1. CTMA Investment - $2.3M; Industry Cost Share - $4.8M
Aging weapon systems are increasing sustainment costs and decreasing system availability. Parts obsolescence for spare parts to support these platforms is one of the greatest challenges in maintaining operational readiness. Factors complicating the process of replenishing spare parts include: A) Traditional sources of supply and OEMs no longer exist or no longer wish to produce the part. B) Demands for critical spares are often in very low quantities – creating very high unit costs. C) Repair processes cannot be performed on many parts because of unacceptable material properties, thermal distortion, or a lack of process control documentation. Laser Engineered Net Shaping (LENS) direct metal deposition technology provides a solution to reduce repair costs and provide higher quality parts. The LENS machine is able to restore the original material that has been lost due to wear, mis-machining, impact or other damage.
CTMA Investment - $2.3M; Industry Cost Share - $4.8M
Realized Benefits
to Date:
$31M+
Laser Engineered Net Shaping (LENSTM) Deployment at Anniston Army Depot and NUWC Keyport
DoD Benefit
Level 1 Benefits: Anniston Army Depot has avoided $6M in costs the first year of the implementation of LENS repairing various turbine components previously scrapped. The unit in service for five years has realized a savings in excess of $30M.
Level 2 Benefits:
Repair Torpedo Cylinder Barrels $90K/year.
Repair Aft Fuel Tank corroded surfaces $500K/year.
Build up Submarine connector rods surfaces $110K/year.
Build up Compressor crankshafts surfaces $150K/year.
Level 3 Potential:
NUWC to pursue certification and utilization for a variety of non-Navy customers. Could include all of Level 2 plus the repair of non-steel, non-aluminum critical parts in DoD inventory not currently repairable. Conservative estimate would be 10X Level 2 or $600M cost savings annually.
Application by Armed Services:
CTMA Sponsored:
U.S. Army (Anniston)
U.S. Navy (NUWC Keyport, WA)
U.S. Navy (NADEP Cherry Point)
Activity Sponsored: Implementation of additional LENS™ machine at ANAD
Potential: NUWC Keyport is pursuing certification and utilization of the unique LENS™ capabilities on a variety of non-Navy components - including Air Force jet engine components, Coast Guard vessel castings, Army heavy-vehicle components and a wide variety of multi-service components from the Defense Logistics Agency (DLA). NUWC Keyport is working with non-Navy customers on potential non-Navy applications for LENS™
Winner 2004 Defense Manufacturing Excellence Award