Advanced Materials for Weapon Systems

The Advanced Materials for Weapon Systems program, managed by the Air Force Research Laboratory (AFRL), is a key element of the Department of the Air Force's science and technology portfolio. Its overarching goal is to develop and demonstrate advanced materials and process technologies that enhance survivability, readiness, affordability, and operational effectiveness of Air Force weapon systems across air, space, and cyber domains. The program supports the Department's priorities by synchronizing research and technology development to address current and future operational requirements. This ensures that weapon systems remain capable and reliable in increasingly complex threat environments.

The Electromagnetic Protection Materials project (formerly Laser Hardened Materials) focuses on developing and demonstrating materials and technologies that protect Air Force personnel, platforms, and mission systems from extreme electromagnetic spectrum environments. This includes threats from directed energy weapons such as lasers and radio frequency sources, as well as nuclear detonations. Specific objectives include advancing computational materials science to model and design protective materials, developing survivable sensor systems for next-generation aircraft, and integrating lightweight, low-cost survivable electro-optic sensors for missile warning. The project also addresses personnel protection by developing visor-based technologies and materials to mitigate risks such as laser exposure and nuclear flash blindness, ensuring aircrew safety and mission effectiveness.

The Non-Destructive Inspection Development project aims to advance nondestructive inspection and evaluation (NDI/E) technologies for monitoring the integrity and performance of weapon system components and materials. Its objectives are to extend the service life of current systems, increase reliability, reduce maintenance costs, and assure manufacturing quality. The project is consolidating efforts in special material inspection and advanced system monitoring to accelerate technological progress. Key activities include developing automated robotic inspection technologies, improving methods for data acquisition and analysis, and integrating computational tools for life prediction and risk-based management.

These advancements are intended to enable just-in-time maintenance, improve mission availability, and reduce inspection man-hours.

The Materials Transition project is dedicated to maturing and transitioning advanced materials and processing technologies for fielded and planned Air Force weapon systems, airframes, aerospace structures, and propulsion applications. The project collects critical data and evaluates materials in operational environments to support industrial development and improve affordability. Efforts include developing materials for next-generation electromagnetic protection and minimizing electromagnetic interference with minimal performance degradation. The project also supports the transition of promising materials and processes to operational use, enhancing the survivability and effectiveness of Air Force platforms.

Within the Materials Transition project, the Air Vehicle Materials Technologies effort focuses on enhancing lift, propulsion, power management, survivability, and affordability of air vehicles through advanced materials and processes. This includes ongoing development and characterization of electromagnetic protection materials and new initiatives to minimize electromagnetic interference in operational systems. The goal is to ensure that air vehicles can operate effectively in contested environments while maintaining cost-effectiveness and reliability.

Another significant component of the Materials Transition project is the Counter Intelligence, Surveillance, and Reconnaissance (ISR) Technologies effort. This initiative aims to develop and demonstrate methods and materials that degrade adversarial ISR capabilities, supporting resilient basing and Agile Combat Employment concepts. The objectives include developing prototypes for counter-ISR technologies, conducting operationally relevant testing, and improving the ruggedization and usability of these technologies for field operators. The effort is designed to delay enemy decision-making and actions, thereby enhancing the Department of the Air Force's operational security and effectiveness.

The Advanced Materials for Weapon Systems program also incorporates Congressional add-ons, such as the Metals Affordability Initiative, polymer printing technology for additive manufacturing, advanced carbon materials for sensor and aerospace platform protection, and certification for advanced materials. These targeted investments support the broader objectives of the program by accelerating the development and transition of innovative materials technologies, improving affordability, and ensuring that advanced materials meet certification and operational requirements.