Materials and Manufacturing
Capabilities for Sustaining
Defense Systems
SUMMARY OF A WORKSHOP
Robert J. Katt, Rapporteur
Defense Materials Manufacturing and Infrastructure
Standing Committee
Division on Engineering and Physical Sciences
NATIONAL RESEARCH COUNCIL
OF THE NATIONAL ACADEMIES
THE NATIONAL ACADEMIES PRESS
Washington, D.C.
www.nap.edu
THE NATIONAL ACADEMIES PRESS 500 Fifth Street, NW Washington, DC 20001
NOTICE: The project that is the subject of this report was approved by the Governing Board of the National Research Council, whose members are drawn from the councils of the National Academy of Sciences, the National Academy of Engineering, and the Institute of Medicine.
This study was supported by Contract No. W91lNF-l0-C-0098 between the National Academy of Sciences and the Department of Defense. Any views expressed in this publication are those of the author(s) and do not necessarily reflect the views of the organizations or agencies that provided support for the project.
International Standard Book Number-13: 978-0-309-26757-1
International Standard Book Number-10: 0-309-26757-9
Cover: Image of a three-dimensional fractal. Although highly complex it shows self similarity at every length scale, mimicking the capabilities needed to sustain today’s intricate defense systems. The two glowing focal points represent the materials and manufacturing required to reach those capabilities. By looking closely at the image it is possible to see the pattern of the two focal points repeated in the structure at many length scales, both large and small, just as materials and manufacturing have to reach every level of the system to create the capabilities needed to sustain our defense systems. Artist: Erik Svedberg, image generated mathematically on a dual core cpu.
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Advisers to the Nation on Science, Engineering and Medicine
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WORKSHOP PLANNING GROUP
ROBERT H. LATIFF, Chair, U.S. Air Force (ret.) and R. Latiff Associates
W. DALE COMPTON, Purdue University
ALAN C. ECKBRETH, Eckbreth Consulting
JESUS M. DE LA GARZA, Virginia Institute of Technology
ROSARIO A. GERHARDT, Georgia Institute of Technology
GEORGE T. GRAY III, Los Alamos National Laboratory
THOM J. HODGSON (NAE), North Carolina State University
MICHAEL F. McGRATH, Analytic Services, Inc.
STEPHEN M. POLLOCK (NAE), University of Michigan
ROBERT E. SCHAFRIK (NAE), GE Aviation
DENISE F. SWINK, Private consultant
STEVEN G. WAX, Private consultant1
_____________
1 Resigned October 8, 2012.
DEFENSE MATERIALS MANUFACTURING AND INFRASTRUCTURE STANDING COMMITTEE
ROBERT H. LATIFF, Chair, U.S. Air Force (ret.) and R. Latiff Associates
ROBERT E. SCHAFRIK (NAE), Vice-Chair, GE Aviation
VALERIE BROWNING, ValTech Solutions, LLC
JESUS M. DE LA GARZA, Virginia Institute of Technology
GEORGE T. GRAY III, Los Alamos National Laboratory
MICHAEL F. McGRATH, Analytic Services, Inc.
E. SARAH SLAUGHTER, Built Environment Coalition
DENISE F. SWINK, Private consultant
A. GALIP ULSOY (NAE), University of Michigan
HAYDN N.G. WADLEY, University of Virginia
STEVEN G. WAX, Private consultant
Workshop Staff
DENNIS I. CHAMOT, Acting Director
ERIK B. SVEDBERG, Senior Program Officer
ROBERT J. KATT, Rapporteur/technical writer
RICKY D. WASHINGTON, Administrative Coordinator (until August 2012)
TERI G. THOROWGOOD, Administrative Coordinator (effective August 2012)
HEATHER LOZOWSKI, Financial Associate
ANN F. LARROW, Program Associate (effective August 2012)
Acknowledgment of Reviewers
This report has been reviewed in draft form by individuals chosen for their diverse perspectives and technical expertise, in accordance with procedures approved by the National Research Council’s Report Review Committee. The purpose of this independent review is to provide candid and critical comments that will assist the institution in making its published report as sound as possible and to ensure that the report meets institutional standards for objectivity, evidence, and responsiveness to the study charge. The review comments and draft manuscript remain confidential to protect the integrity of the deliberative process. We wish to thank the following individuals for their review of this report:
Thom J. Hodgson (NAE), North Carolina State University,
David W. Johnson, Jr. (NAE), Stevens Institute,
Gerald Mahan (NAS), Pennsylvania State University, and
Galip Ulsoy (NAE), University of Michigan.
Although the reviewers listed above have provided many constructive comments and suggestions, they were not asked to endorse the views presented at the workshop, nor did they see the final draft of the workshop summary before its release. The review of this workshop summary was overseen by Lyle Schwartz, University of Maryland. Appointed by the NRC, he was responsible for making certain that an independent examination of this workshop summary was carried out in accordance with institutional procedures and that all review comments were carefully considered. Responsibility for the final content of this summary rests entirely with the author and the institution.
Contents
WORKSHOP PRESENTATIONS AND DISCUSSIONS
Welcome: What Is DMMI? and Meeting Objectives
Open Discussion: Materials Issues and Programs to Mitigate Shortages
Materials Shortages and Strategies to Counter Them
Sustaining Air Force Aging Aircraft into the Twenty-first Century
The Air Force Diminishing Manufacturing Sources and Materials Shortages Program Office
Senate Armed Services Committee Report on Counterfeit Electronic Parts in the DOD Supply Chain
Counterfeit Parts and Parts Obsolescence
DARPA’s TRUST and IRIS Programs
Open Discussion Related to Counterfeit Problems, Substandard Parts, and Substandard Materials
Current Issues at the Defense Microelectronics Activity
Issues at the Office of Compliance of the Center for Devices and Radiological Health