penn state applied research laboratory · 2018. 4. 13. · penn state applied research laboratory...

Penn State Applied Research Laboratory

Tim Bair(814) [email protected]

Distribution Statement A. Cleared for Public Release.

Contract #N00024-12-D-6404

Agenda

• ARL/Materials & Manufacturing Office

• iMAST Overview

• Example Projects & Quad charts

– Coating Technology

– Sustainment Technologies

– Materials Technologies

– Metals Technologies

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“…maintains a special long-term strategic relationship with DoD for technology development and engineering applications.”

Established in 1945 by the Navy post WW II

Technology Areas

Largest Interdisciplinary Research Unit at Penn State – 1140 faculty/engineers, staff, students

FY 16 Funding Expenditures - $ 200+M

Designated an University Affiliated Research

Center by DoD in 1996

– Undersea Weapons

– Undersea Vehicles/UUV’s

– Hydrodynamics and Structures

– Acoustics & Quieting

– Comms and Information

– Power and Energy

– Navigation

– Materials/ Manufacturing

Background/UARC

Relationship

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Comprehensive technical expertise in fields of

specialty; Corporate knowledge and technical memory

Comprehensive knowledge of DoD needs and

problems

Serve as a Trusted Agent & provide objectivity and

independence from commercial interests

Freedom from real and perceived conflicts of interest

Quick response capability

UARC Roles for DoD

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STUDENT PHOTO

Increase warfighter capability

– develop and demonstrate advanced S&T

– mature technology TRL 3/4/5 to TRL6/7

– transition technology to acquisition and current

systems

– design, deploy, and test new solutions

Cost savings for acquisition and lifecycle

– new technology solutions and open standards

– proof of concept before commitment

– design for manufacturing and affordability

– cost / performance design trade tools

Education and Training

– filling pipeline of future engineers & scientists

– providing tools / expertise for training forces

– project opportunities for USMC Fellows

– training manufacturers on new technology

GRADUATE EDUCATION

Laser Automated Rotor Blade StrippingJLTV COST / PERFORMANCE TRADES

JTLV PERFORMANCE / COST TRADES

Engine erosion coatings

ARL/PSU Mission

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Manufacturing Technology

(ManTech)

PEO (Subs)

VIRGINIA

ORP

PEO (Carriers)

CVN 78 Class

PEO (JSF)

F-35

PEO (A)

CH-53K

Affordability Initiatives

PEO (Ships)

DDG 51 Class

Electronics Manufacturing Productivity Facility (EMPF)Operated by American Competitiveness Institute (ACI)Philadelphia, PA

Institute for Manufacturing and Sustainment Technologies (iMAST)Operated by Penn State University, State College, PA

Center for Navy Metalworking (CNM), Operated by ATICharleston, SC

Electro-Optics Center (EOC)Operated by Penn State UnivKittanning, PA

Composites Manufacturing Technology Center (CMTC), Operated by ATI (SCRA)Anderson, SC

COE Legend ContractedGovernment

Naval Shipbuilding and Advanced Manufacturing(NSAM) Center, Operated by ATI, Charleston, SC

Energetics Manufacturing Technology Center (EMTC)Naval Surface Warfare Center – Indian Head (NSWC-IH) Indian Head, MD

• Mission: Industrial Preparedness– Development of enabling manufacturing technology -- new processes and equipment --

for implementation on DoD weapon system production lines

• Funding: $56.7M FY17

• Execution:– 7 Centers of Excellence (COEs)

• 6 Contracted, 1 Government

• Investment Strategy– Addressing affordability (acquisition and life-cycle)

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iMAST Overview

Institute for Manufacturing and Sustainment Technology (iMAST) est’ed February 1995 as one of the Navy ManTech Centers of Excellence

Located at Penn State’s Applied Research Laboratory, iMASTpartners with industry, DoD, and the University to solve advanced weapon system issues.

iMAST provides a focal point for the development and transition of new manufacturing processes and equipment in a cooperative environment with industry, academia and Navy acquisition andsustainment programs.

iMAST supports Navy ManTech with acquisition cost reduction projects as well as a life cycle cost savings focus within the Repair Technology (RepTech) program.

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- Repair Technology (RepTech) Projects: Addresses repair,

overhaul and sustainment functions that emphasize

manufacturing processes and advancing technology as a

component of Navy ManTech.

- RepTech projects target fielded weapon systems and provide

the process and equipment technology needed to repair and

maintain fleet assets. Implementation of RepTech projects target

naval depots, shipyards, Marine Corps logistics bases,

intermediate maintenance activities and contractor facilities

responsible for the overhaul and maintenance of fleet hardware.

Repair Technology

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H-53 Helicopter Blade Refurbishment $828K

AV-8 F-402 AM Repair $TBD

F-18 Portable Cold Spray Repair $368K

688 Class Vertical Launch System Repair $600K

Sub Factory Capacity Planning $7.6M

688/VCS Surface Treatment Repair $1.69M

Submarine Align/Inspection $1.6M

VCS Dual Track SHT $480K

Topside Nonskid Removal $980K

Shaft Seal Refurbishment $4.27M

Retractable Bow Plane Coating $1.3M

CVN/LPD Long Life Non-Skid Repair $4.80M

Acoustic Sensing $2.0M

All Ships 3D Laser Scanning $610K

Cold Spray Shipboard Repair $1.0M

In-Situ MSW/ASW Repair $730K

Total Cost Avoidance Per Year $29M

VLS Tube Repair

NAVSEA PH Shipyard

Transmission

Housing

NAVAIR

FRC East

ARBSS

NAVAIR

FRC East

Main Seawater

Valve

Pearl Harbor

Cougar H

Oshkosh

MRAP

VCS

Shaft

Repair

RepTech Cost

Avoidance

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Sample Projects

Below quad charts are a sample of iMAST

ManTech and RepTech projects that are

currently active or recently completed.

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Before and after pictures showing classic plasma spray

failure and new process after significant qualification testing.

Project Number: S2449

Performing Activity: iMAST/ARL Penn State

Objective: To optimize and implement a

thermal spray coating solution on

cylinder rods on submarines.

Start / End Dates: JAN 2013–DEC 15

Project Cost: $1.2M

MANTECH Investment: $877K (iMAST)

Cost Share: $326K (NSAM)

Weapon System: Submarines

Implementation:

System: Submarine

Site: GD-EB and Navy Undersea Warfare

Center-Keyport

Schedule: APR 2016

Status: Transitioned/Implemented

Pay Off

• Savings across life cycle approximately $300M

• Elimination of seal replacements

• Extension of seal lifetimes

• ManTech ROI = 8:1

• Reduced Total Ownership Cost of System

• Eliminate need for emergent dry docking and replacement of

seals.

Performing Activities:

• COE: iMAST/ARL Penn State and NSAM

• Commercialization Partners: General Dynamics Electric Boat

• Implementing Organization: General Dynamics Electric Boat

Technical Achievements:

• The full scale test bar passed long term testing and survived over 4,500

cycles of testing at General Dynamics Electric Boat with no measurable

wear. This equates to over 70 years of ceramic coating service life.

• An improved surface finish has been tested and improved seal life has

been obtained.

• The selected vendor has completed qualification testing and obtained

NAVSEA approval for production.

Coatings/Mfr’ing Process: Plasma

Spray System Improvements

Distribution Statement A. Cleared for Public Release. of 24

Implementation:

System: F-35 Lightning II Program

Sites: Lockheed Martin and Supply Base

Facilities

Schedule: AUG 2017

Status: Active

Cost

Schedule

Technical

Payoff: (from LMA)

• $98M to the F-35 Program ($35 K / aircraft)

• Total Return Multiplier of 115

Coatings: F-35 Primer

Thickness Measurement

Project Number: A2609-B

Project Title: F-35 Primer Thickness

Measurement

Activity: iMAST/ARL Penn State

Objective: Develop wet and dry film thickness

measurement tools to inspect

primer thickness. Tool will be

implemented at assembly facility & the supply

base. Start / End Dates: OCT 15 – AUG 2017

Project Cost (iMAST): $500K

MANTECH Investment: $850K

Cost Share: $ 0K

Weapon Systems Affected: F-35


• NSAM – LMA Project management & oversight

• Lockheed Martin Aerospace (LMA) – Project co-lead; facility

support

• iMAST – Prototype development / evaluation

• F-35 Lightning II Program Office – Project oversight


• Fabricated prototype of ARL spectrometer-based device

• Eliminated eddy-current and interferometry as viable

technologies to measure coating thickness

• Early testing of ARL device shows strong correlation between

color, intensity, and coating thickness on BMI

Human painters are prone to applying primer until the coating ‘looks good’.

On F-35 composite panels, this tendency leads to over-thick primer

application, requiring subsequent removal (by hand-sanding).

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Implementation: This RR project supported the production of

full scale test articles to be installed for fire

testing (see pictures) and was needed to

qualify this new material as eligible for

application inside submarines. This project

supported the CMTC parent project with the

same name.

System: Future subs

Site: New London CT, Electric Boat

Schedule: TBD

Status: Completed

Payoff: TBD based on actual applications in future

designs and redesigns.

Materials: Fire Safe Resins

Project Number: R2721

Project Title: Fire Safe Resins

Performing Activity: iMAST / ARL Penn State

Objective: Qualify a composite material for

use inside the pressure hull.

Start / End Dates: Oct 2014–Dec 2016

Project Cost:

MANTECH Investment: $ 25K

Weapon System: Submarines and other ships


• iMAST - ARL Penn State – Fire Test Panel Fabrication

• CMTC hosted parent project with ARL technical performer

Technical Achievements: • Manufacturing Technology was developed that results in low cost, high

performance, fire safe composites suitable for use inside a pressure hull.

• To complete the qualification process, an iMAST follow-on project was

conducted that fabricated fire test articles, including an ISO 9705 full scale

room test.

• The test was successfully executed and feedback from the TWH

established it as qualified.


FST test of the new FSR panels. Result: success!

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Sustainment: Topside

Non-skid Removal


Project Title: Improved Topside Non-Skid

Removal for Submarines


Objective: Develop tool(s) capable of

removing nonskid from Submarines without

causing damage to Special

Hull Treatment (SHT).

Start / End Dates: FEB 2012 – MAR 2014

Weapon Systems Affected: Submarines

Implementation:

System: Submarines

Sites: Puget Sound Naval Shipyard

Pearl Harbor Naval Shipyard

Schedule: FY14/Q2 ( Transitioned to 392 project)

Status: Active: Implementation on target. Direction

has been provided by NAVSEA design

requirements and implementation.

Payoff:

• Cost avoidance: $ 672K per year (2 repair jobs/year)

• Labor reduction: $ 95K per nonskid repair job

• Material cost reduction: $ 210K per nonskid repair job

• Eliminate Containment: $ 32K per nonskid repair job

• 5-Year ROI 6:1


• iMAST/ARL Penn State – Project Lead

• PMS-392, PMS-450 – Program Offices

• PSNSY & PHNSY – End-users / Stakeholders

• NAVSEA 05P2 – TWH

• NSWCCD - TA

• Commercialization partners – Terydon, Inc.

• Implementing Organization(s) – PSNSY & PHNSY


• Successful nonskid removal from two active hulls SEP12/JAN 13

• SHT safety testing at PSNSY & IMF FEB 14

• PMS 392 & TWH approved process and funded upgrades JUN 14

• Designed and manufactured Beta Prototype JUN 16


Improved Removal of Topside Nonskid

Implementation:

System: Submarines

Sites: PSNSY&IMF & PHNSY&IMF, PNSY

Schedule: FY17/Q2 (production trials PNSY or NNSY)

Status: Active

Payoff:

• Cost avoidance: $ 120K per yard / per year

• Labor reduction: $ 360K per year

• 5-Year ROI 3.5 : 1

Sustainment: UHP Dual-Track

Crawler System for Coating Removal


Project Title: SHT/MIP Removal Using UHP Dual-

Track Crawler System

Activity: iMAST/ARL Penn State

Objective: Develop, test, demonstrate,

transition and implement a dual-track UHP

water jet system for removal of

SHT coatings from submarines

Start / End Dates: SEP 2014 – SEP 2017

Project Cost: $632K


Cost Share: $ 0K

Weapon Systems Affected: Submarines


• iMAST/ARL Penn State – Project Lead

• PMS-392, PMS-450 – Program Offices

• End-Users / Stakeholders - All Navy Shipyards (PSNSY&IMF Lead)

• Commercialization partners – Terydon, Inc.

• Implementing Organization(s) – PSNSY&IMF & PHNSY&IMF, PNSY


• Fabrication of alpha prototype completed and tested in Lab

• Motion-controller noise in large scale application identified and mitigated

• Dual-Track UHP SHT/MIP Removal system successfully demonstrated

on mockup in shipyard environment

• All four public yards pushing for rapid introduction/transition

Dual-Track UHP SHT

Removal System

Open-Cycle UHP

Removal of Hull Coatings



Sustainment: Acoustic Sensing

Through Electrical Enclosures


Project Title: Acoustic Sensing Through

Electrical Enclosures

Performing Activity: iMAST/ARL Penn

State/NNSY/CTRL

Objective: Technology insertion of a

handheld acoustic sensor capable

of detecting air-borne frequencies

unique to early electrical

Component failure.

Start / End Dates APR 2015 to DEC 2016

Project Cost:


Weapon System(s) Impacted: All ships and subs


• iMAST - ARL Penn State – Technology Modifications

• PEO Carrier/NAVSEA 05 – Technical/Implementation

Assistance

• Subcontractor(s): NNSY/CTRL/NRL

• Commercialization partner – CTRL


• Shore-based testing of CTRL UL101 system at KEMA.

• Data collected and under analysis. Early indications show

relationship between low torque connectors and acoustic signal

• Non-energized acoustic and modal testing on panel at KEMA

showed positive response indicating potential use within closed

electrical enclosures.

Early Electrical Fault Sensing for Preventative Maintenance

Implementation:

System: Electrical Distribution Panels

Site: NNSY

Schedule: TBD, FY16/Q3 expected

Status: Active

Payoff:

• Early warning of impending electrical faults.

• Enabling inspection capability for distribution panels under full

load.

• Improved personnel safety (fire prevention).

• NAVSEA 05 estimated: $10.3M/5yr maintenance cost

avoidance.

• ManTech 5-year ROI = 16.



Project Number: R2713

Project Title: CVN Wire Support Spring Improvement

Performing Activity: iMAST / ARL Penn State

Objective: Develop heat treatment to eliminate

premature failures of the wire support

springs and develop a test method to

identify springs that will fail.

Start / End Dates: MAR 2016 to SEP 2016

Project Cost:

ManTech Investment: $75K

Cost Share:

Weapon System(s): Aircraft Carriers / Mark 7 Arresting

System and Advanced Arresting Gear


• iMAST Project Mgmt/Technical Development

• Stakeholder PMA251 IPT Lead for Fielded Recovery

Systems (Andy Sussman)

• Technical Assistant NAVAIR Lakehurst (Caleb Bonilla)

• Implementation NAVAIR Lakehurst

Technical Status:

• Fracture surface analysis proved evidentiary and indicated

weakness due to forging variation not hydrogen

• Metallographic analysis including optical, SEM and TEM complete

on the existing material lots to differentiate 1998, 2004, 2010 lots

• Consensus is that the difference in performance between the

various lots due to a difference in grain size and embrittlement

induced by phosphorous

• Spring from 2016 lot is expected to perform similarly to the older

springs indicating potential for catastrophic failure

Implementation:

System: Aircraft Carriers

Site: NAVAIR Lakehurst

Quantitative Benefits:

• Produce springs that have an extended life

• Projected ROI > 7 (based on preventing one aircraft

mishap but not including cost of bad springs) $500K

Qualitative Benefits:

• Reduce spring failures / extend spring life

• Prevent damage to aircraft

• Prevent injury to personnel

Metals: Wire Support Spring Improvement

Wire Support Spring

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Project Number: A2647

Title: Additive Manufacturing for NAVAIR

Repair of AV-8B LPC Seal

Performing Activity: ARL/iMAST, CIMP-3D, FRC-E

Objectives: Implement metal based Additive

Manufacturing for repair at FRC-E

Start / End Dates: MAR 15 – SEPT 17

Project Cost: $600K


Weapon System: AV-8B

Implementation:

System: AV-8B - F402 Engine

Site: FRC-East

Schedule: 2.1 Qual Plan: (SEPT 16)

2.2 Exec Plan: (SEPT 16)

2.3 Tech Data Pkg: (SEPT 17)

2.4 Final Report: (SEPT 17)

Status: Active

Payoff:

• Project motivation stems from unknown value of grounded

assets due to unavailable replacement parts or repair options.

• FRC investment in additive repair technology, supported by

initial project testing, shows interest to advance technology.


• Performing Activity: iMAST, ARL Penn State, CIMP–3D

• Program Office: PMA-257

• Implementing Organization: FRC-E


• Repairs for seal ring successfully applied and tested

• Qualification Test Plan submitted to FRC-East

• Initial testing completed by accelerated deadline, supporting:

• FRC-E approval of ~$1M in capital expenditures

• FRC-E cost-savings of ~$1M on expected capital costs

• FAA-approved 3rd party has produced repairs as potential vendor

Metals: Additive ManufacturingRepair of AV-8B F402 Engine Component due to Fretting Wear

http://www.jeffhead.com/usn21/nssn.htm

Developing AM Repair for AV-8B_F402 Ti Seal Ring


Main Circulating Water Pump Casing repaired by Cold Spray

Metals: Cold Spray Technology

for Shipboard Components


Title: Cold Spray Technology for

Shipboard Components


Objective: Develop and implement cold spray

repair processes to repair NAVSEA

shipboard components.

Start / End Dates: JUN 2014 Sep 2016

Project Cost:


Cost Share: $600K– hardware and support

Weapon Systems: Submarines


• iMAST ARL Penn State – project lead

• Puget Sound Naval Shipyard (PSNS) and Intermediate Maintenance

Facility (IMF) – technical assistant and implementing organization

• Cold Spray Equipment Manufacturers– commercialization


• 1st Component, Al-6061 Hydraulic Actuator. TD-63 and TD-16 have

been repaired and approved for use and are in service. Repair of

Al-6061 Hydraulic Actuator with Al 5056 completed

• 2nd Component, #1 Main Circulation Water Pump repair was

approved and component is in service

• 3rd Component –Steel Motor End Bell housings – Repair approved

on mockups. Qualification Testing continues.

• 4th Component – A nickel coating on a mockup of the 70/30 CuNi

swing check valve approved. Qualification testing continues

Implementation:

Systems: Submarines

Site: PSNS & IMF

Schedule: FY2015

Status: 1st and 2nd article have been approved

for use. 3rd and 4th articles are

undergoing validation testing

Payoff:

• Components that don’t have approved repairs and/or replace current

repair process with improved repair processes.

• Help maintain inventories / reduce down time.

• Technology can be implemented on several platforms.

• Reduced LCC for long lead time components (previously

condemned), increased readiness.

• Five year cost savings is >$5M - ROI of 8.3:1.

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FQ3

Laser Clad Repair System (LCRS) for corrosion damage to

VLS missile tubes


Title: VLS-LCRS Updates for Production

Readiness


NUWC-Division Keyport

Objective: To equip the Laser Clad Repair

System for full-scale use, addressing

risk to minimize expected downtime

Start / End Dates: JUN 2013 – SEP 2015

Weapon System: Submarines

Current status: Project completed and implemented

Implementation:

System: USS-Asheville

USS-Jefferson City

Site: Pearl Harbor Naval Shipyard

Schedule: September 2015

Pay Off (10 yr.)

• Cost Avoidance: $6.2M

• ROI: 4.9


• Performing Activity/COE: iMAST/ARL Penn State, NUWC-KPT

• Program Office: NAVSEA 04

• Implementing Organization: Pearl Harbor Naval Shipyard


• Completed system evaluation and identification of necessary

engineering upgrades to laser-based system as well as design of

LCRS back-up (GTA) system

• System upgrades and training for Pearl welders complete

• System application on USS Asheville complete (Dec 14) and

successfully demonstrated on one tube.

Metals: VLS-LCRS Updates


Advanced Manufacturing

Enterprise

• Advanced Manufacturing Enterprise (AME)

– “technologies, processes, and practices that foster rapid, superior

execution of manufacturing enterprises across the life cycle”*

– Above-the shop floor solutions

– Thrust Areas:

1. Model based tools and approaches that optimize producibility during early

design and support standard data environments for life cycle support

2. Network centric manufacturing capabilities to facilitate resilient and

adaptable supply chains;

3. Intelligent manufacturing planning and factory execution

4. Modeling and simulation capabilities advancing the above business

practices

* DoD Manufacturing Technology Program

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Title: PSNS Submarine Factory Simulation

and Capacity Planning

Performing Activity: Puget Sound Naval Shipyard, iMAST

Objective: Develop a simulation-based capacity

planning system to improve the PSNS

Submarine Factory’s ability to

schedule workload and resources

Start/End Dates: APR 2016 – MAR 2018

Project Cost: $600K

Cost Share: None

Weapon System: Demilitarized Submarines

Payoff:

• Estimated $3.9M savings in recycling costs per submarine

• 2 submarines processed per year

• Project cost = $600K

• Total savings over 5 yrs = 2 subs/yr x 5 yrs x $3.9M/sub -

$600K cost = $38.4M

iMAST Technical Achievements

• ARL/iMAST developed an initial simulation model of the

PSNS Submarine Factory

• ARL/iMAST developed 4 official data files to document the

PSNS Submarine Factory model: Map, Flowchart,

Resource List, and Entity List

• Data collection meetings and initial simulation model

demonstration conducted at PSNS on 12/6-8


• PSNS - Project Lead, Facility Technical Support,

Implementing Organization

• iMAST - Technical Development, Project Management

Support

AME: Submarine Factory Simulation

and Capacity Planning

Development of a Capacity Planning System Supported

by a Simulation Model

Implementation

System: Submarines

Site: PSNS

Schedule: APR 2016 - MAR 2018

Status: In-Process


Project Number: A2476

Project Title: LIF NDE Gen II Transition

Performing Activity: iMAST/ARL Penn State, NAVAIR

Pax River

Objective: Define and develop depot-ready

specifications to implement Laser Induced

Fluorescence (LIF) NDE technology for

incipient heat damage in polymer matrix

composite structures.

Start / End Dates: OCT 2011 – SEP 2014

Project Cost: $1100K


External Funding: $800K (planned)

Weapon System(s): F-35, V-22, F/A-18, H-53K

Implementation:

System: V-22 / F/A-18

Site: FRC-East / NAVAIR-PAX

Schedule: Planned for FY 2015-16

Status: Prototype proposals in process

Payoff:

• Enabling NDE technology to detect and map incipient heat damage

on polymer matrix composite structures.

• Provide multiple platform, on-wing inspection opportunity for high

value components (wings, tails and fuselages).

• Hardware design specifications enables production of multiple units

to support FRC inspection needs.

• ManTech 5-year ROI = 12


• iMAST ARL Penn State - Technology Modifications (Lead)

• NAVAIR Patuxent River – NDE functionality

• NAVAIR Depots (FRC-East, FRC-Southeast, FRC-Southwest) –

Technical Assistance, Depot requirements

• Commercialization partner – TBD


• Designed and assembled a breadboard LIF apparatus for

component evaluation

• Collected extensive, high-resolution spectra on four sets of

registered samples provided by NAVAIR Composites Technology

Office (4.3.4.4).

• Successfully generated separate predictive models capable of

classifying 5HSAS4 Epoxy and BMI composite by the 80%

mechanical strength criterion

Portable LIF Prototype

LIF NDE GEN II Transition

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ARL Penn State is actively engaged in support of the

Navy ManTech program

The list of technology innovations successfully

implemented speaks for itself

As a DoD UARC, ARL serves as a Trusted Agent &

provide objectivity and independence from

commercial interests

Our technology expertise is a best described as

dynamic to accommodate our primary mission to be

at the edge of innovation in applying technology to

solve DoD engineering and manufacturing challenges

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Summary

penn state applied research laboratory · 2018. 4. 13. · penn state applied research laboratory...

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