Forging, forming, and welding were not well matched for vehicle program needs.Īdditive manufacturing (AM) technologies present new opportunities in material processing and flexible fabrication that provide a compelling avenue for producing new vehicle hull concepts.Īn additive manufacturing method can be generally described as a freeform fabrication system that creates a part by digitally controlling a material processing unit to build the part one layer at a time in the designed shape. A truly versatile technology enables exploration of new design concepts, rapid implementation, and flexibility to accommodate multiple vehicle platforms. They were able to demonstrate successful fabrication and material quality, but restricted geometrical design freedom and agility in manufacturing. The focus was on fabrication methods for thicker underbody hulls of vehicles that required fewer welded joints during manufacturing, directly increasing the durability of the hull against underbody attacks. Jointless Hull project team standing under the the full-scale tool being manufactured.įormer Army ManTech programs for underbody hulls focused on technologies such as forging and forming for consolidated hull structures and high-energy buried arc weld to minimize weld porosity. While developments in maneuverability and protection systems have aided the warfighter to avoid such threats, the rapid replenishment of vehicle underbody inventory remains critical. During the Vietnam War it was estimated that 73 percent of all vehicle losses were suffered because of anti-personnel and anti-tank mines. Underbody threats are an age-old problem for all military ground vehicles.
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