1 / 20

Air Force Cold Spray Applications

28 MXG/AFETS. CSAT 2014. Brian L. James. Air Force Cold Spray Applications. Need Technology Insertion. Aircraft Aging Rapidly Average Age (20-30-40 Years). Updated repair methods would improve repair & sustainment. Air Force Technology Insertion . Background

walker
Télécharger la présentation

Air Force Cold Spray Applications

An Image/Link below is provided (as is) to download presentation Download Policy: Content on the Website is provided to you AS IS for your information and personal use and may not be sold / licensed / shared on other websites without getting consent from its author. Content is provided to you AS IS for your information and personal use only. Download presentation by click this link. While downloading, if for some reason you are not able to download a presentation, the publisher may have deleted the file from their server. During download, if you can't get a presentation, the file might be deleted by the publisher.

E N D

Presentation Transcript

  1. 28 MXG/AFETS CSAT 2014 Brian L. James Air Force Cold Spray Applications

  2. Need TechnologyInsertion Aircraft Aging Rapidly Average Age (20-30-40 Years) Updated repair methods would improve repair & sustainment

  3. Air Force Technology Insertion • Background • 2007 Aging Aircraft Repair Feasibility Study • Innovative process/mechanism for solving operational aircraft availability problems • Repair of previously un-repairable/unobtainable DoD managed components through the use of innovative technology • Integrated team: Operational Maintenance, Depot, Gov/Univ R&D, Industry • Mr. Victor Champagne – USA/ARL • Col Charles McFarland – USAF/ACC • Mr. Tosh Farr – AFMC 419 SCMS/CL • Mr. John Robertson – HQ USAF • Mr. Rob Norcross – USAF ACC • Dr. Brian Kowal - USAF AFMC • Mr. Robert Hrabe – H.F. Webster Eng • Mr. James Yankel – USAF AFMC • Mr. Omar Medoza – USAF AFMC • Mr. Bill Raphael – USAF AFLMC • Mr. Thomas Condron – USAF AFLMC • Dr. Christian Widener – South Dakota School of Mines and Technology

  4. Cold Spray Collaboration

  5. Cold Spray Applications • B-1 Forward Equipment Bay B-1 Hydraulic Line Chafing Location – Cold Spray Pretreatment Integrally stiffened bonded panel – composite metal hybrid structure CS Applied Jan 2011 (2 A/C) ~3 Years 4151 Combined Flt Hrs Chafing Point Wear Tested Chafing Point Wear Tested CS Repaired June 2012 1+ Year, 155 Flight Hours CS Applied Mar 2009 4+ Years, 2202 Flight Hours Nose Landing Gear Accumulator Line

  6. Problem B-1 FEB Panels 8 panels per aircraft Four panels per side, Lt and Rt sides After

  7. Chafing Wear on Operational Panel • B-1 Forward Equipment Bay Before After

  8. Cold Spray Repair Process Grit Blasted Fastener Hole Cold Spray – as deposited Note: Panel back surface temperature near hole can be maintained below 100°C to protect composite & prevent aging of aluminum panel

  9. Repaired Surface Before Deposited material ground flush with surface Hole filled & re-drilled back to OEM specifications Repaired Fastener OEM Fastener Hole

  10. Transition and Implementation Official Approval Documents and Commitment: • Engineering Technical Assistance Request (ETAR) E12-00248 FEB Panel • Tinker Air Force Base-B-1 Chief Engineer Jeff Vaughn • 2. Engineering Technical Assistance Request (ETAR) E09-00065 NLG Lines • Tinker Air Force base B-1 Hydraulic Engineer Barry Magerus • 3. Aircraft Modification Proposal (AF-1067) Mar 2011 MLG Lines • Langley Air Force Base ACC B-1 A4V1 Lt Col Joseph Shirey Cold Spray Transition Locations Ellsworth AFB Hill AFB Tinker AFB Mid-America/MOOG-Webster, MA and Fargo, ND

  11. Problem Hydraulic Tubing Chafing • ROI primarily based on lost flight hours and reduced maintenance man-hours • #1 Maintenance man-hour driver on the B-1 • Estimated at least 1800 Mission Capable (MC) hours ~75 days improvement per year • Equates to $78M annually in lost training and maintenance costs* • * Based on AFIT Study, “Total Cost Comparison of B-1B Non-mission Capable (NMC) Drivers using Finite Source with Spares Queueing, Maj Dan Diehl, 2012 Chafing Points Wear Tested Spoiler Actuator line Nose Landing Gear Accumulator Line Main Landing Gear Line

  12. Process Development Cold Spray Hydraulic Line pre-treatment • Goals • Reduce the occurrences between PDM/HVM cycles • Reduce MMHs • Improve aircraft availability

  13. Action PlanCold Spray Hydraulic Line pre-treatment • Develop logistical and maintenance procedures for implementation chafing limits • Implementation TO changes • Equipment • Define future development • Non-B nut lines • On vehicle

  14. ProblemF-16 Air Inlet Housing Repair sites Nominated by AFMC Gen Wolfenbarger Staff Repaired Sump

  15. ProblemF-15 AMAD - Magnesium Housing Repair sites Nominated by AFMC Gen Wolfenbarger Staff Spares availability problem High Cost/High Demand Before After

  16. ProblemF-16 ADG- Magnesium Housing Repair sites Nominated by AFMC Gen Wolfenbarger Staff Spares availability problem High Cost/High Demand Before After

  17. BenefitsROI $2M $78M Total Annual Savings and ROI $2.9M Return on Investment Ratio 11 *excluding hydro tube analysis

  18. Future Work • Global Hawk • A-10 Plenum • B-2 AMAD • F-15 CGB • C-5 Match Set Housing • The other 60 Candidates • FY13 Rapid Innovation Fund Award Pending • Implement cold spray at 2 operational units and one depot, coupon testing, qualification, etc. • Teaming Arrangement: H. F. Webster Engineering, VRC, Moog, ARL, General Atomics, SDSM&T

  19. Questions? Brian L. James, USAF, GS-12 Chief Engineer - Air Force Engineering and Technical Services

  20. Expected Return on Investment • FEB Panel (ROI ~ 6 months) • Single panel savings = $225K • B-1B annual savings > $9.6M • Huge Potential savings if implemented AF wide • Investment at field level < $1M in equipment, training, & qualification • Anticipate ALC investment higher • Hydraulic Lines(ROI ~ 1 month ) • Primarily maintenance man-hour savings • B-1B >1800 Mission Capable hours (75 days) improvement per year (potentially much more) • Equates to $78M annually in lost training and maintenance costs*

More Related