Autonomous and Adaptive Cold Spray Repair

OUSD (R&E) CRITICAL TECHNOLOGY AREA(S): Advanced Materials; Advanced Infrastructure & Advanced Manufacturing OBJECTIVE: Demonstration of autonomous and adaptive CS repair of damaged panel fastener holes via robotic arm incorporating tool changing to: identify damaged areas; pre-machine damaged holes; apply CS, including bookend C633 buttons; and post-machine back to restored dimensions. DESCRIPTION: Current robotic CS repairs are performed by time-consuming robotic path-planning which has a heavy demand for non-recurring engineering. Development of autonomous and adaptive robotic path planning and tool changing to accommodate varying CS repairs would reduce this workload and associated time and costs and push the State-of-the-Art for CS repair processes. PHASE I: PHASE I: This topic is intended for technology proven ready to move directly into a Phase II. Therefore, a Phase I award is not required. The offeror is required to provide detail and documentation in the Direct to Phase II proposal which demonstrates accomplishment of a Phase I-type effort, including a feasibility study. This includes determining the scientific and technical merit and feasibility of ideas appearing to have commercial potential. This feasibility study must include an assessment of the state of the autonomous and adaptive repair processes and how offeror's innovations contribute to cost and schedule reductions for labor costs, material costs, and non-recurring engineering costs. This assessment should validate the product-market fit between the proposed solution and a potential AF stakeholder. The offeror should have defined a clear, immediately actionable plan with the proposed solution and the AF customer. Phase I-like efforts have been accomplished on damaged Integrally Bladed Rotor (IBR) components. Damaged blades are irregular and inconsistent. Routines were developed to locate areas of damage, blend them out, and perform surface finishing, all requiring minimal support from an operator or engineer. Phase I-like efforts have been accomplished on damaged Integrally Bladed Rotor (IBR) components. Damaged blades are irregular and inconsistent. Routines were developed to locate areas of damage, blend them out, and perform surface finishing, all requiring minimal support from an operator or engineer. PHASE II: PHASE II: Eligibility for D2P2 is predicated on the offeror having performed a Phase I-like effort predominantly separate from the SBIR Programs. Under the phase II effort, the offeror shall sufficiently develop the technical approach, product, or process in order to conduct a small number of relevant demonstrations. Identification of manufacturing/production issues and or business model modifications required to further improve product or process relevance to improved sustainment costs, availability, or safety, should be documented. These Phase II awards are intended to provide a path to commercialization, not the final step for the proposed solution. The successful Phase 2 effort will deliver at least two manufacturing technology demonstrations resulting in an autonomous and adaptive CS repair process that could feasibly be transitioned for use at DAF installations with potentially different robotic arm and turntable systems/configurations. The Offeror should communicate how their technology approach will result in a credible pathway to production repair. The Phase 2 awardee will build on the current state of the art to advance the Technology Readiness Level in supporting these outcomes of interest by further developing processes that demonstrate enhanced performance in the area above. The awardee will coordinate with the Department of the Air Force technical point of contact (TPOC) via regular information exchange meetings and technical reports. The final deliverable will be transition of developed autnomous and adaptive CS repair processes to DAF end user, including on-site training and setup for DAF use. Tasking requirements to include: 1. Procurement of robotic arm 2. Development of routines to identify and perform CS repair and machining 3. Demonstration of simulated autonomous CS process 4. Delivery of routines to AF end-user along with any required setup/installation and training PHASE III DUAL USE APPLICATIONS: The contractor will pursue commercialization of the various technologies developed in Phase II for transitioning expanded autononmous and adaptive CS repair capability to a broad range of potential government and civilian users and alternate applications. Direct access with end users and government customers will be provided with opportunities to receive Phase III awards for providing the government additional research & development, or direct procurement of products and services developed in coordination with the program. REFERENCES: 1. Tegler, E. (2021, July 28). Cold Spray Technology Could Allow The Air Force To Repair Instead Of Incessantly Replacing Aircraft Parts. Forbes. https://www.forbes.com/sites/erictegler/2021/07/28/cold-spray-technology-could-allow--the-air-force-to-repair-instead-of-incessantly-replacing-aircraft-parts/ KEYWORDS: Cold Spray; adaptive machining; robotic path planning