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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