Modeling & Manufacturing for Affordable, Sustainable Composites (MMASC)

The objective of this modification is to provide a basis for the additional work needed for the Modeling & Manufacturing for Affordable, Sustainable Composites (MMASC) effort. The scope of this effort is to develop techniques to enhance certification of composite structures aided by high-fidelity damage modeling and to ensure “just-in-time S&T and data delivery” that will be directly applicable to on-going Air Force development programs that provide a strategic advantage to U.S. defense industry and/or sustainment of active fleet. For this in-scope additional work the following tasks have been added: (1) Validation of wearout model for various operational spectra (ex, fighter, bomber, transport, etc.) to explore damage growth behavior of representative design details such as wing-to-spar joint that exhibits multiple competing failure modes; (2) Development of Ceramic Matrix Composite (CMC) data for AFP: Perform testing of panels manufactured using AFP process and demonstrate equivalency to existing data to evaluate the AFP machine configuration variability and Develop methods for joining of Oxide/Oxide CMCs with potential application to repair; (3) Development of lightening AFP head and validations; (4) Development of machine-learning (ML) algorithm for in-process inspection system; (5) Development of over-molding protocols for aircraft applications: Review of automotive applications and compression molding processes; Development of over-molding protocols; and Manufacturing demonstration; (6) NDI-driven modeling for sustainment: Develop a working prototype of an inspection System and Develop data analysis algorithm; (7) Low Cost Attritable Aircraft Technology (LCAAT) program: Conceptual design for one or more attritable vehicle variants; Performance definitions and subsystem performance report; and Cost and risk analysis report; and (8) Low Cost Attritable Aircraft Platform Sharing (LCAAPS) program: Trade studies on readiness for rate production and cost; Best flexible production processes and flexible tooling requirements; Assessment of long-term maintenance concerns; and Recommendations on manufacturing principles to address those concerns.