28th Bomb Wing

UNCLASSIFIEDUNCLASSIFIEDWorld Class Airmen … Expeditionary Combat Power

Air Force Cold Spray Applications

28 MXG/AFETS CSAT 2014

Brian L. James

World Class Airmen … Expeditionary Combat Power

NeedTechnology Insertion

Aircraft Aging RapidlyAverage Age (20-30-40 Years)

Updated repair methods would improve repair & sustainment

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Background

o 2007 Aging Aircraft Repair Feasibility Study

o Innovative process/mechanism for solving operational aircraft availability

problems

o Repair of previously un-repairable/unobtainable DoD managed

components through the use of innovative technology

o 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

Air Force Technology Insertion

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Warfighter

Ellsworth AFB

Government R&D

•Army Research

Lab•Navy

Mantech Air Force Maintenan

ce•AFETS

Air Force Engineeri

ng•OC-ALC

University•SDSMT

SD State University

Center•R3S

Industry•HF Webster

•MOOG

2010 ARCApplied Research Center

Cold Spray Collaboration

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Integrally stiffened bonded panel – composite metal hybrid structure

B-1 Hydraulic LineChafing Location – Cold Spray

Pretreatment

Cold Spray ApplicationsB-1 Forward Equipment Bay

CS Applied Jan 2011 (2 A/C)~3 Years 4151 Combined Flt Hrs

CS Repaired June 20121+ Year, 155 Flight Hours

Chafing PointWear Tested

Nose Landing Gear Accumulator Line

Chafing PointWear Tested

CS Applied Mar 20094+ Years, 2202 Flight Hours

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Problem B-1 FEB Panels

After8 panels per aircraft Four panels per side, Lt and Rt sides

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Chafing Wear on Operational Panel

B-1 Forward Equipment Bay

Before

After

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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

Cold Spray Repair Process

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Before

Deposited material ground flush with surface

Repaired Surface

Hole filled & re-drilled back to OEM specifications

Repaired Fastener OEM Fastener Hole

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Transition and ImplementationOfficial Approval Documents and Commitment:

Cold Spray Transition LocationsEllsworth AFB Hill AFBTinker AFBMid-America/MOOG-Webster, MA and Fargo, ND

1. Engineering Technical Assistance Request (ETAR) E12-00248 FEB Panel

o Tinker Air Force Base-B-1 Chief Engineer Jeff Vaughn

2. Engineering Technical Assistance Request (ETAR) E09-00065 NLG Lines

o Tinker Air Force base B-1 Hydraulic Engineer Barry Magerus

3. Aircraft Modification Proposal (AF-1067) Mar 2011 MLG Lines

o Langley Air Force Base ACC B-1 A4V1 Lt Col Joseph Shirey

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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

Main Landing Gear Line

Spoiler Actuatorline

Nose Landing Gear Accumulator Line

Problem Hydraulic Tubing Chafing

Chafing PointsWear Tested

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Goalso Reduce the occurrences between PDM/HVM cycleso Reduce MMHso Improve aircraft availability

Process Development Cold Spray Hydraulic Line pre-treatment

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Action PlanCold Spray Hydraulic Line pre-treatment

Develop logistical and maintenance procedures for implementation

chafing limitso Implementation TO changes

Equipmento Define future developmento Non-B nut lineso On vehicle

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ProblemF-16 Air Inlet Housing

14Repaired Sump

Repair sites

Nominated by AFMC Gen Wolfenbarger Staff

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ProblemF-15 AMAD - Magnesium Housing

15

Before After

Repair sitesNominated by AFMC Gen Wolfenbarger Staff Spares availability problemHigh Cost/High Demand

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ProblemF-16 ADG- Magnesium Housing

16

Before After

Repair sites Nominated by AFMCGen Wolfenbarger StaffSpares availability problemHigh Cost/High Demand

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BenefitsROI

0

100

200

300

400

500

600

700

800

900

1000

F-16 ADG F-16 Air Inlet Hsg

F-15 AMAD

B-1 FEB Panel

Hydro Tubes

Annual Savings ($K) ROI Ratio

Total AnnualSavings and ROI$2.9MReturn on Investment Ratio 11*excluding hydro tube analysis

$78M$2M

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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

o Implement cold spray at 2 operational units and one depot, coupon testing, qualification, etc.

o Teaming Arrangement: H. F. Webster Engineering, VRC, Moog, ARL, General Atomics, SDSM&T

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Questions?

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

World Class Airmen … Expeditionary Combat PowerWorld Class Airmen … Expeditionary Combat Power

• 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

Expected Return on Investment

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*