Enabling Materials Innovation for Future Economic Growth

Transcription

1 Enabling Materials Innovation for Future Economic Growth Building an Integrated MGI Accelerator Network Georgia Tech Hotel and Conference Center 5 June 2014 Rick Barto, Ph.D. Sr. Manager, Applied Sciences Lab Lockheed Martin Advanced Technology Laboratories (ATL) Cherry Hill, NJ Rick.barto@lmco.com

2 Outline Lockheed Martin and Applied Sciences Laboratory Opportunity Challenges R&D Opportunities Summary and Future Outlook 2

3 The LM ATL Applied Sciences Lab Mission Develop technologies and capabilities to create and improve force-after-next-force mission effectiveness for LM Businesses and our DoD customers: Maximize the performance of the human-machine system Enlist technology around humans to adapt to their condition Flip the materials science Golden Triangle upside down Design to novel / flexible manufacturing processes Knock down barriers to introduction of materials

4 LM Advanced Materials & Nanotechnology Applications At a Glance Aeronautics Materials Sensors/Electronics Information Systems & Global Security Electronics Systems Materials Sensors/Electronics Computing Copyright 2014 by Lockheed Martin Corporation Control Algorithms Space Systems Materials Sensors/Electronics Power 4

5 LM Advanced Materials and Nanotechnology Modeling and Simulation Development Areas Additive Manufacturing Materials Functional and Structural Materials Laser-Material Interactions Modeling & Simulation Optical, IR, Bio, and Chemical Sensors Sensors Flexible / Hybrid Electronics Copyright 2014 by Lockheed Martin Corporation 5

6 Opportunity (circa 2011 to?) A new era of materials innovation We re poised to advance and leverage materials science 3D / additive manufacturing gaining commercial traction In silico / concurrent design of materials / manufacturing can be envisioned 6

7 Flipping the Materials Science Golden Triangle Upside Down Properties (Performance) Flip Properties (Performance) Define Current Approach to Material and Component Design Drive ICME* Enabled Future Approach Process (Mfg) Drive Structure (Material) Process (Mfg) Select / Structure (Material) *Integrated Computational Materials Engineering We currently select the process & structure which determines material properties (component performance) An effective ICME process with MGI innovation would start with rational selection of material properties and then deriving the structure and process 7

8 Challenges Aversion to change and risk is real and understandable Integration of disciplines for materials design innovation still emerging Innovation infrastructure still not fully defined and instantiated MGI is catalyzing Stakeholders are diverse and communicate differently 8

9 Risk and Change I m the program manager of a $1B+ satellite program Joe engineer has a wiz-bang new material for thermal control OK, what are its off-gassing characteristics? How does it handle ionizing radiation, atomic oxygen, and UV? How reliable are its thermal properties over 10 years in space? Who else has used it? What, of my 100+ risk items, are you taking off the table so I can absorb the new risk? Materials innova-on must address reliability, sustainment, and logis-cs Head- on early in the product development cycle 9

10 Pervasive Issues for the Innovation Infrastructure 1. Crea(ng a business case 2. Implemen(ng effec(ve verifica(on and valida(on, risk mi(ga(on, and tolerance of models and linking tools 3. Establishing adequate standards, data, and integra(on, par(cularly in manufacturing supply chains 4. Encouraging integra(on among product design, structures, materials, and manufacturing 5. Addressing need for personnel with ICME exper(se 6. Managing and mi(ga(ng uncertainty quan(fica(on and risk Source: Integrated Computational Materials Engineering (ICME): Implementing ICME in the Aerospace, Automotive, and Maritime Industries, A Study Organized by The Minerals, Metals & Materials Society Warrendale, PA 15086,

11 Infrastructure Needs for Aerospace, Automotive, and Maritime 11 Current Needs/Barriers and Their Solutions for Implementing ICME in the Near Term Automotive Aerospace Maritime Improved Quantitative Modeling Tools Cultural Barriers and/or Intellectual Property Issues Establishing a Business Case for ICME X X X X X X X X X Workforce Development X X X Lack of Past Experience in Implementing ICME ICME Standards X X Linkage Software and Tools Regulations and Certification! X Source: Integrated Computational Materials Engineering (ICME): Implementing ICME in the Aerospace, Automotive, and Maritime Industries, A Study Organized by The Minerals, Metals & Materials Society Warrendale, PA 15086, 2013 X X X X

12 Interacting Disciplines for MGI and ICME Critical disciplines identified in the 2013 TMS Aerospace ICME Implementation Study Aerodynamicist Fluid dynamicist Concept designer Airworthiness representative Configurator/ preliminary designer Cost estimator Customer Designer ICME integrator Information scientist/data management Manufacturing engineer Marketing team Materials engineer Materials supplier Oversight/chief engineer Product engineer/integrated product team lead Research experimentalist Research modeler Structures engineer/stress analyst Supply chain management Sustainment engineer & logistician Systems architect/engineer Test engineer 12 Source: Integrated Computational Materials Engineering (ICME): Implementing ICME in the Aerospace, Automotive, and Maritime Industries, A Study Organized by The Minerals, Metals & Materials Society Warrendale, PA 15086, 2013

13 Composite Structure ICME Challenges Multiscale Uncertainty Fracture Fatigue Damage tolerance Microcrack Progressive failure Effects of defects High stiffness fibers Processing effects Open / filled hole compression Compression strength after impact Sandwich panel moisture effects Interacting failure modes Stiffener / stringer terminations Large fastened structures Unitized structure Bonded (Pi) joints Continuum Loads Mfg process Repair Damage Physics of Failure Significant challenges remain in all areas 13

14 Of This Vast Landscape... Some of the Most Difficult Are: High stiffness fibers Bonded joints Moisture intrusion / impact in sandwich structures Stiffener / stringer terminations Large fastened structures Effects of defects Interacting failure modes 14

15 AFRL Integrated Computational Methods for Composite Materials (ICM2) 15

16 Aerospace ICME MGI Research Opportunities across a Digital Thread Opportunity 1: Model Linking Opportunity 3: Full Scale Models A B C Opportunity 4: Product Data Management Opportunity 2: Process Property Structure Informatics 16

17 The Payoffs A robust new cadre of Materials Knowledge Workers Viable economic expansion of 3D / additive manufacturing Regional competitive advantage for well-trained workforces Rapid adaptation to global economical / technology trends 17

18 Summary and Future Outlook The opportunity is real and momentum is building A cohesive MGI strategy can spur regional and cross-cutting new ecosystems (e.g. GaTech IMat) Challenges can be overcome with an integrated system view New business models and IP sharing frameworks must emerge Innovation can be harnessed from both the technology and business communities 18

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20 Materials Innovation Tool Chain Structure Design Ab ini(o Molecular Dynamics Mesoscale Micromechanics Goal Setting Cons(tu(ve Relns Matls Informa(cs (Process- Structure) Structural Analyses Manufacturing Planning Mission modeling Requirements Cost Property Selec(on Opera(onal / Environmental Contraints Design Verifica(on Test/Eval/Qualify Fabrica(on planning Sustainment tes(ng Device Deisgn Ab ini(o Device Physics Exptl Interface Circuit Level Device Design System Level Design Mask Layout Fab Model Copyright 2014 by Lockheed Martin Corporation