Technology Driven ·  Warfighter Focused

AH-64 Composite Sump

U.S. ARMY MANTECH»Click to View/ Print Brochure


Manufacture a light weight main transmission Composite Sump for the AH-64 Apache to replace the metal EV31A-T6 magnesium alloy sand cast sump. The current sump’s complex part geometry, thin-wall construction, and magnesium material represent a challenging sand casting. The cast magnesium sump experiences a high manufacturing rejection rate and heat transfer/corrosion issues. Advanced Resin Transfer Mold (RTM) compounds, wear resistant materials, tooling concepts and cooling methods will be applied to the manufacturing process to improve manufacturing efficiency and reduce component costs and weight.


• Project is in its planning phase, including preparation of subtier supplier statement of works and related procurement activities. The planning tasks support the evaluation of materials for the composite sump system application, addressing wear resistance, thermal conductivity, fill molding compounds, elimination of corrosion and support of repair techniques. Additionally, a major effort is focused on evaluation of various tooling techniques that include incorporation of integral heating and cooling methods for reduction in processing manufacturing steps and cycle time, supporting overall fabrication cost per program goals.


• Improved reliability via improved wear resistance, enhanced structural integrity and mechanical properties, and corrosion elimination
• Supports 3400 (E model) and future 3850 HP engines
• Reduced manufacturing cost by 14%
• Reduced component weight by 31%
• Reduced manufacturing processing steps by 31%
• Reduced manufacturing cycle time by 45%
• Reduce parts count by 24%

Transition and Weapon Systems / Secondary Items Impacted

• The proposed light weight composite sump will transition to the AH-64 E production, along with applicable technology transfer for the Block I and II legacy sumps and CH-47 Cargo; transitions to Apache PM for production (Lot 8, AH-64E) in 1Q FY19.



POC: Army ManTech Manager, U.S. Army Research, Development, and Engineering Command (RDECOM), Aviation Missile Research, Development and Engineering Center (AMRDEC), Manufacturing Science & Technology Division, ATTN: RDMR-SEM, 5400 Fowler Road, Redstone Arsenal, AL 35898-5000

If this is your first visit, please read our Security Disclaimer: All Web surfers are welcome at the U.S. Army ManTech Website and it is important that you understand the following: This is an official United States Government Information System for authorized, unclassified use only. The system is monitored to ensure information security, system integrity, and the limitation of use to official purposes. Parts of this server are available for use by non-DoD individuals. Some links on this website are locked. (If the area is locked there will be a notation to that effect next to the appropriate link). Your use of this system is subject to monitoring at all times. Unauthorized or illegal activities, involving this system, can result in criminal prosecution under the Computer Fraud and Abuse Act of 1986.
Do not discuss, enter, transfer, process, or transmit classified and/or sensitive national security information of greater sensitivity than that for which this system is authorized. Use of this system constitutes consent to security testing and monitoring. Unauthorized attempts to upload information or change information on this service are strictly prohibited and may be punishable under the Computer Fraud and Abuse Act of 1986 and the National Information Infrastructure Protection Act.