Northrop Grumman researchers in Dayton, Ohio develop micro-scale testing for high-temperature, low-observable materials; Defect rate fell from 70% to under 10%
Micro Magic | Northrop Grumman
Micro Magic In Dayton, a small team is turning tiny samples of advanced materials into major gains in stealth, quality and efficiency. In Dayton, a small team is turning tiny samples of advanced materials into major gains in stealth, quality and efficiency. By Suzanne Kubler In the world of aerospace, efficiency is paramount. A team of Northrop Grumman researchers in Dayton, Ohio, has that down to a science. They are pioneering methods inside the Dayton Survivability Advanced Materials Lab that are setting the standard in the industry. The group, led by chemist and materials process engineer, Amber Hancock, has found a way to transform minuscule quantities of complex materials into solutions that work seamlessly at full scale — saving resources and ensuring quality. Their work is revolutionizing how Northrop Grumman tests high-temperature materials, solving complex problems on a remarkably small scale. Just a tiny dab of specialized material, no larger than the eraser on the tip of a pencil, offers the Northrop Grumman team the answers to how much larger and costly quantities will respond to different factors. “Our lab developed techniques that even the material suppliers haven’t been able to figure out. They make the product and can’t predict the behavior of their own material like we can,” said Amber. “The raw material has changed over the years. The technique I developed can pick up on these changes and ensure consistent, high-quality parts, while other tests cannot.” The team’s efforts revolve around low-observable materials essential for the stealth capabilities of aircraft, as well as composite materials primarily for the B-2 Spirit program. Amber and her team are also creating coatings for new platforms that make them undetectable by radar. Amber estimates that before this process, 70% of the parts didn’t initially meet quality requirements; due to a change in raw material from the supplier — that number is now less than 10%. “Our team created methods in the industry that are completely unique to Northrop Grumman,” she said. This allows Northrop Grumman to be a step ahead of everyone else when it comes to solving materials issues as they arise. It also allows the team to come up with solutions to material needs as aircraft become more advanced with lighter materials and with higher temperature capability. “We know how to combine these things through small scale testing, and this knowledge is really powerful and keeps us ahead in the game of stealth for the next gen fighters,” said Amber. Robert Jurek, a systems engineer, works in the Advanced Materials Lab with Amber. Robert specializes in composite materials and says the testing process Amber developed is a game-changer. “It has opened the door to develop a more robust cure cycle that works with every material that comes through our door from the supplier despite chemical differences,” said Robert. He says it allows the team to use materials that would not have worked through processing with the previous method. For Amber, who started her role at Northrop Grumman in early 2021, problem-solving is exhilarating, and her team’s cutting-edge work in support of the B-2 is her proudest career achievement so far. “Developing a technique for processing composite materials that provides high-temperature capability and strength has been the pinnacle of my career,” she said. “Helping to develop something so impactful this early on is extraordinary.” The personal satisfaction Amber gets from her work is rooted deeply in her background and community. She grew up in Dayton amidst a strong aerospace presence and wanted to follow in the footsteps of her father, her inspiration and a chemist who researched Air Force lubricants. During grad school, she spent time at Wright-Patterson Air Force Base, doing research for her master’s thesis. “I got to meet some of the Air Force personnel that our work at Northrop Grumman directly impacts,” said Amber. “I’m passionate about our mission and having friends who are Air Force pilots keeps our work’s impact front and center in my mind. Knowing that our innovations help them and other warfighters perform their missions safely is incredibly fulfilling.” Northrop Grumman’s Dayton Advanced Materials Lab uses micro-scale testing to predict full-scale behavior of high-temperature, low-observable composites, cutting defects, adapting to material changes, and improving performance and reliability for stealth platforms like the B-2 Spirit.