material design and structural analysis tool to provide design solutions, reduce design cost, and improve operations safety for military, industrial, and commercial helicopters and other rotorcraft. The new, laboratory-developed design and analysis tool provides rapid solutions early in the design process to assess component damage tolerance and has the potential to trim component risk reduction costs and schedules by as much as 50%. The new technology also enables mission enhancement improvements in certification and supportability. AFRL scientists, assisted by UDRI, developed the unique composite material design and structural analysis tool based on an analysis code known as the B-spline analysis method (BSAM). BSAM uses a revolutionary numerical approach to model solid mechanics problems. The BSAM software consists of evolving computer code that analyzes the three-dimensional stress behavior within a layered composite material. The software performs general-purpose solid mechanics analysis based on an innovative method of assembling B-spline approximations of deformation in a numerical format to efficiently solve complex mechanics problems.

Multi-Gas Analyzer (MGA)

ARNOLD ENGINEERING DEVELOPMENT CENTER

Using Small Business Innovation Research (SBIR) contracts Advanced Fuel Research, Inc. (AFR) conducted research and development on innovative optical designs, hardware designs, and software designs that resulted in a package of new technology that provides benefits to the Air Force. AFR developed the Multi-Gas Analyzer (MGA), based on extractive Fourier transform infrared spectroscopy, to simultaneously measure multiple chemical species in exhaust gases.

Lightning Protection Developed for Airborne Laser Aircraft

AIR FORCE RESEARCH LAB

A rotary lightning protection system (RLPS) was developed for the Airborne Laser (ABL) aircraft. The technology is a significant advancement over the current state of the art due to its minimal wear and particulate generation, low electrical noise production, and ability to perform well in extreme environments. Honeybee Robotics developed an RLPS for the ABL aircraft under a Small Business Innovation Research (SBIR) Phase I contract. AFRL awarded Honeybee an SBIR Phase II contract to further develop the technology for integration with the turret interface of ABL aircraft.

Silicon Lightweight Mirrors Developed for High-Energy Laser and Aerospace Systems

AIR FORCE RESEARCH LAB

Under the SBIR contract, Schafer Corporation successfully manufactured high-performance silicon and silicon carbide foam-core lightweight mirrors up to 13 cm in diameter, and is working on manufacturing mirrors up to 56 cm in diameter. Since larger mirrors have a much broader range of applications, Schafer plans to scale SLMS mirrors from 0.5 to 1.5 meters during the next 2 years. A second significant impact of SLMS technology is the athermal characteristic of these mirrors. The silicon surface of the mirror can be easily polished to a surface figure of 0.02 waves per RMS at 633 nm at room temperature and will hold that surface figure while operating at temperatures as low as 27°K. This means these lightweight mirrors are easier to manufacture for low-temperature applications and do not have to be actively cooled to prevent distortion, further reducing the weight of the aerospace system transporting the mirror.

AFRL Transistor Technology Results in Commercial Product Development

AIR FORCE RESEARCH LAB

AFRL and industry partner SemiSouth Laboratories, Inc., achieved a milestone in transistor technology and product development. They developed switching devices known as Harsh-Environment, Low-Loss Field-Effect Transistors (HEL2FET™), which offer electrical component manufacturers a line of switching devices with potential applications for motor drives, converters/inverters, and other electrical power equipment that has high-temperature operational requirements. The Air Force also has several power system requirements that this technology can satisfy, including electromechanical actuator motor drives to operate flight control surfaces, motor drives for fuel pumps, power modules, solid-state circuit breakers, radiation-tolerant power management and distribution components for space platforms, and integrated radar power supplies.

AFRL Reaches a Milestone with Vapor-grown Carbon Nanofibers

AIR FORCE RESEARCH LAB

AFRL and Applied Sciences developed nanofibers that simultaneously provide tailored electrical conductivity over a broad range and mechanical reinforcement for some composite matrix materials. The nanofibers typically grow to several tens of microns in length, but subsequent milling can reduce the length to fewer than 10 microns. The SBIR contract resulted in the modification of two nanofiber grades, PR-19 and PR-24. This result is due to a nondebulking process that preserves the length of the carbon nanofiber. PR-19 contains a chemical vapor deposition (CVD) layer and has a diameter of ~150 nm. PR-24 contains a minimal CVD layer and has a diameter of ~100 nm.

Packaging Techniques for Liquid Crystal Polymers

ARMY RESEARCH OFFICE

Individual Chemical Alarm System (ICAS)

MARINE CORPS SYSTEMS COMMAND

Smiths Detection - Pasadena developed a wearable personal protective badge that continuously monitors the atmosphere for chemical threats. The badge utilizes a low cost and low power nanocomposite sensor array to detect the presence of chemical threats in the air. The sensor array is rugged and the response is repeatable enabling multiple measurements. The sensor array is highly sensitive to chemical warfare agents and toxic industrial chemicals. The badge produces audible and visual alarms when a chemical threat is detected. The Marine Corps anticipates using this technology for personal protection.

Acoustically Intelligent Surfaces

ARMY RESEARCH OFFICE

Background noise in static and mobile headquarters enclosures presents a challenge to effective command and control within the Army’s Theaters of Operation. Fully equipped command and control shelters, both hard and soft walled, can become extremely noisy – to the point of jeopardizing control of current operations. Through the SBIR Program, QRDC, Inc. developed a unique energy and space efficient solution based on the development of Acoustically Intelligent Surfaces™ using Smart Skin technology. By adapting state-of-the-art proactive sound and vibration management technology into the walls of the shelters, sound energy is diverted and channeled to regions where it does not add overwhelming background noise.

Advanced Magnesium Corrosion Protection

ARMY RESEARCH OFFICE

Hydrogen Generation for Fuel Cell Applications

ARMY RESEARCH OFFICE

MesoSystems Technology, Inc. and MesoFuel, Inc., a subsidiary of Intelligent Energy, Inc., have developed a compact, ammonia-based hydrogen generator. This device is composed of a lightweight MesoChannel™ reactor, high-effectiveness heat exchangers, high-capacity ammonia adsorbent, and flow/temperature control components. Ammonia is reacted at approximately 600° Celsius to form a 75/25 mixture of hydrogen and nitrogen with trace quantities of ammonia remaining in the product gas. The ammonia is removed using an adsorbent and the remaining hydrogen/nitrogen mixture is fed to a fuel cell for the production of electrical energy. Additionally, a multi-fuel reactor was developed with integrated hydrogen separation, which allows production of high-purity hydrogen.

Metal Plate Forming

OFFICE OF NAVAL RESEARCH

The current method of producing three dimensional shapes for Navy ship hulls and other structures consists of manual thermal forming by skilled labor that uses oxy-acetylene torches and water hoses. The process is very costly, labor intensive, inaccurate, and slow. Native American Technologies Company (N.A. Tech) has developed the Light Induced Thermal Shape Forming (LITS-Form) process to address this problem. The LITS-Form process uses advanced high-energy heat sources, automated manipulators to position the heat at precise locations, intelligent controls, and computerized off-line planning. The process is cost effective, uses minimal labor, produces highly accurate parts, and is up to 100 times faster than manual plate forming.

Navy Develops Environmentally Friendly Protective Chromium Coating for Aluminum

NAVAIR PATUXENT RIVER

The first drop-in replacement for the ROHS, WEEE, and ELV directive's designated carcinogen hexavalent chromate. The coating is the only coating in the world that is an environmentally safe and economical replacement that meets or exceeds corrosion protection, electrical conductance, and paint and rubber bond adhesion specifications for all hexavalent chromate applications. The coating was developed by the Naval Air Systems Command (NAVAIR) Patuxent River, Maryland because of the lack of commercially available alternatives to the industry accepted hex material. TCP-HF can be used on aluminum, zinc, copper, brass and a wide variety of other metals. The technology was licensed to METALAST International in 2005 and is commercially available worldwide.

Navy Medical Researchers Launch New Methods for Treating Autoimmune Disease

NAVAL MEDICAL RESEARCH CENTER

While assigned to the Naval Medical Research Center (NMRC), Navy immunologist Dr. Carl June made a profound discovery—the key to a hypothesized second signal in T-cell stimulation. June’s discovery of the function of the CD28 molecule in that second pathway led to major advances in the search for safe and effective therapies for autoimmune disorders.

AFRL's Laser Technology Leads to Successful Airborne LIDAR Pipeline Inspection System

AIR FORCE RESEARCH LAB

AFRL recently completed a four-phase project that resulted in a differential absorption light detection and ranging (LIDAR) system that progressed from a conceptual laboratory demonstration to a unit suitable for field use. AFRL initially designed the system to monitor Air Force base environmental cleanups and dumpsites and detect underground diesel fuel tank leaks.

AFRL/Industry Research Effort Improves Semiconductor Film Quality

AIR FORCE RESEARCH LAB

The quest for new and improved electronics and photonic devices drives the continual pursuit of epitaxial technique advancements and a clearer understanding of epitaxial growth’s underlying physics. Scientists use epitaxial techniques to match the orientation of a deposited crystal with the orientation of the crystal that comprises the underlying substrate material. When the crystal orientations of two or more different materials (heteroepitaxial) are not properly aligned, defects (i.e., misalignment and dislocation of atoms) result. An accumulation of these defects is known as the defect density. AFRL is exploring ways to reduce defect density and thereby increase semiconductor efficiency.

Scientists Develop Ceramic-based Body Armor for Warfighters

AIR FORCE RESEARCH LAB

AFRL scientists and engineers collaborated with industry to develop a novel metal-ceramic hybrid material for use in higher-performance, lighter-weight small arms protective inserts (SAPI) for body armor vests. In 18 months, this low-cost, high-payoff technology development program evolved from initial laboratory research into a technology system that exceeds the capabilities of most SAPI plates. If the technology continues to perform beyond specified requirements, AFRL scientists expect several military branches to purchase it at a cost savings of approximately $400 per armor vest, resulting in a total cost savings in the millions.

Characterizing Aeroacoustic Loads

AIR FORCE RESEARCH LAB

The AFRL Air Vehicles Directorate developed an accessible and extensive database of dynamic acoustic loads that affect aircraft structure and subsystems. This database will allow engineers to produce aircraft with longer structural life, lower maintenance costs, and increased readiness. During flight, an aircraft is subjected to strong pressure fluctuations caused by airflow and acoustic resonance. The resulting acoustic loads have high sound pressure levels at high frequencies that can damage weapons, crack nearby surfaces and components, and radiate intense noise. With the laboratory-developed database, engineers can assess the effects of this phenomenon and use the knowledge to design aircraft with increased structural life, lower maintenance costs, and increased readiness.

Breakthrough System Utilizes Foveal Vision Paradigm with Infrared Multiresolution Imagery

AIR FORCE RESEARCH LAB

Nova Sensors developed the Variable-Acuity Superpixel Imager (VASI™) under a Phase II SBIR contract to reduce the bandwidth required for IR imagery readout and processing while maintaining maximum resolution foveae on regions of interest (ROI). This accomplishment maps the biologically motivated paradigm of foveal vision from the visible to the IR spectrum. Vertebrate eyes typically have a small area of high resolution (foveal region), in addition to radially decreasing resolution in the periphery. These characteristics allow an animal to maintain visual awareness of its surroundings, they provide the animal with sufficient resolution (using the fovea) to identify objects of interest while processing the imagery with enough speed to successfully react to most dangers. In contrast, most engineered visible or IR camera systems have a fixed spatial resolution that requires trade-offs between the resolution, field of view (FOV), and frame rate in order to process the resultant imagery in real time. Biological systems inspired some designers to develop visible spectrum cameras that have either a programmable or a fixed (requiring a pan/tilt assembly to control the gaze of the system) multiresolution capability. Nova Sensors developed a system that combines the benefits of foveal vision with the advantages of IR sensing.

AFRL Demonstrates Upper Surface Blowing Concept

AIR FORCE RESEARCH LAB

AFRL scientists worked with Compositex, Inc., as part of a Small Business Innovation Research program to prove the upper surface blowing (USB) concept as one method to achieve powered lift. Engineers successfully demonstrated USB during the flight test of a small unmanned air vehicle (UAV) that weighed approximately 6 lbs. Not only did the demonstration’s success prove the possibility of using USB technology, it also opened up possibilities for using the same type of small UAV to demonstrate future air vehicle concepts.

Software Development Produces a CYMFONY of Information Extraction Tools

AIR FORCE RESEARCH LAB

While traditional Information Extraction (IE) is almost exclusively restricted to indexing based on keywords, research pursued by this team supports a more sophisticated form of IE based on a detailed grammatical analysis of source text. Text documents are processed based on the presence of important entities (e.g., names of people, places, companies, products, brands), relationships between entities (e.g., person “X” is employed by company “Y”), and key events such as the venture capital industry and management changes in companies.

High-Performance Modulators Spark Second Phase of Photonics Revolution

AIR FORCE RESEARCH LAB

AFRL scientists and engineers working in conjunction with Air Force (AF) contractor IPITEK, achieved significant advancements in the research and development of low-cost, high-performance electro-optic polymer modulators instrumental in achieving very high modulation rate signals on optical carrier beams. Electro-optic polymer modulators satisfy a number of current and future military needs. The commercial potential for low-cost, high-performance electro-optic polymer modulator technology could impact the entire spectrum of information communication systems. The commercial market potential for fiber-to-the-home technology is huge, given the estimated 100 million households and 50 million potential commercial and institutional users in the US alone.

Extending Gas Turbine Engine Blade Life Saves Millions

AIR FORCE RESEARCH LAB

AFRL officials from the Materials and Manufacturing Directorate’s Manufacturing Technology (ManTech) Division, in partnership with LSP Technologies, Inc. (LSPT), of Dublin, Ohio, anticipate greater cost savings for the warfighter with their RapidCoaterTMoverlay application system, which introduces automation to the Laser Shock Peening (LSP) program. LSP technology is already credited with over $100 million in cost avoidance.

Dynamic Digital Sand Table

ARMY RESEARCH OFFICE

Xenotran Corporation has developed a 3-Dimensional (3-D) geospatial terrain data modeling tool. The tool called the XenoVisionTM Mark III Dynamic Sand Table uses digital elevation data with a corresponding image file, and produces a 3-D, full color terrain model in less than 3 minutes. This model can be reconfigured with fresh data within the same time frame. The Mark III displays the 3-D terrain data models in a 4’x3’ large table format and allows for quick visualization of scenarios to support current operations, mission planning and rehearsal, and general situational awareness.

Advanced Portable Power

ARMY RESEARCH LABORATORY - ABERDEEN

Advancements in telecommunications and electronic weaponry are key to a dismounted Soldier’s ability to leverage portable electronic equipment during combat. Laptops, GPS, night vision goggles, cellular phones, two way-radios, laser-designators, chemical-biological sensors, and other portable electronic devices require equally portable and sustainable DC power sources to maintain the Soldier’s technological advantage. Currently, primary batteries provide the majority of portable DC power for the dismounted Soldier; however, major drawbacks are added weight and low power density. For example, in a typical 72-hour mission, up to half of the rucksack weight for a dismounted Soldier outfitted with standard electronic gear is in primary batteries. This creates a logistical problem for Soldiers who must prioritize either extra batteries or adequate ammunition and supplies. The ever-growing power demands for the Soldier’s electronic gear exacerbates this dilemma. As this power gap widens and today’s Soldier becomes increasingly networked on the battlefield, portable DC power sources must provide much higher energy density than current state of the art can supply.

New Visor Offers Clear Improvement

AIR FORCE RESEARCH LAB

A newly developed visor for flight helmets permits aircrew members to vary the visor’s tint from 15–65% simply by turning a knob. The visor can also adjust itself automatically as lighting conditions change and operate for many hours off of a small battery. This unprecedented capability will allow pilots to optimize their vision and enhance the visibility of helmet-mounted displays (HMDs).

Nickel Nanostrands™ Expand Nanotechnology Engineering Capabilities

MATERIALS & MANUFACTURING DIRECTORATE

Researchers at the Air Force Research Laboratory Materials and Manufacturing Directorate, working with Metal Matrix Composites of Heber, Utah have developed a new form of nano-structured nickel that dramatically expands nanotechnology design engineering capabilities. The new materials are called nickel nanostrands™ and were developed under Phase I of an Air Force Small Business Innovation Research (SBIR) program. Nickel nanostrands are strands of sub-micron diameter nickel particles linked in chains, microns to millimeters in length. They are very similar to carbon nanofibers but provide the additional properties of nickel, significantly expanding the variety of options available for developing tomorrow's nanostructure technologies.