1100 Air Vehicle Health Management Toby Cordell

8/8/2019 1100 Air Vehicle Health Management Toby Cordell

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Air Vehicle

Health Management

Tobey CordellS&K Technologies

Rapidly delivering war-winning capability

Keepem flying & Keepem relevant

Agile Combat Support Systems WingAgile Combat Support Systems Wing

16 March 2005

AF Corrosion Managers Conference


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Air Vehicle Health Management

This work was sponsored by the

Aeronautical Systems Center,

Agile Combat Support Systems Wing,

Aging Aircraft Systems Squadron,

WPAFB, OH

AF Contract Number: F09650-03-D-0001

AF Program Manager:

Major Timberlyn Harrington

Chief, Air Vehicles Branch

937-255-7210 x3739


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EnhancedDepot & Field

Decision Making

Aging Aircraft Structures Strategy

Multipledegradationmechanisms

Integrated Approach:AFRL, ASC/EN, and ASC/ACSSWworking together withwarfighter customers and depot

maintainers


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Overall AVHM Program Flow

Focus StructuresFuselage KC-135Wing E-8Attachments C-130Empennage C-5

Structural AnalysisFailure Mode Identification;

SI Evaluation & Validation

NDI

Deliver Optimal NDITechniques

PreventionAlloy & Product Form

Damage Rates;Prevention &

SuppressionRepairOffer Repair

Scenarios; Mat Sub

Test Data

ASIP Requirements SPO Business Model


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Fleet Management / Structural Analysis

FM / SA

Structural FocusStructural Focus

EffortsEfforts

CrossCross--CuttingCutting

EffortsEfforts

C-130 E/HCenter Wing Box

C-5 A/BTie-Box

Structural DamageManagement Tool

Integrated ProbabilisticRisk Assessment

AFGROW UpdatesAdvanced Structural

Failure Criteria

Cost of CorrosionKC-135/E-8

Upper Wing Skins


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C-130 Center Wing Box Assessment


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C-130 Center Wing BoxTeardown and Analysis


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C-130 Center Wing BoxBeing Sectioned by SKT forEvaluation


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C-5 Teardown and Analysis


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SKT Dayton is continuing to build anduse a structural component inventory


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Multi-Component Inventory

Added:

C-130 526 parts

Warner Robins

storage site parts

Misc. parts from C-5,

C-141 and C-130 A/C

61-2668 fuselage panels

Cherry Point C-130 wing

http://missioncontrolonline.com/Wacis/main.cfm

See Reports: aircraftpartslist.xls


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For Lack of a Comprehensive DamageManagement Tool..

Structural Impact of Corrosion Damage cannotbe Projected to a Future Date / next PDM toallow cost effective A/C management

Inability to anticipate and manage maintenanceschedule / costs

Some aircraft prematurely removed from

service due to projected cost and scheduleimpact of managing structurally insignificantcorrosion damage


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Structural DamageManagement Tool

DTAAFGRO

W

EnvironmentalSeverity Index

Prevention

RepairTechnolog

y

Non-DestructiveInspection

Structural Damage Management

Mat Sub;Property Data

Existing; Advanced(MAUS, UltraSpect);

Data Mining

Corrosion Rates;

CPC Effectiveness

Basing Effects;

Environmental Sensors

Structural

Analysis

Compliance with ASIPMil-Std-1530B

Fleet ManagementDecisions

Repair, Replace, Retireor Return to Service

Structural

IntegrityAssessment

withEnvironmental

Damage

RiskAssess

RepairAssess


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(t

Predict To Be Condition


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Prevention

Prevention investmentsproviding new products andprocesses that delay or

suppress the onset ofstructural damage(corrosion, fatigue, etc.)

Structure and alloy specific

rates are generated for use inSDMT or stand alone forcorrosion predictionmeasurements


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Prevention

Exposure racks - coupons

ESI basing strategies

Enhanced CPCs and processes

Coatings

Web-based enhanced materialsselection


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Corrosion Kinetics of Structural Materials

Corrosion KineticsCorrosion Kinetics

OutdoorExposure On-Aircraft ExposureLaboratory

Accelerated Exposure

SKT racks

Battelle racks

Battelle - coupons Battelle - sensors OSU

Luna

U Virginia


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Worldwide OutdoorExposure Testing forEnvironmental Severity


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On-Aircraft Monitoring

300 corrosivity sensors now flying on F-15,KC-135, C-130, F-16, C-141 (2+ years)

Same type sensors also deployed onground-based racks

End goal is to correlate sensor readings withstructure corrosion enabling eventual use of

sensors to determine when inspections arerequired

Some sensors are under CPCs


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Passive Sensor Methodology

Battelle designed, passive, credit card sizedsensors

Output = Electrical signal proportional tocumulative corrosion of SensorElement

Sensors manually measured periodically (~3-4mo.)

E

ntire process has been successful and datais being obtained

System reliability being evaluated; excellent todate


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Installation Examples C-130

Rainbow

Fitting

EngineDry Bay

RightSlopingLongeron

Left MLG


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FF--16 Corrosion in Aft Cockpit Floor16 Corrosion in Aft Cockpit Floor


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SKT CPC Evaluation Database


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CPC Database: Overview

Interactive database containing information aboutmost of the commercially available CPCs, includingQPL data

Several search options to navigate the databasequickly

Detailed material information, vendor contactinformation and applicable specifications for eachCPC in the database

Repository for CPC evaluation data currently dividedinto laboratory data and real environment data

Project objective, specimen/structure, results,pictures and available reports presented with eachstudy


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CPC Database: Search options

Key word: CPC brand name

or CPC vendor

Specification-US Military or

Boeing specs

Tester: list of all companies

that have tested CPCs and

have data in the database

CPC type: water-displacing

or non water-displacing


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CPC Info with Sort Capability


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CPC Database: Lab Data


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Creating a new lessons learned section Please send SKT anecdotal data on CPC

performance will be cleared by AFCPCObefore being posted to website

QPL list is updated several times per year

Continue updating data as new studiesare completed and published (e.g. C-5CPC study presented at this conference)

CPC Database:continuing improvements


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Advanced Aircraft Corrosion Protection

Transition non-chrome pretreatmentto depot paintapplication forreduced hazardous

waste stream

Providequalification data inaccordance with newSAE spec. for

aircraft paintsystems and draftTO 1-1-8 update

AC-131 application on KC-135


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NDI and Health Monitoring

NDI

Structure SpecificNDI

Generic NDI andNDI Management

Structural HealthMonitoring


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Structure Specific NDI

Methodologiesand hardware forquantification

and/or monitoringof structuraldegradation

Includesenhancements ofNDI data integrity

UltraSpect MP on C-130 E/H Wing


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Advanced Corrosion Inspection

Implementing automated inspections at ALCs Corrosion in hidden structure

KC-135 and E-3 fuselage applications

B-52, KC-135, and E-3 wing applications

MAUS inspectionof B-52 wing

splice


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Repair and Replacement

Material Substitution (Mat Sub) Key data development for limited promising

alloys

Initial considerations for F-15, C-130, KC-135

Defense Logistics Agency involvement

ALC purchase / stock listing process difficult

and vital

Some weapons systems have already madechanges


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Components which can become critical to bothairworthiness and life cycle cost due toenvironmental degradation must be managed in

the same robust manner as structurally significantfatigue critical components

The ability to anticipate damage for the

next PDM would be a significant steptoward managing the cost of repairs andreadiness of our aging fleet

Damage Management Status


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Aging Aircraft Program

Old Process

ATD?

RDT&EAging AircraftProgram & $$$

ASC/CC PEO

YES

Rack &

Stack

No

AFRC

ACC AFSOCAMCAETC

ANG

ATD = Advanced Technology Demonstration (ATD)DTMP = Depot Technology Modernization PlanAATT = Aging Aircraft Technology Team

JCAA = Joint Council on Aging AircraftAFFVB = USAF Fleet Viability Board

AATT

DTMP

NationalReviews

JCAA

MAJCOMPublications

Deficiencies

AFFVB

A i Ai ft P


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Aging Aircraft Program

New Process

Solution candidates

RDT&E - Aging AircraftProgram & $$$

MAJCOMsMAJCOMs

CRRA CapabilityPlanning

ASC/CC PEOAEAG

Deficiencies

1. NDI forCracks without

Fastner Removal

RACK & STACK

AFRL (Science & Technology) ATDs Industry Commercial-Off-The-Shelf (COTS) Current Projects JCAA

Warfighter

AFMCInput


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New Requirements Process

Revise AgingAircraft Strategy and

Program

July 05

Aging AircraftAdvisory GroupEndorse Integrated Priority List

August 05Executive Aging Aircraft

Advisory GroupAllocate and Advocate Program

January 05Aging Aircraft WorkingGroup

(Needs Review)Validate/Prioritize

Deficiencies/Needs

June 05Aging Aircraft Working

Group(Program Review)

Validate/Prioritize Solutions

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1100 Air Vehicle Health Management Toby Cordell

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