Ammunition and Weapon Systems Engineering Services

Providing environmental and engineering solutions from initial ideas through design/analysis, prototype testing/evaluation to production

Concurrent Technologies Corporation (CTC) uses a “design-to-production” approach, examining the entire process/system lifecycle, from environmental concerns to producibility. CTC’s full-service solutions team consists of engineers, scientific experts, technicians, and project managers with in-depth experience in materials, design, analysis, rapid prototyping, testing, and manufacturing.

Innovative, Full Lifecycle Engineering Solutions
Both the Department of Defense (DoD) and the commercial industry can benefit from CTC’s award-winning approach to ammunition. The National Armaments Consortium and the DoD Ordnance Technology Consortium recognized CTC for Outstanding Technical Achievement for its groundbreaking manufacturing process that improves logistics and the end product. CTC is developing and testing prototype ammunition cartridges that:

Increase performance
Improve accuracy
Reduce weight
Reduce manufacturing footprint
Lower the total cost of ownership

This work is building on decades of experience developing industry-leading engineering solutions that cover research and development through testing, technology transition, and implementation.

CALL OR EMAIL:

Lori Denault
Director,
Mechanical Design & Analysis

814-269-6246
ammunition@ctc.com

Core Ammunition and Weapon Systems Capabilities

Technical Engineering Services

Modeling and Simulation

Structural FEA
Dynamic analyses and firing simulations
Terminal ballistics
Fluid flow and thermal analyses
Metal forming and manufacturing processes

Design and Engineering

Prototype design and development, design maturation and CAD/TDP
Product & process enhancement
Design for manufacturability and cost reduction
Design optimization and weight reduction

CAE Software

Abaqus FEA
Ansys FEA
Fluent CFD
JMP Statistical Analysis / DOE
PTC Creo
Solidworks
Autodesk Inventor
Catia
SolidEdge

Technology Transition

MRL/TRL evaluation
Facility layout and scale up
Cost modeling
Technology evaluation, maturation, insertion, and transition

Material Characterization, Testing, and Inspection

Mechanical Property Testing

Temperature ranges from −130°C to +2200°C
Tensile, compression, bend, shear and flexure
Drop tower, impact and dynamic tear
Ductility and formability
Fracture and fracture toughness

Metallurgical Analysis

In house PhD expertise
Material characterization and selection/development
Stereoscopic microscopy
Light optical microscopy
Energy dispersive spectrometry
Micro and nano hardness
Image analysis

Laboratory Testing

High and low temperature, cyclic temperature, humidity, condensation, ultraviolet
Cyclic corrosion, salt fog testing, accelerated weathering, stress corrosion cracking, total immersion corrosion, coating evaluation
Chemical analysis – wet chemistry and instrumental methods
Materials compatibility
Test method development

Metrology Capabilities

FARO Edge ScanArm ES
Coordinate measuring machine (CMM)
SpatialAnalyzer software

Prototype Fabrication and Additive Manufacturing

Metal Injection Molding

Mold design and best practices for product design
110 ton injection molding machine
Prototype solvent debind and hydrogen sinter equipment
Secondary operations and heat treatment partners
Metal forming and manufacturing processes

Small Caliber Ammunition Prototyping

Bullet/projectile fabrication and assembly equipment
Taper presses and trimming equipment
Cleaning, deburring, and tumbling processes
Ammunition inspection, priming, and loading capability
Class 10 federal firearms license

Additive Manufacturing (AM)

Intricate net-shaped components in titanium, aluminum, corrosion resistant steel, and nickel-based materials
SLM 280HL laser powder bed fusion capability
Hybrid manufacturing AMBIT™ laser directed energy deposition integrated into a Haas Automation VF-11 vertical milling machining center
VRC Gen III cold spray

Traditional Fabrication Prototyping

Friction stir welding
Fusion welding with certified welders
CNC lathes and mills
EDM

Core Ammunition and Weapon Systems Capabilities

CTC operates two facilities in Johnstown, Pennsylvania, with more than 400,000 ft2 of combined office, laboratory and high-bay demonstration space that meet DoD security requirements. CTC’s Environmental Technology Facility offers two large high-bay spaces totaling over 130,000 ft2 that are routinely used to develop and demonstrate engineering and advanced manufacturing technologies and to fabricate large-scale first-of-a-kind prototype structures.

Ammunition and Weapon Systems Engineering Services

Ammunition

Developed a single-piece stainless steel cartridge case that can increase lethality, improve accuracy, and reduce cartridge weight

CTC has utilized advanced metal injection molding (MIM) processes to develop a single-piece, high-strength stainless steel cartridge case that is stronger, stiffer, and lighter than traditional brass. The metallic design allows for trade space between weight reduction and lethality with affordable costs in mass production.

Weapon Systems

Novel manufacturing approaches provide more than $40 million cost savings

CTC improved the affordability of the 155MM howitzer by converting multi-part components to single-piece titanium investment castings, including simplifying the 60-part saddle to one-part. The casting process and other innovative production processes reduced costs by $40 million for the initial-rate and full-rate production of nearly 590 guns, with proportional cost avoidance for subsequent orders.

Process Development and Optimization

Development of a coating process for steel tipped enhanced performance round (EPR) penetrators to improve their corrosion resistance

CTC is improving the environment compatibility, shelf life, and ruggedness of Army EPR ammunition through development, test and evaluation of enhanced corrosion coatings for steel tipped projectiles. Corrosion testing, rough handling, and first article testing were performed prior to technology transition and production implementation.

Manufacturing Support

Production line successfully transitioned to client facility, allowing client to meet deliverable schedule

CTC developed the M-72 FFE production line to assist our client with meeting their deliverable schedule for qualification units. CTC built jigs/fixtures and quality test equipment in addition to setting up a production line for preproduction/debug and LRIP/qualification. The production line was transitioned to the client facility, and CTC provided setup and training to the client’s employees.