Abstract: Systems and methods described herein are directed towards a radar system and a dual frequency electronically scanned array (ESA) capable of transmitting and receiving radio frequency (RF) signals at least two frequencies. The ESA includes a plurality of antenna elements which form a first effective aperture at a first radio frequency (RF) frequency and operational over a first scan range and which form a second effective aperture at a second radio frequency (RF) frequency and operational over a second scan angle. The first and second scan ranges are complementary so as to provide the radar system having an overall scan range. The plurality of antenna elements are spaced apart from each other by an amount related to at least one of the first and second scan ranges and/or one or more operating frequencies of the radar system.

Abstract: A manifold structure has at least one flow passage and a center manifold section that has at least one machined cavity. The manifold structure includes a plurality of ultrasonically additively manufactured (UAM) finstock layers arranged in the flow passage. After the finstock is formed by UAM, the finstock is permanently joined to the center manifold section via a brazing or welding process. Using UAM and a permanent joining process enables joining of the UAM finstock having enhanced thermal features to a vacuum brazement structure. UAM enables the finstock to be formed of dissimilar metal materials or multi-material laminate materials. UAM also enables bond joints of the finstock to be arranged at angles greater than ten degrees relative to a horizontal axis by using the same aluminum material in the UAM process and in the vacuum brazing process.

Abstract: A manifold structure and method of forming a manifold structure includes using an ultrasonic additive manufacturing (UAM) process to build up a solid structure, machining the solid structure to form a cavity and free-standing support pillars within the cavity, and using a UAM process to build up a finstock layer over the cavity. The support pillars formed by machining have yield strengths high enough to support UAM of the finstock layer over the cavity. A plurality of finstock layers are built up within the cavity to segment the cavity into a plurality of cavities. UAM of the finstock layers enables the finstock layers to be stacked in a direction normal to a direction of flow through the cavity for efficiently transferring heat through the manifold structure.

Abstract: A manifold structure is provided to cool a heat-dissipating surface and includes an inlet fluid passage, an outlet fluid passage, and at least one cooling channel that is connected between the inlet fluid passage and the outlet fluid passage and extends along a length of the heat-dissipating surface. Additively manufactured fins are arranged in the cooling channel. The fins are configured to provide a geometry transition area between fins having a first geometry and fins having a second geometry, and a material transition area between fins formed of a first material and fins formed of a second material. The manifold structure is configured to provide a gradient convection coefficient by way of the geometry transition area and a gradient thermal conductivity by way of the material transition area across the length of the heat-dissipating surface.

Abstract: A manifold structure is provided to cool a heat-dissipating surface and includes an inlet fluid passage, an outlet fluid passage, and at least one cooling channel that is connected between the inlet fluid passage and the outlet fluid passage and extends along a length of the heat-dissipating surface. Additively manufactured fins are arranged in the cooling channel. The fins are configured to provide a geometry transition area between fins having a first geometry and fins having a second geometry, and a material transition area between fins formed of a first material and fins formed of a second material. The manifold structure is configured to provide a gradient convection coefficient by way of the geometry transition area and a gradient thermal conductivity by way of the material transition area across the length of the heat-dissipating surface.

Abstract: Methods and apparatus for an antenna assembly including one or more array blocks having one or more corporate manifolds, each having an input port, a plurality of output ports, and a plurality of phase shifters, each of the phase shifters located at a respective one of the output ports. Array blocks can further include a plurality of serial manifolds each having an input port and a plurality of output ports, the input port coupled to a respective output port of one of the corporate manifolds; and plurality of antenna elements coupled to respective output port of one of the serial manifolds.

Abstract: Systems and methods described herein are directed towards a radar system and a dual frequency electronically scanned array (ESA) capable of transmitting and receiving radio frequency (RF) signals at least two frequencies. The ESA includes a plurality of antenna elements which form a first effective aperture at a first radio frequency (RF) frequency and operational over a first scan range and which form a second effective aperture at a second radio frequency (RF) frequency and operational over a second scan angle. The first and second scan ranges are complementary so as to provide the radar system having an overall scan range. The plurality of antenna elements are spaced apart from each other by an amount related to at least one of the first and second scan ranges and/or one or more operating frequencies of the radar system.

Abstract: A blind mate connector assembly comprises a first manifold and a second manifold removably coupled to the first manifold that defines a connector housing positionable between a primary electronics assembly and a secondary electronics assembly. A plurality of connector cavities are defined between the first and second manifolds. A plurality of right angle cable connectors, each situated within one of the plurality of connector cavities, extend partially through the connector housing to facilitate blind mate connection between the primary electronics assembly and the secondary electronics assembly. The connector housing comprises at least one mechanical float mechanism configured to facilitate movement of each right angle cable connector in multiple degrees of freedom. The connectors are replaceable by disassembling the first and second manifolds.

Abstract: Methods and apparatus for an antenna assembly including one or more array blocks having one or more corporate manifolds, each having an input port, a plurality of output ports, and a plurality of phase shifters, each of the phase shifters located at a respective one of the output ports. Array blocks can further include a plurality of serial manifolds each having an input port and a plurality of output ports, the input port coupled to a respective output port of one of the corporate manifolds; and plurality of antenna elements coupled to respective output port of one of the serial manifolds.

Abstract: A manifold structure has at least one flow passage and a center manifold section that has at least one machined cavity. The manifold structure includes a plurality of ultrasonically additively manufactured (UAM) finstock layers arranged in the flow passage. After the finstock is formed by UAM, the finstock is permanently joined to the center manifold section via a brazing or welding process. Using UAM and a permanent joining process enables joining of the UAM finstock having enhanced thermal features to a vacuum brazement structure. UAM enables the finstock to be formed of dissimilar metal materials or multi-material laminate materials. UAM also enables bond joints of the finstock to be arranged at angles greater than ten degrees relative to a horizontal axis by using the same aluminum material in the UAM process and in the vacuum brazing process.

Abstract: A blind mate connector assembly comprises a first manifold and a second manifold removably coupled to the first manifold that defines a connector housing positionable between a primary electronics assembly and a secondary electronics assembly. A plurality of connector cavities are defined between the first and second manifolds. A plurality of right angle cable connectors, each situated within one of the plurality of connector cavities, extend partially through the connector housing to facilitate blind mate connection between the primary electronics assembly and the secondary electronics assembly. The connector housing comprises at least one mechanical float mechanism configured to facilitate movement of each right angle cable connector in multiple degrees of freedom. The connectors are replaceable by disassembling the first and second manifolds.

Abstract: Systems and methods described herein are directed towards a radar system and a dual frequency electronically scanned array (ESA) capable of transmitting and receiving radio frequency (RF) signals at least two frequencies. The ESA includes a plurality of antenna elements which form a first effective aperture at a first radio frequency (RF) frequency and operational over a first scan range and which form a second effective aperture at a second radio frequency (RF) frequency and operational over a second scan angle. The first and second scan ranges are complementary so as to provide the radar system having an overall scan range. The plurality of antenna elements are spaced apart from each other by an amount related to at least one of the first and second scan ranges and/or one or more operating frequencies of the radar system.

Abstract: Systems and methods described herein are directed towards a radar system and a dual frequency electronically scanned array (ESA) capable of transmitting and receiving radio frequency (RF) signals at least two frequencies. The ESA includes a plurality of antenna elements which form a first effective aperture at a first radio frequency (RF) frequency and operational over a first scan range and which form a second effective aperture at a second radio frequency (RF) frequency and operational over a second scan angle. The first and second scan ranges are complementary so as to provide the radar system having an overall scan range. The plurality of antenna elements are spaced apart from each other by an amount related to at least one of the first and second scan ranges and/or one or more operating frequencies of the radar system.

Abstract: A ballistic radome is provided and includes a flattened radome portion disposable in a primary field of view (FOV) of an antenna and a curved radome portion configured to define an extended FOV of the antenna about the primary FOV.

Abstract: A manifold structure and method of forming a manifold structure includes using an ultrasonic additive manufacturing (UAM) process to build up a solid structure, machining the solid structure to form a cavity and free-standing support pillars within the cavity, and using a UAM process to build up a finstock layer over the cavity. The support pillars formed by machining have yield strengths high enough to support UAM of the finstock layer over the cavity. A plurality of finstock layers are built up within the cavity to segment the cavity into a plurality of cavities. UAM of the finstock layers enables the finstock layers to be stacked in a direction normal to a direction of flow through the cavity for efficiently transferring heat through the manifold structure.

Abstract: An array antenna including two interleaved array antennas, capable of being operated independently at a first frequency, or together, at a second frequency. Each of the two array antennas is composed of alternating elements of an antenna array, and the two arrays are interleaved. Each of the interleaved arrays may be operated independently, e.g., in the X band, or the arrays may be driven together, as a single array with more densely spaced elements, e.g., in the Ku band.

Abstract: A method of forming a component having multiple material properties includes forming, by additive manufacturing, a particle containment structure on a base layer; filling the particle containment structure with a first layer of particles, the layer of particles being contained by the particle containment structure; curing the first layer of particles; repeating the forming the particle containment structure, filling the particle containment structure with one or more additional layers of particles and curing the one or more additional layers of particles until a desired component dimension is achieved; forming, by additive manufacturing, a cover to encapsulate any exposed particles; and fully curing the particle containment structure, particles and cover.

Abstract: A hydraulic card retainer can be operable to retain a CCA within a card cage. The hydraulic card retainer can comprise a tube section which defines an interior envelope. The interior envelope can be operable to contain a volume of fluid. The hydraulic card retainer can further comprise an interfacing section which can be in fluid communication with the tube section. The hydraulic card retainer can further comprise an actuator which can be at least partially supported by the interfacing section and which can also be operable to form a fluid-tight seal at the interfacing section. The actuator can operate to apply a compression force to the volume of fluid upon actuation. The compression force can cause at least a portion of the tube section to expand, thereby generating and applying a retaining force between the CCA/chassis assembly and the card cage.

Abstract: A hydraulic card retainer can be operable to retain a CCA within a card cage. The hydraulic card retainer can comprise a tube section which defines an interior envelope. The interior envelope can be operable to contain a volume of fluid. The hydraulic card retainer can further comprise an interfacing section which can be in fluid communication with the tube section. The hydraulic card retainer can further comprise an actuator which can be at least partially supported by the interfacing section and which can also be operable to form a fluid-tight seal at the interfacing section. The actuator can operate to apply a compression force to the volume of fluid upon actuation. The compression force can cause at least a portion of the tube section to expand, thereby generating and applying a retaining force between the CCA/chassis assembly and the card cage.

Abstract: A method of forming a component having multiple material properties includes forming, by additive manufacturing, a particle containment structure on a base layer; filling the particle containment structure with a first layer of particles, the layer of particles being contained by the particle containment structure; curing the first layer of particles; repeating the forming the particle containment structure, filling the particle containment structure with one or more additional layers of particles and curing the one or more additional layers of particles until a desired component dimension is achieved; forming, by additive manufacturing, a cover to encapsulate any exposed particles; and fully curing the particle containment structure, particles and cover.