High Yield Machining of Thermal Protection Systems

Recently, basic feasibility of a robotic solution was investigated on a Lockheed Martin Hypersonic Engineering and Accelerated Technologies (HEAT) Independent Research and Development (IRAD) program. The IRAD project successfully demonstrated the ability to attach a head with a diamond coated wire saw to a robot for automated material processing of graphite billets. The demonstration equipment was not large enough to cut actual flight shapes. Combining existing technologies with the Lockheed Martin HEAT team’s knowledge of composite machining and robotics, the objective of this project is to scale up the IRAD technology to develop a prototype robotic wire saw cutting system and demonstrate more efficient processing of flight shapes from raw 3DCC billets.

The wire saw process will benefit multiple hypersonic strike systems to increase yield from billets. As a secondary effect, we expect even increased yield and reduced overall raw material costs by working with 2D and 3D C/C suppliers to modify their sizes and optimize around the wire saw capability. Material and labor savings amounts to a total program savings of $15.55M resulting in a return of investment (ROI) of 3.3.

Upon meeting Lockheed Martin’s HEAT product requirements and confirmation of a positive business case, the project shall allocate the wire saw setup for U.S. Navy and Rapid Capabilities and Critical Technologies Office (RCCTO) Conventional Prompt Strike (CPS) production as required. Information from this project will be utilized to formally approve the new process for production.

*Prepared under ONR Contract N00014-21-D-7001 as part of the Navy ManTech Program.

*DISTRIBUTION STATEMENT A. Approved for public release: distribution unlimited. DCN# 2024-11-6-309; Approval Date: 11/14/2024