Physical Optics Corporation — Department of Defense SBIR Phase II: MDA16-015

Description

To address the MDAs need for a repeatable manufacturing process for aerospace-grade, thinned-walled aluminum alloy propellant tanks, Physical Optics Corporation (POC) developed the new Robotic Bonding (ROBOBOND) system, which utilizes conventional computer numeric control (CNC) machinery to perform friction stir welding (FSW) with minimum setup, allowing the technology to become widely available. POC previously defined the system parameters and demonstrated a technology readiness level (TRL)-5 prototype on an industry-standard four-axis CNC to provide stir welding, proving technology repeatability and retrofitability. POC will enhance the ROBOBOND technology based on prior results and findings, mature the ROBOBOND tools and support systems, optimize the process parameters, and integrate the systems into a semi-automated prototype that can be retrofitted onto a commercially available CNC machine. Performance objectives such as weld seam strength, weld seam microstructure, and vessel integrity will be defined. POC will demonstrate the ROBOBOND process on an actual thin-walled aluminum tank shell produced by an aerospace manufacturer. POC will further develop the technology and determine how the technology can increase profitability, speed, and reliability in aerospace lean manufacturing environments. The next-generation ROBOBOND system will reach technology readiness level (TRL)-6 and be ready for initial testing for transition to customers.Approved for Public Release | 18-MDA-9522 (23 Feb 18)