R. Cochran, Boeing-St. Louis, Maryland Heights, MO; H. N. Chou, Boeing Phantom Works, St. Louis, MO
Low cost fabrication and assembly processes are the primary driving force for weapon systems such as Small Diameter Bomb (SDB) and Joint Direct Attack Munition (JDAM). Both of these programs have taken a more commercial approach in defining the requirements of the weapon components to become more cost effective. JDAM started this acquisition reform by virtually elimination military and Boeing specific process specification which drove up costs without adding value to the product.
SDB recently has followed this model as well as looking at processes and suppliers that were traditionally non-aerospace to take advantage of processes that were better fit for the higher rates of production for weapons. Automotive, Marine, and Recreational vehicle industries have been sought out for proven cost competitive processes.
Some of the processes that have been qualified and are being used on SDB and JDAM are as follows:
Aluminum Die Castings - Structural and Nonstructural
Inertia Welded Steel Warhead Case
Permanent Mold Aluminum Castings
17-4PH Metal Injection Molding
Shape Memory Alloys
Other processes under development with Phantom Works
Semi-Solid Metal (SSM) Aluminum Castings
Lost Foam Aluminum Castings
V-process Aluminum Castings
Spinduction solid state welding without flash
An overview of these processes and qualification and finishing processes will be discussed.
This presentation will summarize materials and processes being developed and utilized on weapon programs such as Small Diameter Bomb (SDB) and JDAM. These programs are shifting to commercial processes to improve affordability to the customer without sacrificing structural integrity. Low cost casting, welding, and other processes such as Metal Injection Molding will be discussed.
