N121-066 TITLE: Transparent Armored Windows for Ships

TECHNOLOGY AREAS: Materials/Processes

ACQUISITION PROGRAM: LPD 17 Program, PMS 317

RESTRICTION ON PERFORMANCE BY FOREIGN CITIZENS (i.e., those holding non-U.S. Passports): This topic is "ITAR Restricted". The information and materials provided pursuant to or resulting from this topic are restricted under the International Traffic in Arms Regulations (ITAR), 22 CFR Parts 120 - 130, which control the export of defense-related material and services, including the export of sensitive technical data. Foreign Citizens may perform work under an award resulting from this topic only if they hold the "Permanent Resident Card", or are designated as "Protected Individuals" as defined by 8 U.S.C. 1324b(a)(3). If a proposal for this topic contains participation by a foreign citizen who is not in one of the above two categories, the proposal will be rejected.

OBJECTIVE: The objective is to develop a next generation, transparent armored window using advanced materials and/or innovative manufacturing process improvements for use onboard naval ships.

DESCRIPTION: Transparent armor windows are specially designed to protect the ship’s crew from ballistic or fragmentation penetration and to allow for visibility during night and day operations. Transparent armor windows are installed on surface ships where visibility of the topside environment is needed for performing navigation and mission requirements such as flight operations. Window panels range in size from small square panels (2.5 ft x 2.5ft) to large rectangular panels (2.5 ft x 5.5ft), and the overall weight is a function of the window thickness (ref (3)). LPD 17 Class ships have transparent armor windows installed on the bridge, in debark control, in the helicopter control tower, in the well-deck control and vehicle conflagration stations. The window design requires protection from threats while arresting fragments that could injure personnel, as well as the ability to handle the marine environment of surface ships. Current window systems are outfitted with window wipers and embedded heating elements. Some are treated with a radar cross-section reduction film. The current technology for the production of transparent armored windows produces high stress-concentrations (bi-axial) within the laminated panel sections. It should be noted that the current TAW design meets the ballistic testing requirements as outlined in ref (4); however, the built-up, embedded stresses as a result of the materials and manufacturing process usually "releases" after the TAW is installed on the ship. Thus, thus the interlayer striations and stressors within the laminate schedule contribute to the manifestation of internal, post-manufacturing surface defects which in turn leads to early failure of the windows. The cracks, crazing, and chemical attack (caused by some onboard cleaning products) all contribute to TAW failures and jeopardizes the ballistic protection properties and negatively impacts visibility. TAW’s are a long lead manufacturing material item (18-24 weeks after receipt of the purchase order). Because of their weight and location, they cannot be repaired, only replaced, and replacement requires a depot level capability. The current TAW design is more than 20 years old. Since the inception of this TAW design there has been significant improvements in ceramic development, nanotechnology, etc. as well as in manufacturing processes.

This topic seeks to explore the application of advanced materials and/or innovative manufacturing processes to produce large panel, transparent, armored windows for use onboard naval ships. It is anticipated that the utilization of advanced materials (such as but not limited to, nanotechnologies, glass, laminates, and films) and /or manufacturing processes (assembly of laminate schedules, autoclaving processes, etc) will improve the current life-cycle of TAW panels. Of particular interest are concepts that address improvement in current manufacturing processes and provide increased resistance to chemical attack as well as providing shorter manufacturing lead times. Additionally, there is interest in concepts that incorporate the ability to provide embedded heating elements or have material properties/characteristics that provide equivalent ice phobic functionality without the use of embedded heating elements while meeting performance requirements as specified in MIL-STD-662 (ref (4)). Proposed concepts shall be manufactured and delivered in such a manner as to be readily installable into the existing footprint of the current LPD TAWs. Using the LPD 17 Class ship specification 625d, 095-625, MIL-PRF 46108C, type II construction methods as guidance (ref (2 and 3)), the proposed TAW concepts shall meet or exceed all of the applicable ship specifications such as optical qualities, visible light transmittance , Electromagnetic Interference (EMI), shock, vibration, applied static pressures, allow for the use of night vision goggles and have the capability to integrate with existing ship service support systems (ref (1 and 2)). Finally, proposers shall describe how radar cross-section films could be incorporated into the proposed concept and will consider any resultant impact of the films on any prospective manufacturing process concepts. Proposed concepts should be robust enough to withstand off-gassing/curing of shipboard construction materials (i.e. curing of paint coatings within a confined space) and should be compatible with standard shipboard cleaning products and processes.

PHASE I: Develop an innovative concept for transparent armored windows through the application of advanced materials and/or innovative manufacturing process and demonstrate the feasibility of developing the concept and meeting shipboard armor protection for large, transparent, armored windows. Perform bench top experimentation, where applicable, as a means of demonstrating the identified concepts. Identify materials, manufacturing process and performance goals to develop the next generation of TAW’s. Establish validation goals and metrics to analyze the feasibility of the proposed solution. Finally, describe the approach that will be used in Phase II to perform material qualification of test samples.

PHASE II: Develop, demonstrate and build prototype window coupons, as identified in Phase I, for laboratory evaluation. In a laboratory environment, demonstrate and evaluate the ability of prototype coupons to meet the performance goals established in Phase I. Develop manufacturing techniques in accordance with US Navy specified requirements for safety and protection as identified in the reference material. The contractor will be expected to develop manufacturing control procedures, produce test samples of a specified size using selected manufacturing techniques, conduct quality assurance inspection, and report results. Develop a cost benefit analysis identifying window manufacturing cost, and a Phase III installation, testing, and validation plan. Successful window prototypes/coupons will be subjected to MIL-STD 662 in Phase III.

PHASE III: If the Phase II effort is successful, the contractor is expected to support the Navy in transitioning the armored windows to shipboard use should a Phase III award be made. Specifically, in accordance with the Phase III testing and validation plan, the contractor will manufacture window coupons and test in accordance with MIL-STD-662. The contractor will manufacture transparent armored window coupon(s) using approved design and manufacturing techniques, develop first article test procedures, and conduct testing in accordance with US Navy specified qualification requirements. Provide report of final test results for qualification. Once validated, windows will be manufactured and installed onboard a navy ship for evaluation.

PRIVATE SECTOR COMMERCIAL POTENTIAL/DUAL-USE APPLICATIONS: Improved TAWs could be used in any work environment requiring ballistic window protection such as banks, portable police shield, residential security, and limousines/cars.

REFERENCES:
1) LPD 17 Class Bridge Compartment and Helo Control Compartment Design, Available at www.dodsbir.net/sitis.

2) LPD 17 Class Section 625 Specification – Shipboard Window Requirements, Available at www.dodsbir/net/sitis.

3) MIL-PRF 46108C, Performance Specification: Armor Transparent. Available at http://www.everyspec.com/MIL-PRF/MIL-PRF+(030000+-+79999)/MIL-PRF-46108C_20160/

4) MIL-STD-662, V50 Ballistic Test for Armor. Available at http://assist.daps.dla.mil/quicksearch/

KEYWORDS: TAW; armored window; ballistic protection; transparent armor; blast fragmentation resistant; bullet resistant glass

** TOPIC AUTHOR (TPOC) **

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