af life cycle management center modernizing air force...

AF Life Cycle Management Center

Providing the Warfighter’s Edge

Modernizing Air Force

Propulsion

Mr. Rafael Garcia, SES

Director of Propulsion

Air Force

AFLCMC… Providing the Warfighter’s EdgeAFLCMC… Providing the Warfighter’s Edge

Air Force Propulsion

Strategic Focus Areas

Mission

Develops, acquires, tests, fields,

sustains, and modernizes

leading-edge propulsion systems

through life cycle management

for the U.S. warfighter and

international partners

Vision

Be the Propulsion Center of

Excellence for the U.S. Air Force

and International Partners

2


Air Force Propulsion

Roles and Responsibilities

Senior AF Official accountable for AF Propulsion Enterprise

Deputy PEO for Propulsion

Propulsion Capability Development Lead

Life Cycle Management responsibility

Single face and voice to propulsion stakeholders

Represent AF to DoD, joint services, and industry

Develop engine readiness requirements

Reduce engine costs – improve engine reliability

Ensure the highest levels of engine safety

Develop/implement policy and guidance

Develop and maintain propulsion workforce competencies

Concept

Development

Material

Solution

Analysis

Technology

Development

Engineering &

Manufacturing

Development

Production &

Deployment

A B C

Operations &

Support

IOC FOCMDD

Pre-Systems Acquisition Systems Acquisition Sustainment

LRIP/IOT&EFRP

Decision

Point

Post

CDR A

= Decision Point

Developmental Planning

System Development

Production

Fielding

Product Support & Upgrades

Disposal

3READY AFFORDABLE SAFE EFFECTIVE


4

Air Force Propulsion Portfolio

AFLCMC… Providing the Warfighter’s Edge

TF33-102C(E-8C)

1963/1991

Air Force Propulsion Portfolio

From Early Technology To Cutting Edge Propulsion Systems

1965 1975 1985 1995 2005 2015

AE2100(C-130J)

1998

F137(RQ-4)

1991/1998

TF34(A-10)1971

T700(HH-60)

1978

F110-100(F16C/D)

1986

F101-102(B-1B)

1983

F118-100(B-2)1988

AE1107(V-22)1998

F103(KC-10)

1969/1971

F138(C-5M)

1982/2002

J85(T-38)

1958/1960

F100-220(F-15, F-16)

1986

F135-100(F-35)2007

F139(KC-46)

1984/2018

F117-100(C-17)

1981/1991

T400(UH-1N)

1971

T53(UH-1H)

1961

T106(T-6)1989

T102(MQ-9)

1965/2001

F118-101(U-2)1998

T56(C-130H)

1954

AETPGen 62016

JSTARS

Recap2023

B-212025

Advanced

Trainer2020+

F108-100(KC-135R)

1980

TF33-103(B-52H)

1961

F110-129(F-16C/D)

1991

TF33-100(E-3A)1974

F107(ALCM)

1979

F108-201(RC-135)

1982

F100-229(F-15E)

1989 F119(F-22)1991

Long-Term


We Are Propulsion

6

Warfighter Expectations:

Deliver readiness today and prepare for readiness of tomorrow

Provide affordable propulsion capability

Ensure engine safety

Deliver effective and efficient propulsion power

AF Propulsion

Integrated propulsion policy, planning & execution

Technology Development Lead

Technical support and lifecycle management

Sustainment of propulsion enterprise

Propulsion Sustainment

War Readiness (WRE) Repair Network Integration

(RNI) Propulsion Operational

Safety, Suitability & Effectiveness (OSS&E)

Tech Support International Sustainment

Planning

Propulsion Readiness

Requirements (PRS)

R2D2

Workload

Optimization

Propulsion Development

Technology Development

Component Improvement

Program (CIP)

International Acquisition

Cross-Cutting Programs

Oil Analysis Program (OAP)

Comprehensive Engine Mgmt System (CEMS)

Engine Health Management (EHM)

Enterprise Influence

Product Support

Strategies

Engine Life Management

Plans (ELMP)

Propulsion System

Integrity Program (PSIP)


Affordable Readiness Opportunity

• Complex repair and inspection

requirements not achievable with

current/legacy inspection methods

• Effective lifecycle management

requires development of innovative

inspection, cleaning, and repair

methods for increased efficiency and

capability

65% Engine Workload

Increase over the FYDP

7

Modernization Required for Increasing Propulsion Workload


Bending the Cost Curve

DoD Turbine Engine Investments

Technology Can Bend the Cost Curve

Material is the largest sustainment

cost driver

Engine Sustainment

Material

85% Labor, G&A

15%

8

Sustainment

60%

Acquisition

28%

Development

10%

S&T

2%

DoD's Turbine Engine Investments

Does not include

the cost of Fuel


Additive ManufacturingCapability Deployment – Current Efforts

• Main focus fixturing and tooling

– Using ABS for rapid prototyping prior to final tool making

– Using ABS and ULTEM printers to produce tooling and non-flight-critical aircraft parts

• Maturation of Advanced Manufacturing for Low-Cost Sustainment (MAMLS)

– Baseline use of AM by DoD, identify and capture best practices, develop technology, execute demonstrations, create implementation plans

– Phase I (2016-2017): develop paint hard mask demonstration for TF33 accessory gearbox (AGB) and rear compressor case

– Phase II (2017-2018): develop heat exchanger technology

• Rapid Engineered Additive Legacy (REAL) Tubes SBIR

– 15 month project to design weld, trim, and check fixtures for low purchase quantity legacy tubes

9

B-1 Interior Lexan Panel Replacement

TF33 AGB Paint Mask Demonstration

REAL Tube Weld/Trim/Check Fixture


Additive ManufacturingFuture Capabilities

• TF34 Pressure Regulator

– AM Tiger Team organic project

– Reengineer housing to alleviate supply

shortage

• Fuel/Oil Coolers

– Develop fuel/oil coolers starting with common

F110-100/F118-101 cooler

– Future projects for other engines

• Cast Accessory Housings

– Reengineer cast accessory housings across

multiple engines

10

TF34 Pressure Regulator

TF34 Cutaway Oil Cooler

F110 Hydraulic Pump


Inspection TechnologyCapability Deployment – Current Efforts

11

• Airfoil inspection techniques

• Rotating fracture critical component

inspections

• Dimensional restoration repairs

• Integrally bladed disks vibratory

analysis

• Oil analysis techniques

• Automated Integrated Inspection Station (AIIS)– Sonic InfraRed (SonicIR) crack detection– Optical/White light photogrammetry

inspection• Advanced Topographical Optical

Sensor (ATOS)TM

• Dimensional and visual defect inspection

Requirements

Innovations

• Automated Eddy Current Inspection System (AECIS)– Inspect rotating fracture critical

components– Detection of potentially life-reducing

material defects• Flaw size detection

capability of .005” x .005”

Improve Process Thru-put , Reduce Cost


Inspection TechnologyFuture Capabilities

• Novel methods to inspect components without removing coatings

• “Intelligent” inspection to characterize crack indications

• Technology assisted visual & dimensional inspection methods

• Full field digital inspections

• Inspection and repair of composite parts

12

Projects

Interface Inspection Method for Thermal Spray Coatings

Efficient 3-D Finite Element Process Modeling to Enable Linear Friction Welding of

Aerospace Components

Efficient Evaluation of Fiber Coating Chemistry

Novel Passive Concepts for Combustion Instability Reduction

Real Time Thermal Imaging Capability for Propulsion Systems

Advanced Machining of Aerospace Materials

Mask-Free Thermal Spray Module


T56 Series 3.0 & 3.5

Depot Maintenance Contract

13

Project

Description

RFP and POCs

• Objective: Provide depot maintenance for T56 end

items in support of C-130H

• Scope: T56 Series 3.0 USAF, USCG, and USN

end items; T56 Series 3.5 USAF end items

• Acquisition Strategy: Competitive FAR 15 Single

Award ID/IQ FFP Contract – LPTA Award

• Timeframe: FY18-26 (8 ½ years)

• Dollar Value: $904M

• Challenging Requirements:

• Movement of GFE

• Timely funding from other service rqmts

• RFP: Released 12 May 17; Proposals due 11

July 17

• POC(s):

o Program Manager: AFLCMC/LPSC,

405-734-5251

o Contracting Officer: AFLCMC/LPK,

405-734-6995

o Technical Lead: AFLCMC/LPSEC,

405-734-4680

• Customers: AMC, ANG, AFR, AFSOC, ACC,

PACAF, AFMC, USCG, USN

• Contract Type: ID/IQ FFP

• Program Type: USAF, USCG, USN

• Number of Users: 3

C-130H

T56 ENGINE


T56-A-15 FMS Overhaul/Repair

14

Project

Description

RFP and POCs

• Objective: Provide CLS to FMS

• Scope: Provide contracting vehicle to

overhaul/repair T56-A-15 engines for FMS

Countries

• Acquisition Strategy: TBD

• Timeframe: TBD

• Dollar Value: ≈ $40M - Competitive

• Identify Challenging Requirements: USAF

approved Source Approval Requests (SAR)

from Rolls-Royce Authorized Maintenance

Centers/Overhaul Facilities (AMC/AMOF)

• RFP: TBD

• POC(s):

o Program Manager: AFLCMC/LPSIB,

LPSIC 405-734-3759; 405-736-7312

o Contracting Officer: AFLCMC/TBD

o Technical Lead: AFLCMC/LPSIC,

405-736-7485; 405-736-7434

• Customers: FMS (T56 IEMP Partner Nations)

• Contract Type: TBD

• Program Type: Air Force


Representative picture

depicting the product


J85 Intermediate-Level Mx Contract

15

Project

Description

RFP and POCs

• Objective: Provide Intermediate-Level whole engine

repair for the J85 Engine; supports T-38 and pilot

training program

• Scope: Intermediate-level repair of J85-5 engines

utilizing Reliability Centered Maintenance concept

• Acquisition Strategy: Competitive FAR 15 Single

Award ID/IQ FFP Contract – LPTA

• Timeframe: FY19-FY25 (7 years)

• Dollar Value: ~$620M (labor + consumable materiel)

• Challenging Requirements: • Movement of GFE from current repair facility

• Vendor qualification requirements

• Viable plan to mitigate production gap coverage during

transition

• RFP: 1 Oct 17

• POC(s):

o Program Manager: AFLCMC/LPSCC,

405-734-3407


405-739-8572

o Technical Lead: AFLCMC/LPE,

405-734-9199

• Customers: ACC, AETC, AFGSC, Navy,

NASA, Foreign Military


• Program Type: USAF, USN, NASA, Foreign

Military

• Number of Users: 4T-38

J85 ENGINE


F108-100 Non-StandardRepair (NSR) Contract

16

Project

Description

RFP and POCs• Objective: Provide non-standard (limited) whole

engine repair for F108-100

• Scope: Long-term contract for inspection,

disassembly, and limited repair up to full overhaul

based upon engine work scope

• Acquisition Strategy: Competitive

• Timeframe: ~ FY19-FY24

• Dollar Value: ~ $30M/yr (~24 engines/yr)

• Challenging Requirements: • Multiple levels of repair require multiple pricing

options

• Overhauled engines must be delivered in CPUP

configuration

• Quick Engine Change (QEC) kit support

• RFP: ~ Jan 18

• POC(s):

o Program Manager: AFLCMC/LPSB,

405-734-4667


405-734-6724

o Technical Lead: AFLCMC/LPSEB,

405-734-4666

• Customers: AMC, AFRC, ANG


• Program Type: USAF



B-52 Re-engine

17

Project

Description

RFP and POCs

• Objective: Re-engine B-52 Aircraft

• Scope: Identify COTS propulsion systems for

B-52

• Acquisition Strategy: TBD

• Timeframe: 2019-2025

• Dollar Value: ~$3B

• Identify Challenging Requirements: Selecting

appropriate propulsion system to minimize

airframe modifications while achieving

performance thresholds

• RFP: TBD

• POC(s):

o Program Manager: AFLCMC/WWD

405-734-5892

o Contracting Officer: AFLCMC/PZK

405-622-7263

o Technical Lead: AFLCMC/LPSA,

405-734-4316

• Customers: AFGSC, AFR

• Contract Type: TBD




Small Engines

18

Project

Description

RFP and POCs

• Objective: Develop alternative small engines to address

shortfalls in current industrial base & integrate operational

needs w/ development efforts

• Scope: Integrate LP, AFRL, DARPA, EBJ, and industry to

develop small engine components, materials, and

prototypes for 200lb and 650lb engines



• Dollar Value: $163M*

• Identify Challenging Requirements:

• Diminishing industrial base

• Low knowledge base for small engine design

• Meet aggressive cost requirements

• Find trade between: attritable, durability, and

service life

• RFP: TBD

• POC(s):

o Program Manager: AFLCMC/LPA,

937-255-5624


937-255-7696


937-255-7693

• Customers: EB, DARPA, LP

• Contract Type:



*Refers to LCMC small engine roadmap projected value


Other Transaction Authority

19

Project

Description

RFP and POCs

• Objective: Stand up propulsion consortium to meet

rapid prototype needs

• Scope: Consortium members will execute prototyping

projects that address USAF propulsion requirements



• Dollar Value: $45M

• Identify Challenging Requirements:

• Need programs/projects that can use the

consortium to meet their needs

• Targeting Rapid Prototyping Tasks

• RFP: 14 April 17

• POC(s):

o Program Manager: AFLCMC/LPA,

937-255-5624


937-255-2134


937-255-7693

• Customers: LP

• Contract Type: Fixed




Summary

• Air Force Propulsion is the Propulsion Center of

Excellence for the USAF and international partners

• Executing programs while continuing to work

challenges

• Future shaped by renewed emphasis on capability

sustainment and acquisition opportunities

• Modernization is necessary to keep Air Force Propulsion

…Ready, Affordable, Safe and Effective

af life cycle management center modernizing air force...

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