Air Vehicle Health Management

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Air Vehicle Health Management
Agile Combat Support Systems Wing
Rapidly delivering war-winning capability

• Tobey Cordell
• SK Technologies

16 March 2005AF Corrosion Managers Conference
Keepem flying Keepem relevant
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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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Aging Aircraft Structures Strategy
Enhanced Depot Field Decision Making
Integrated Approach AFRL, ASC/EN, and ASC/ACSSW
working together with warfighter customers and
depot maintainers


Multiple degradation mechanisms
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Four Focus Areas

• Fleet Mgmt / Structural Analysis ASSESS
• Prevention PREVENT
• NDI and Health Monitoring DETECT
• Repair and Replacement MANAGE

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Overall AVHM Program Flow
Focus Structures Fuselage
KC-135 Wing E-8 Attachments
C-130 Empennage C-5
ASIP Requirements
SPO Business Model
Structural Analysis Failure Mode
Identification SI Evaluation Validation
Prevention Alloy Product Form Damage Rates
Prevention Suppression
NDI Deliver Optimal NDI Techniques
Repair Offer Repair Scenarios Mat Sub Test Data
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Fleet Management / Structural Analysis
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C-130 Center Wing Box Assessment
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C-130 Center Wing Box Teardown and Analysis
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C-130 Center Wing Box Being Sectioned by SKT for
Evaluation
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Fleet Mgmt / Structural Analysis

• Damage state knowledge / morphology
• Damage prediction software (To Be)
• Structural integrity analysis software (ASIP)
• Cost of corrosion assessment tools

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C-5 Teardown and Analysis
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SKT Dayton is continuing to build and use a
structural component inventory
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Multi-Component Inventory
http//missioncontrolonline.com/Wacis/main.cfm
See Reports aircraftpartslist.xls
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For Lack of a Comprehensive Damage Management
Tool..

• Corrosion is identified but not quantified
• Structural Impact of Current Corrosion Damage is
  not a metric that can be used to make disposition
  decisions- maintenance or condemnation
• Time is wasted and Structural Life REDUCED by
  doing some corrosion repairs

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For Lack of a Comprehensive Damage Management
Tool..

• Structural Impact of Corrosion Damage cannot be
  Projected to a Future Date / next PDM to allow
  cost effective A/C management
• Inability to anticipate and manage maintenance
  schedule / costs
• Some aircraft prematurely removed from service
  due to projected cost and schedule impact of
  managing structurally insignificant corrosion
  damage

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Structural Damage Management
Corrosion Rates CPC Effectiveness
Basing Effects Environmental Sensors
Compliance with ASIP Mil-Std-1530B
Environmental Severity Index
Prevention
DTA AFGROW
Structural Integrity Assessment with Environmenta
l Damage
Structural DamageManagement Tool
Structural Analysis
Non-Destructive Inspection
Risk Assess
Repair Assess
Repair Technology
Fleet Management Decisions
Mat Sub Property Data
Existing Advanced (MAUS, UltraSpect) Data Mining
Repair, Replace, Retire or Return to Service
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Predict To Be Condition
?t
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Prevention

• Prevention investments providing new products and
  processes that delay or suppress the onset of
  structural damage (corrosion, fatigue, etc.)
• Structure and alloy specific rates are generated
  for use in SDMT or stand alone for corrosion
  prediction measurements

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Prevention

• Exposure racks - coupons
• ESI basing strategies
• Enhanced CPCs and processes
• Coatings
• Web-based enhanced materials selection

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Corrosion Kinetics of Structural Materials
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Worldwide Outdoor Exposure Testing for
Environmental 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 on ground-based
  racks
• End goal is to correlate sensor readings with
  structure corrosion enabling eventual use of
  sensors to determine when inspections are
  required
• Some sensors are under CPCs

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Passive Sensor Methodology

• Battelle designed, passive, credit card sized
  sensors
• Output Electrical signal proportional to
  cumulative corrosion of Sensor Element
• Sensors manually measured periodically (3-4 mo.)
• Entire process has been successful and data is
  being obtained
• System reliability being evaluated excellent to
  date

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Installation Examples C-130
Engine Dry Bay
Rainbow Fitting
Left MLG
Right Sloping Longeron
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F-16 Corrosion in Aft Cockpit Floor
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SKT CPC Evaluation Database
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CPC Database Overview

• Interactive database containing information about
  most of the commercially available CPCs,
  including QPL data
• Several search options to navigate the database
  quickly
• Detailed material information, vendor contact
  information and applicable specifications for
  each CPC in the database
• Repository for CPC evaluation data currently
  divided into laboratory data and real environment
  data
• Project objective, specimen/structure, results,
  pictures and available reports presented with
  each study

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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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CPC Database continuing improvements

• Creating a new lessons learned section
• Please send SKT anecdotal data on CPC performance
  will be cleared by AFCPCO before being posted
  to website
• QPL list is updated several times per year
• Continue updating data as new studies are
  completed and published (e.g. C-5 CPC study
  presented at this conference)

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Advanced Aircraft Corrosion Protection

• Transition non-chrome pretreatment to depot
  paint application for reduced hazardous waste
  stream
• Provide qualification data in accordance with
  new SAE spec. for aircraft paint systems and
  draft TO 1-1-8 update

AC-131 application on KC-135
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NDI and Health Monitoring
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Structure Specific NDI

• Methodologies and hardware for quantification
  and/or monitoring of structural degradation
• Includes enhancements of NDI 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 inspection of 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 made changes

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Damage Management Status

• Components which can become critical to both
  airworthiness and life cycle cost due to
  environmental degradation must be managed in the
  same robust manner as structurally significant
  fatigue critical components
• The ability to anticipate damage for the next PDM
  would be a significant step toward managing the
  cost of repairs and readiness of our aging fleet

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Aging Aircraft ProgramOld Process
ACC
AFSOC
AETC
AMC
AFRC
Warfighter
ANG
ATD?
No
Rack Stack
YES
ASC/CC PEO
RDTE Aging Aircraft Program
ATD Advanced Technology Demonstration
(ATD) DTMP Depot Technology Modernization
Plan AATT Aging Aircraft Technology
Team JCAA Joint Council on Aging Aircraft AFFVB
USAF Fleet Viability Board
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Aging Aircraft ProgramNew Process
AFMC Input
CRRA Capability Planning
Deficiencies

• MAJCOMs

RACK STACK
Warfighter
1. NDI for Cracks without Fastner Removal
Solution candidates
ASC/CC PEO AEAG

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

RDTE - Aging Aircraft Program
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New Requirements Process