Unmanned Aerial Systems Industry Overview & Material Usage Trends

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1 Unmanned Aerial Systems Industry Overview & Material Usage Trends Douglas A. McCarville, PE, TF Integrated Defense Systems Phone: February 11/19/04 22, 2005

2 Puget Sound Materials Expo

3 What is a UAV? Brief History Why UAV s? Procurement Industry Overview Operational UAV s Development Programs Material Trends Summary/Conclusions

4 What is a UAV? Common Names Drones Robot Planes Pilotless Aircraft <6, 2 ounce Source: Black Widow, AeroVironment, Inc. Remotely Piloted Vehicle (RPV) 166, 26,750# Unmanned Aerial Vehicle (UAV) Traditional Role Remotely or Self Piloted Expendable or Recoverable Source: Global Hawk, Northrop Grumman Intelligence, Surveillance and Reconnaissance/Target Acquisition (ISR/TA)

5 Department of Defense (DOD) UAV Classes Close Range (UAV-CR) - ~ 30 miles UAV-Short Range (UAV-SR) - Flight duration 8-10 hrs, ~ 125 miles UAV-Endurance (UAV-E) - Flight duration around 24 hrs, multiple missions Shipboard Source: Dragon Eye Naval Research Laboratory Tactical & Endurance Source: Dark Star Lockheed Martin

6 Descriptive Classes Tactical lb rapid deployable Endurance - > 24 hrs flight duration Vertical Takeoff & Landing (VTOL) Man Portable back-pack, hand launch Optionally Piloted Vehicle (OPV) - general aviation aircraft adapted to allow manned or unmanned operations Micro Air Vehicle (MAV) -< 6 in Research - specific investigations no production intent Source: X-36, Boeing Source: UAV Forum,

7 What is a UAS? Unmanned Aerial System (UAS) Aircraft, Ground Controls & Support Equipment Critical Platform Technologies Source: Dragon Warrior Naval Research Laboratory Mission Management - Automate, Human-Machine Interface & Planning Flight Stability, Command & Control Communications Miniaturize and Standardize Low Observable Apertures, Edges, RF & Infrared Propulsion Fuel Consumption/Extraction, LO, Noise & Durability Sensors Cost, Weight, Size and Power Miniaturization - Avionics, Sensors & Communications Weapons Time Critical Targets, Directed Energy, Standoff, Self Protection High Performance Materials Weight Multi-Functional Structures - Weight, LO & Volume

8 What is a UAV? Brief History Why UAV s? Procurement Industry Overview Operational UAV s Development Programs Material Trends Summary/Conclusions

9 UAV Brief History Aerodrome first UAV Langley Aerodrome WWI tested but not used (Sperry Torpedo) WWII German s V-1 & V2 flying bomb Vietnam - BQM-34 Firebee photoreconnaissance 1970 & 80 s Israeli Air Force Desert Storm tactical and intelligence gathering Balkans conflict surveillance Afghanistan added reconnaissance Operation Iraqi Freedom - ten UAV s types 2003 Iraq Predator and Hunter: drop arms ~1,500 developed, 60 nations possess U.S. companies, colleges & government organizations working on ~ 150 UAV s Sperry Torpedo Firebee Pioneer Source: Smithsonian National Air & Space Museum, Cradle of Aviation Museum, U.S. Air Force Museum & Navy

10 What is a UAV? Brief History Why UAV s? Procurement Industry Overview Operational UAV s Development Programs Material Trends Summary/Conclusions

11 Why UAV s? Source: Predator General Atomics Proved worth in Balkans & Desert Storm Predator dropped Hellfire - armed reconnaissance Urgent Need seen & UAV s put on Fast Track Transformation Technology - change the way wars are fought Dull Loitering for communications relay or signal jamming Dirty Environmental Testing (pollution, chemical, biological & radiation) Dangerous Reconnaissance and Suppression of hostile are defenses

12 UAV Pros & Cons Pros Take over dull, dirty or dangerous missions Eliminate loss of life Ground Cockpit can control multiple vehicles Cheaper (to-date small lots high per unit) Lower operations and support costs Cons 100 times greater accident rate Flying in same airspace as manned Requirements creep Ground Cockpit Air vehicle may be cheaper but entire system may not Significant technology advancement needed

13 UAV Implementation Hurdles Other options: manned aircraft, blimps & space satellites Risky New Technologies Paradigm Shift (silk scarf syndrome, pilots would rather fly real plane) UAV Procurement has Reputation of not getting past the development phase Tension Between Services Congressional Consolidation Initiatives Gold Plating/Requirement Creep more sensors, more weapons and more missions until too expensive and vulnerable Federal Aviation Administration (FAA) regulations (Coast Guard and NASA taking lead)

14 UAV Primary Military Roles Persistence, Precision, Survivability, Flexibility and Lethality (create time-sensitive targets and desired battlefield effects) Source: SensorCraft Jane s Defense Weekly Carry Sensors that Provide Commanders with ISR/TA - Intelligence gathering information about the enemy - Surveillance track groups/area under suspicion - Reconnaissance inspect areas to gather military information (bomb damage assessment, hazardous environments, etc.) - Target Acquisition detect/identify to allow weapon deployment (air defense missiles, artillery, air bases & command/control facilities)

15 UAV Military Roles (Cont.) Airborne Communications Node Special Operations Support Team with Manned Aircraft Source: X-45C Boeing - Predictive Battlespace Awareness: Net-centric constellation of manned and unmanned assets - Direct Fighter Aircraft - Global Hawk & Predator with Multi-Mission Maritime Aircraft (MMA) Carry/Drop Arms Air-to-air combat - Armed reconnaissance - Survivable deep strike - Airborne electronic attack - Persistent strike air patrol - Destruction/suppression of enemy air defenses

16 UAV Future Civilian Applications Medical Re-supply Law Enforcement - long duration surveillance Transportation Department follow hazardous material Energy Department high-altitude measurement instruments Homeland Security - Coast Guard - Border Patrol - Watch key assets - oil and gas pipelines, nuclear, dams, etc. Source: Fire Scout Northrop Grumman

17 What is a UAV? Brief History Why UAV s? Procurement Industry Overview Operational UAV s Development Programs Material Trends Summary/Conclusions

18 Congressional UAV Development Considerations Pace Scope - field many cheap UAV s or few expensive highly capable ones, sensors are starting to dominate the cost Cost vs. Capabilities price tag too high no longer expendable - R&D costs are about twice procurement costs Future Roles & Applications Manned vs. Unmanned - JSF: $37 M to B-2: $1.2B) - Dragon Eye: $30 K to Global Hawk $57 M Management Department of Defense (DOD) Industrial Base will ability to make manned aircraft erode

19 Management of UAV s Military Services 1988 Navy run Joint Program Office (JPO) Defense Airborne Reconnaissance Office (DARO) Office of the Assistant Secretary Of Defense for Command, Control Communications and Intelligence (OASD(C3I) Provide oversight Military Services Under OSD Program Development & Acquisition 2001 UAV Planning Task Force 2003 UAV Roadmap 2002 UAV JPO Promote Air Force and Navy UCAV Interoperability 2003 DOD Interoperability Working Group Joint Services and International Cooperation Tactical Control System (TCS) Common Ground Control System

20 UAV Acquisition Three Primary Methods Traditional Services acquisition pipelines Advanced Concept Technology Demonstrations (ACTD) Evolutionary Acquisition with Spiral Development (EA/SD) Examples Pioneer, Hunter and Shadow acquired by traditional means Others accelerated by circumventing milestones Predator and Global Hawk went through 3-5 year ACTD s instead of decades Global Hawk considered EA/SD and capabilities added incrementally as technology becomes available

21 Trends/Projections Fielded Major Platforms , , Total UAV s: in Iraq in 2004 (240 Raven s) Source: Dragon Eye, Navy Army plans: 6,000 UAV s by 2010 (mostly hobby size) Worldwide market (U.S. services & foreign militaries/governments): 1,000 to 2,000/yr small UAV s by end of decade UAV Annual Funding Profile UAV % of U.S. Aircraft Funding $ M Year Year Source: Unmanned Aerial Vehicles: Report to Congress

22 Recent/Projected Procurement U.S. DOD average $363 M/yr 2001: $667 M 2002: $907 M 2003: $1.1B 2004: $1.39 B - 4 Global Hawks - 16 Predators $700 M for J-UCAV Worldwide UAV Funding ($ B) OEM Procurement RDT&E Source: Unmanned Systems Magazine, Nov. 2004

23 What is a UAV? Brief History Why UAV s? Procurement Industry Overview Operational UAV s Development Programs Material Trends Summary/Conclusions

24 Industrial Base Considerations Need may be overrated? Loss of manned aircraft expertise (JSF last manned tactical fighter?) Commonality exists stealth airframe, advanced avionics, high performance engines & advanced materials Companies that loose manned contract can go after unmanned Boeing JSF J-UCAS Big 3 defense contractors (Lockheed Martin, Boeing and Northrop Grumman) all fighting/teaming for new contracts Low barriers (many vehicles inexpensive to produce) make it attractive to small companies UAV s are a growth industry!

25 UAV Vendors Past Barriers DOD interest cyclic Small orders Manned lucrative Source: UAV Forum,

26 Major Platforms as of 2003 UAV s 1% of military aircraft inventory (163/13,794) UAV s 32% of reconnaissance vehicles (163/485) Service Prime Qty Global Hawk Air Force Northrop Grumman 4 Predator Air Force General Atomics 48 Pioneer Navy/Marines AAI 47 Hunter Army Northrop Grumman 43 Shadow Army AAI Source: Global Hawk Northrop Grumman Source: Predator General Atomics Source: Pioneer, Navy Source: Hunter Northrop Grumman Source: Shadow, AAI Source: OSD UAV Planning Task Force

27 What is a UAV? Brief History Why UAV s? Procurement Industry Overview Operational UAV s Development Programs Material Trends Summary/Conclusions

28 UAV Maturity Vaporware - designs on paper or briefing slides Developmental Hardware - nonproductionized flying prototype Production Systems - currently on contract DOD Designated Source: X-47, DARPA Source: Directed Energy Vehicle AFRL Source: Pioneer, UAV Inc.

29 US Military Missiles, Rockets, Drones and Probes Designation System Puget Sound Materials Expo (1) Vehicle Purpose C - Transport D - Decoy E - Special Electronics, Communication G - Surface Attack I - Interception (air or space) L - Launch Detection M - Scientific Measurements, Calibration N - Navigation Q - Drone, UAV R - Reconnaissance S - Space Operations Support T - Training U - Underwater Attack W - Weather R Q 1 A Predator (1) (2) (3) (4) (5) (2) Type of vehicle: B Booster M - Guided Missile, Drone, UAV N - Probe R - Rocket Q - UAV S - Satellite (3) Model Number (4) Version A - First (prototypes) B Second (sometimes system) (5) Popular Name Source: Air Force Joint Instruction (AFJI) , and in DOD Publication L

30 DOD Designated UAV Platforms RQ/MQ-1 Predator: General Atomics RQ-2 Pioneer: UAV Inc. (Joint IAI & AAI Corp. venture) RQ-3 DarkStar: Lockheed Martin/Boeing RQ-4 Global Hawk: Northrop Grumman (Teledyne Ryan) RQ-5 Hunter: Northrop Grumman (TRW, Israel Aircraft Industries (IAI)) RQ-6 Outrider: Alliant Techsystems RQ-7 Shadow 200: AAI RQ-8 Fire Scout: Northrop Grumman MQ-9 Predator B (Hunter Killer): General Atomics CQ-10 SnowGoose: Mist Mobility Integrated Systems Technology

31 Tier III Overview 1990 Pentagon wants classified LO-HAE (Low-Observable High-Altitude Endurance) UAV to replace U-2 and SR Joint Requirements Oversight Council (JROC) endorse three-tier approach to acquiring an endurance Tier II Predator RQ-1 Medium Altitude Endurance (MAE) Tier III: too many technological and financial risks. Tier II+ Global Hawk RQ-4 High Altitude Endurance (HAE) Tier III DarkStar RQ-3 Very Low Observable (VLO)

32 Air Force: RQ/MQ-1 Predator Tier II Medium Altitude Endurance (MAE) Started 1994 first ACTD to transition to military duty Prime General Atomics Aeronautical Systems, Inc. (GA-ASI) Mission RQ -1 Reconnaissance & Target Acquisition MQ -1 Multi mission, laser designating & weapon firing Airframe - Composite Fuselage, Wings & Control Surfaces Feature Description Comment Altitude Medium 10-15,000 ft Endurance Long 24 hr Range Moderate 400 nm Speed Slow mph Cost/Vehicle $ 4.5 M Cost System $ 30 M Payload 450 # Surviellance Equipment: (2) electro-optical (E-O) cameras (1) infrared (IR) Multi-spectral Targeting System (MTS) Synthetic Apeture Radar (SAR) Hellfire missiles Controls Ground Pilot yoke, joystick & rudder Communication Satellite Wingspan - 48 ft Fuselage 27 ft Empty Weight: - 2,800# Source: Predator, General Atomics.

33 Predator History Début 1995 Balkans surveillance (weapon movement & battle damage) Used in all Mid East Operations First UAV to fire a weapons against enemy combat forces After the gulf war put on Fast Track Current Fleet ~ 65, ~ 30 lost: attrition, combat missions, lack of redundant systems, wing icing, loss of satellite communications link In Air Force LRIP ~ 25/yr (~130 total) Extremely Versatile: - Navy: Broad Area Maritime Surveillance (BAMS) - NASA: B-ER 49 hour on-time atmospheric research - Army: Extended Range Multi-purpose (ER/MP) - Heavy Fuel Engine (HFE) Weaponized B version MQ-9 Hunter-Killer Wingspan - 67 ft Empty Weight: - 10,000# Altitude = 50,000 ft 800# internal payload - 30 hours 3,000 # external stores (8 Hellfire) Source: Predator, General Atomics.

34 DARPA: RQ-3 Dark Star Tier III- Very Low Observable (VLO) TIII Spin-off best altitude, endurance, and signature for a $10M Prime Lockheed Martin/Boeing - wing development and production Mission fly surreptitiously over hostile territory st prototype crashed on takeoff 1999 USAF cancels because of cost and Global Hawk 2003 USAF acknowledged use of new stealthy high-endurance UAV in Operation Iraqi Freedom Feature Description Comment Altitude High 65,000 ft Endurance Medium 12 hr Range Moderate 500 nm Speed Moderate 285mph Cost/Vehicle $ 10 M Cost System? Stealth LO flying-wing design Payload 1,000 # Tactical Endurance Synthetic Aperture Radar Recon/Optical electro-optical camera Controls GPS/INS navigation system Communication Wideband line-of-sight link or a J-band SATCOM link. Wingspan - 69 ft Fuselage 15 ft Empty Weight: - 8,600# Source: Dark Star Lockheed Martin

35 Air Force: RQ-4A/B Global Hawk Tier II+ High Altitude Endurance (HAE) Began as ACTD in 1994 Entered LRIP in 2002 Prime Northrop Grumman (Teledyne Ryan) Mission All weather, long dwell persistent source of high quality imagery Composites ~ 65% of structural weight - Vought Aircraft Industries assembles the wings - Alliant Techsystems provides ~3600 # of graphite epoxy wing structure - Aurora Flight Sciences provides composite: ruddervator assemblies, engine nacelles and fuselage components Feature Description Comment Altitude High 65,000 ft Endurance Long 35 hr Range Long 5,400 nm Speed Moderate 250 mph Cost/Vehicle $48 M Cost System $57 M Payload 2,000 # All weather SAR Multi-targeting Indicator (MTI) E-O camera digital camera and IR sensor AN/ALR-69 radar warning receiver AN/ALE-50 towed decoys Signals Intelligense (SIGINT) sensors Controls Autonomous flight plans GPS/INS navigation system Wingspan ft Fuselage 44 ft Empty Weight: - 26,750 # Source: Global Hawk, Northrop Grumman

36 Global Hawk History ACTD: 8 delivered (4 remain) Operation Enduring Freedom (Afghanistan): - Imagery intelligence workhorse - 15,000 images, 50 missions & 1,000 flight hours - 2 lost - engine failure & improperly installed bolt Air Force: LRIP 19, ~ 50 total (4-7/yr) DOD concern additions making system unaffordable - radar modes, signals intelligence capability & larger B version) 2001 first UAV trans-pacific UAV flight California to Australia Navy: Global Hawk Maritime Demonstration (GHMD), as many as 50 for Broad Area Maritime Surveillance (BAMS) Homeland Security: evaluating Foreign Governments: Australia, Germany and NATO Source: Global Hawk, Northrop Grumman

37 Army: RQ-5 Hunter Army, Navy & Marine Corps: RQ-2 Pioneer Wingspan - 17 ft Speed 110 mph Cost $ 1 M Source: Pioneer, Navy Deployed 1986, every major operation (23,000 hrs) Low radar/infrared cross section & remote control Over horizon target surveillance, naval gunfire spotting and battle damage assessment Out of production: - Navy no longer flies - Marines till end of decade Wingspan - 30 ft Speed 130 mph Cost $ 1.2 M Source: Hunter, Northrop Grumman First flight 1994 Unmanned Aerial Vehicle - Short Range (UAV-SR) Battlefield surveillance and target acquisition Terminated in cost overruns, crashes, unreliable Army uses for test & evaluation Shadow to replace

38 Army: RQ-7 Shadow 200 Tactical Unmanned Aerial Vehicle (TUAV) - twin-boom pusher layout Day/night reconnaissance, surveillance, target acquisition & BDA Conventional wheeled take-off/landing or catapult launch/tailhook catch Dormant until Hunter problems Navy dropped out to pursue vertical take-off and landing UAV 1999 LRIP, 2003 full rate production 2009 Currently 41 systems: 4 air vehicles, 2 ground control stations & launcher/landing system RQ-7B larger wings more efficient airfoil & increased fuel capacity 6 hr duration Wingspan - 11 ft Speed 140 mph Range - 67 m Cost - $ 350K/10.7 M Source: Hunter, AAI

39 Navy: RQ-8A Fire Scout Special Operations Command: CQ-10 SnowGoose Length - 23 ft Speed 140 mph Range 110 m Endurance - 5 hr Shipboard capable to replace Pioneers 2000 Engineering and Manufacturing Development (EMD) 2001 cancelled because of changing requirements Critics slow, survivability, mobility, range & payload NG lobbying/improvements: increased lift, survivability & weapons 2003 chosen for Vertical Takeoff and Landing (VTUAV) demo, Navy to test till 2008 Pin-point delivery of small cargo items Self-propelled autonomous GPS-guided parafoil Combined cargo/fuel 600 lb Speed 40 mph Altitude 18,999 ft Cost - $250 K Source: Snow Goose, MMIST Inc.

40 Marine, Army: Man Portable UAV s Wingspan - 4 ft Speed 40 mph Range 6 m Endurance - 1 hr Source: Dragon Eye Naval Research Laboratory Over-the-hill reconnaissance, surveillance and target acquisition at the tactical level (platoons, squads, etc.) Sparta Composites produces composite wings/airframe Stored in backpack & launched by hand or bungee Lap-top ground controls & 2 vehicles 70K Marines plans to buy 1,000 vehicles & 350 stations $40 M 250 used by army in Iraq to provide snapshots of operating theatre Source: Pointer, AeroVironment Source: Raven AeroVironment

41 Air Force: Desert Hawk Force Protection Aerial Surveillance System (FPASS) Small UAV s Enhance security of oversee bases Conduct area surveillance: patrol base perimeter & runway Initial systems deployed in Operation Enduring Freedom System Desert Hawk: six UAV's, ground control station, computer displays, recorder, communications equipment, interchangeable payloads and launch equipment. $300 on airframe, $30K in cameras, computer motor and mechanical parts AeroMech Engineering uses foam construction Launched with bungee chord Length 3 ft Range - 5 m Speed 60 mph Duration 1 1/2 hr Altitude 500 ft Source: Desert Hawk, Lockheed Martin

42 What is a UAV? Brief History Why UAV s? Procurement Industry Overview Operational UAV s Development Programs Material Trends Summary/Conclusions

43 Navy & Marine Corps: Scan Eagle A-15 Low-cost, long-endurance UAV Boeing and The Insitu Group Intelligence surveillance and reconnaissance (ISR) and communications Catapult launched, flies preprogrammed or operator initiated missions Global Positioning System (GPS) guided Two mobile deployment units bought by Marine Corps for use in First Marine Expeditionary Force (1MEF) in Iraq Wingspan - 10 ft Endurance - 15 hr Source: Scan Eagle, Boeing

44 DARPA/Army: Hummingbird A-160 Unmanned helicopter for Army s Future Combat System (FCS) First flight 2002 Boeing purchase Frontier Systems in 2004 Mission: surveillance, targeting, communications and data relay, lethal & non-lethal weapons delivery, precision re-supply and special missions operations (extract people under fire) Army: two in 2006 Speed 160 mph Range 2,500 m Endurance 40 hr Altitude 30,000 ft Source: Hummingbird, Boeing

45 DARPA: Dragonfly X-50A High-speed, vertical takeoff and landing (VTOL) Canard /Rotor/Wing (CRW) - combines vertical takeoff/landing with high-subsonic cruise speed Two technology demonstrators assembled Remote control of a pilot in the ground station cockpit Conducted first hover flights in 2003 Length 8 ft Speed 575 mph Rotor/wing 12 ft Source: Dragonfly, Boeing

46 AFRL: SensorCraft Extremely high altitude long endurance Blend wide spectrum of emerging technologies Identify camouflaged, concealed, and deceived targets Trade between: - sensor coverage/field of view - endurance - altitude - engine efficiency/power generation Advanced RF capabilities integrated into the aircraft structure Source: SensorCraft, AFRL

47 Vertical Lift istar MAV Allied Aerospace Dragon Stalker Guardian Source: UAV Forum, Golden Eye

48 Coast Guard: Eagle Eye HV-911 Vertical Unmanned Aerial Vehicle Started 1986, Will enter Service 2006: Coast Guards Deepwater Modernization Bell, Lockheed Martin, AAI & Textron formed Team Eagle Eye - Lockheed brings low cost composite capability - mostly fiberglass Fast long endurance surveillance aircraft, Tiltrotor technology: - Patrol coastline for drug smugglers, refugees nd ships in distress - Transmit video & infrared to cutter & ashore command centers Full rate production contract, 5 per year, total ~ 70 Other programs considering: - UCAR program - FCS: Extended Range Multi Purpose (ERMP) - UAMC Pioneer replacement - Commercial: law enforcement, news gathering, etc. Length 18 ft Speed 230 mph Duration 5.5 hr Payload # Range 300 m Source: Eagle Eye, Bell Helicopters

49 DARPA: Mini/Micro Air Vehicles (MAV) Measure inches not feet and cost thousands not millions Ability to conduct perch and stare missions DARPA $30M MAV effort, Army and Secretary of Defense 350 as part of ACTD due to end in 2005 Length 6 in Speed 35 mph Duration 1 hr Payload 1 # Source: Mini-UAV, Victory Systems Source: Black Widow AeroVironment

50 Puget Sound Materials Expo Air Force & Navy: Consolidated Unmanned Combat Air Vehicle (UCAV) Joint Unmanned Combat Air Vehicle (J-UCAS) DARPA leading five year $4B effort Strike and Suppression of Enemy Air Defenses (SEAD) First UAV developed primarily for combat Boeing X-45, Northrop Grumman X-47 Field: Air Force 2010, Navy 2015 By 2010, 1/3 of deep strike aircraft to be unmanned (Day one force enabler deep penetration aircraft) - 75 B-2 s and F117A s - 14 UCAV s High risk high payoff - new technologies required Stealth skins, control surfaces, fairings and ducts Source: X-45A, Boeing Range m Speed.8 mach Duration 24 hr Payload 4,500 # Source: Pegasus, Northrop Grumman

51 Joint Unmanned Combat Air Vehicle (J-UCAS) DOD ordered order Air Force and Navy programs to combine like JSF First flight 2006, operational by 2008 Smaller than manned fighters with comparable weaponry: stealthiness and survivability advantage Fly autonomously with no pilot direct stick help Boeing to build (3) X-45C Northrop to build (3) Three full scale X-47B: mostly composite materials by Burt Rutan Scaled Composites Source: X-45C, DARPA Source: X-47B, DARPA

52 DARPA & Army: Unmanned Combat Armed Rotorcraft (UCAR) Rotorcraft - Armed reconnaissance and attack missions Carry conventional weapons rockets, missiles ands guns directed energy weapons Cost 20-40% of cancelled Boeing-Sikorsky RAH-66 Comanche ($4-8M) Phase I: Four teams received $3M to develop conceptual designs : -Northrop Grumman - Lockheed Martin/Bell Helicopter Textron - Boeing - Sikorsky Aircraft/Raytheon 2003 downselect Lockheed and Northrop Phase II: preliminary select one contractor Phase III: fly 2006 Phase IV: System Design and Development (SSD) Source: UCAR, Lockheed Martin

53 Navy: Broad Area Maritime Surveillance UAV (BAMS) Provide global coverage through persistent long range surveillance Maritime/land ISR capability, ability to send sensor data directly to the aircraft carrier & wide range of sensors to include E-O, IR and SIGNT Navy version of Global Hawk: 360 degree sensor point of view, surface search radar, communications intelligence and acoustic relay BAMS ($2 B value) to operate along side of Multi- Mission Maritime Aircraft (MMA) surveillance aircraft Phase I: 2005 Global Hawk Maritime Demonstration (GHMD) - Develop Concept of Operation (CONOPS) - experiment with alternate sensors - study integrated Tactical Control Systems (TCS) Phase II : 2008 BAMS UAV, GH or new vehicle? Source: MMA, Boeing Source: BAMS,

54 Army: Future Combat Systems (FCS) Prime Boeing and Science Applications International Corporation (SAIC) Class I: weigh: ~35 #, backpackable & used for immediate situational awareness Class II: ducted fan, conventional or rotorcraft: - reconnaissance, security/early warning, line-of-sight target acquisition/designation at company level, beyond line-of-sight & non line of sight DARPA: Organic Air Vehicle (OAV): weapons system targeting in adverse weather Class III: #, battalion level, mine & chemical/biological/nuclear weapon detection, 6 hr endurance & 24 mile radius Vehicle mounted capable of takeoff and landing from unimproved sights 2 yr maturation with system selected in 2007 System Design and Development (SSD) in 2008 Operational with first FCS equipped unit in 2014 Source: Dragonfly Pictures, Inc

55 What is a UAV? Brief History Why UAV s? Procurement Industry Overview Operational UAV s Development Programs Material Trends Summary/Conclusions

56 Air Force: UAV Air Vehicle Directorate Aggressively Develop, Field, and Operate UAV s: Cut Cost Reduce Weight Increase Performance Candidate Revolutionary Technologies: Automated Flight Control Systems Autonomous Aerial Refueling Flexible Structures Active Flow Control Design Tools for Advanced Technologies Dual Use Potential Low-Cost/High Performance Composites Multifunctional Integrated Structures and Subsystems

57 Composite & UAV s Benefits/Needs Remain aloft as long as possible Maximize payload carrying capability Harsh environment (marine, desert, icing, etc.) Stealth requirements Composite Application Small UAV s: - may be entirely composite (foam, bonded shells, etc.) - similar construction to remote control airplanes Large UAV s: - Methods, materials & standards similar to manned aircraft - Aluminum substructure, composite skins, RAM, RAS

58 Global Hawk Manufacturing Source: Global Hawk, Northrop Grumman Composites ~ 65% of structural weight Aluminum substructure Composite skins, ruddervator nacelles and fuselage components Source: GH Tooling, Aurora Flight Sciences

59 UAV Composite Usage Current usage: in Europe & North America composites used on UAV's amounts to 1/10 the amount used on fighter aircraft Low barrier to entry: variety of vehicles, material and structures make UAV s an attractive niche for composite companies seeking future growth Future Material Developments (25 yrs): - Nano materials - Morphing airframes - optimize shape for mission & flight conditions (stretching skins & shape memory alloys) - Aerodynamic maneuvers impossible for manned aircraft

60 What is a UAV? Brief History Why UAV s? Procurement Industry Overview Operational UAV s Development Programs Material Trends Summary/Conclusions

61 Summary/Conclusions UAV market projected to double in the next ten years Legacy DOD platform (RQ series) entering production and being upgraded Services in various stages of large development procurement activities: - Coast Guard: Deepwater Modernization - DARPA: Organic Air Vehicle (OAV): - Army: Future Combat Systems (FCS) - DARPA & Army: Unmanned Combat Armed Rotorcraft (UCAR) - Navy: Vertical Takeoff and Landing (VTUAV) - Navy: Broad Area Maritime Surveillance UAV (BAMS) - Air Force & Navy: Joint Unmanned Combat Air Vehicle (J-UCAS) Revolutionary technologies needed: high performance multifunctional material Vehicle variety and low barriers to entry make it an attractive growth markets Large/small companies, government and schools working on over 150 vehicles

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